description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to data cache circuits, and more particularly, to a method, system, and computer program product for implementing a dual-addressable cache.
2. Description of Background
A cache is a high-speed array of recently-accessed data or other computer information and is typically indexed by an address. Certain caches, like translation caches (also known as translation-lookaside buffers (TLBs)), can have two viable indices, such as a virtual address index (before translation) and a real address index (after translation). If such an array is indexed by one type of address (e.g., virtual address), but a search or update is required based on the other type of address (e.g., real address), a linear search of the array is typically required in order to determine any occurrence of the desired address (in this case, the real address).
One solution is a content addressable memory (CAM) array, which refers to a large structure that provides a highly parallel lookup of the non-indexed address type. Unfortunately, CAMs are expensive to build, take up significant amounts of chip area, and usually have significant logic restrictions (e.g., ability to manipulate only a portion of the address) in order to make them practical. An alternative solution is to have two directories (i.e., arrays), each one indexed by one of the two address types, with updates of both arrays required in order to keep them synchronized. However, this solution, by definition, requires double the number of arrays, as well as a great deal of synchronization logic, which may not be practical.
What is needed, therefore, is a more efficient way to implement caches, in terms of ease of operation, as well as time and memory requirements.
SUMMARY OF THE INVENTION
The shortcomings of the prior art are overcome and additional advantages are provided through the provision of an array indexing scheme that utilizes both virtual and real addressing indices and a single directory. The method includes adding fields for indirect indices to each congruence class provided in a cache directory. The cache directory is indexed by primary addresses. In response to a request for a primary address based upon a known secondary address corresponding to the primary address, the method also includes generating an index for the secondary address, and inserting or updating one of the indirect indices into one of the fields for a congruence class relating to the secondary address. The indirect index is assigned a value of a virtual index corresponding to the primary address. The method further includes searching congruence classes of each of the indirect indices for the secondary address.
System and computer program products corresponding to the above-summarized methods are also described and claimed herein.
Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1A illustrates a format of an entry for a translation cache utilizing virtual address indexing methods in the prior art;
FIG. 1B illustrates a sample format of a congruence class for multiple entries associated with an index that utilizes virtual address indexing methods in the prior art;
FIG. 1C illustrates a sample format of a translation cache entry identifying an associated virtual index in the prior art;
FIG. 1D illustrates a sample directory of congruence classes utilizing virtual address indexing in the prior art;
FIG. 2 illustrates a system upon which the dual-addressable cache may be implemented in exemplary embodiments;
FIG. 3 illustrates a modified format of a congruence class for multiple entries in exemplary embodiments;
FIG. 4 is a graphical depiction of the dual-addressable cache architecture and sample implementation in exemplary embodiments; and
FIGS. 5-6 are flow diagrams describing a process for performing a search, update, and entry utilizing indirect indices in exemplary embodiments.
The detailed description explains the preferred embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with exemplary embodiments, a dual-addressable cache system and method is provided. The dual-addressable cache includes an addressable cache directory in which the entries of the directory have two different addresses, and are indexed by the first (primary) address. In a translation cache, a primary address refers to the nature of indexing utilized and may be either of the virtual address or the real (physical) address. For purposes of illustration, the primary address will be described herein with respect to a virtual addressing index.
In a two-dimensional directory implementation, there is an index identifying the corresponding congruence class (i.e., all entries which map to the same index) and the other dimension represents the associativity (number of entries within each congruence class). Attached to each congruence class is an LRU (least recently used) indicator to track the age of each of the corresponding entries within that congruence class.
Clearly, this type of directory is easily searched by the first, or primary, address, since that is how it is indexed. To enable it to be indexed quickly by the second (secondary) address, a set of indirect indices is added to each congruence class, together with a separate LRU logic indicator (indirect LRU) for managing the age of these indices independently of the age of the regular entries in the congruence class.
When searching the directory by the secondary address, the secondary address is used to produce an index, much like the primary address (if the addresses are similar enough, it could even be exactly the same method). Of course, this won't point to the entries which necessarily have the secondary address. Rather, it will point to entries whose primary address maps to the same index. A set of indirect indices are provided which point to all of the congruence classes that have entries containing secondary addresses with this index. Accordingly, given a secondary address, only a handful of congruence classes in the cache directory need to be examined for entries that may match the secondary address. This is much more efficient than having to search all of the congruence classes (since secondary address doesn't necessarily have anything in common with the primary address), or having to use complicated (and functionally limited) structures like CAM arrays to speed up the secondary address searching. It is also simpler than using a second directory, indexed by secondary address, to fulfill the function. The dual-addressing cache implementation may be utilized for any type of cache system. However, for purposes of illustration, the dual-addressable cache implementation will be described with respect to a translation cache.
Turning now to FIGS. 1A-1D , the formatting of cache components utilized in the prior art will now be described for background purposes. The format of a typical entry 102 of a translation cache is shown in FIG. 1A . The entry 102 includes a virtual address (VA) 104 , a real address (RA) 106 that corresponds to the virtual address 104 , and a valid bit (V) 108 . The valid bit 108 will be set to ‘1’ if, and only if, the entry 102 is valid (e.g., the entry 102 is valid if it is currently in use).
Multiple entries may be associated with a single index for specifying that these entries are related. This association of entries (associativity) is referred to as a congruence class. A sample format for a congruence class is shown in FIG. 1B . The congruence class 110 of FIG. 1B includes two entries 102 and 112 that share the same index. The format of the second entry 112 also includes a virtual address (VA 114 ), a real address (RA 116 ), and a valid bit (V 118 ). The congruence class 110 also includes suitable LRU logic (L) 120 for managing the entries 102 , 112 (e.g., a single bit pointing to the LRU entry) so that only the most recently accessed addresses are stored in the directory. Implicit in any cache design is the notion that in order to work effectively, the distribution of addresses amongst the congruence classes should be fairly close to uniform, thus allowing the partitioned nature of the addresses by congruence class to achieve the overall goal of the cache to contain the most recently accessed addresses.
Assume the associated directory, or array, has some number, C, of congruence classes (CCs), numbered CC 0 , CC 1 , CC 2 , . . . , CC c-1 , which is indexed by VA in some suitable manner. Making C a power of two and choosing the least significant address bits from VA to produce an index from 0 up to c−1 is one method. This index is referred to herein as a virtual index (VX). As shown in FIG. 1C , VA (e.g., VA 104 ) is then broken up into two components, a virtual base address (VB) 122 and the virtual index VX 124 . The corresponding VX 124 does not need to be part of the entry 102 of FIG. 1C , since it is implicit from the congruence class index; however, it is shown here for purposes of illustration and ease in explanation.
Turning now to FIG. 1D , a directory 126 of congruence classes utilizing virtual address indexing is shown. In order to look up a specific virtual address, a corresponding virtual index VX (not shown) is extracted, the congruence class for the VX (CC VX) is looked up (e.g., CC 0 110 ), and both entries 102 , 112 are examined in order to determine whether the desired virtual address is in either of them. This process is easily implemented because the directory 126 is utilizing a virtual addressing index scheme. Performing a look up by a particular real address, however, is not as simple. If there is no correlation between virtual addresses and real addresses, the desired address could be present in any entry in the entire directory 126 , or perhaps not present at all. The provision of indirect indices resolves this issue.
Two conditions should be met in order to efficiently implement the indirect indices of the dual-addressing cache system. First, the secondary address should be indexable by the same number of congruence classes as the primary address. The more similar the addresses (frequently the case with virtual and real addresses), the easier this is to accomplish, but even if the two addresses are quite dissimilar, the task of assigning addresses to a fixed set of indices in a fairly uniform manner may require some form of hashing or other suitable mechanism. Second, there needs to be more indirect indices per congruence class than there are entries per congruence class. Even as little as one more index is sufficient. While the design can work with the same number of indirect indexes as entries, efficiency is significantly degraded. Essentially, every entry is pointed to by an indirect index, so in order for an entry to exist, there has to be room in its congruence class as well as room in the set of indirect indices that point to it. These elements are described further herein.
Turning now to FIG. 2 , a system upon which the dual-addressing cache features may be implemented in exemplary embodiments will now be described. The system of FIG. 2 includes a processor (e.g., central processor unit (CPU)) 202 that executes instructions and manipulates data stored in memory. CPU 202 requests data from a memory device (e.g., main memory) 204 which is in communication with the CPU 202 . These requests may be routed through a controller device 208 that manages the requests and transmission of data between CPU 202 , memory device 204 , and also from a cache (directory) 206 which is also in communication with CPU 202 via controller device 208 . Cache 206 comprises storage for frequently accessed data and addresses. Cache 206 also includes a translation cache component 210 comprising entries (that may further be grouped by congruence class) for translating between virtual and real addressing. The translation cache component 210 further includes indirect indices for implementing a dual-addressing method as described further herein.
In order to implement indirect indices, each congruence class (e.g., 110 of FIG. 1B ) is extended with additional fields resulting in a modified congruence class 300 as shown in FIG. 3 . Using the example provided in FIGS. 1A-1D , three indirect indices are designated (i.e., one more than the associativity of each congruence class). The modified congruence class 300 of FIG. 3 illustrates three indirect indices 302 - 306 . Each indirect index (IX) is a number from 0 to C−1, much like the virtual index described above. The indirect indices are referred to herein as IX 1 302 , IX 2 304 , and IX 3 306 . An LRU logic (IL) 308 is provided for managing the indirect indices 302 - 306 . The LRU logic IL 308 is separate from, and may be a little more sophisticated (as there should be more IXs than entries to manage) than, the logic indicator (e.g., L 120 of FIG. 1B ) needed to manage the entries in the modified congruence class 300 .
An indirect index allows a directory of the modified congruence class to be quickly searched by an equivalent real index (RX) of a real address. If real addresses are similar in form to virtual addresses, the real indices could use exactly the same extraction as the corresponding VXs, only using the real addresses instead. Otherwise, some mapping from real address to the numbers 0, 1, 2, . . . , C−1 (for spreading the real addresses amongst the different combinations) may be used.
Turning now to FIG. 4 , implementation of the dual-addressable cache indexing scheme will now be described. Given an entry with virtual address VA (broken down in to virtual base VB and virtual index VX) a real address RA (e.g., RA 106 ) is broken down in real base address (RB) 402 and real index (RX) 404 , and an indirect index IX (e.g., IX 1 302 ) is inserted into one of the three indirect index fields (e.g., 406 ) in congruence class RX 408 , and the value it takes on is VX. The directory is now ready to be indexed by real address as shown and described in FIGS. 5 and 6 .
Turning now to FIG. 5 , implementation of a two-stage look-up process utilizing the dual-addressable cache will be described. In step 502 , a real address (e.g., RA 106 ) is provided. A real index is formed for the real address at step 504 . The real index may be generated in a similar manner as that described above with respect to the virtual index. At step 506 , a congruence class (e.g., 408 of FIG. 4 ) corresponding to the RX (e.g., 404 ) is examined. All indirect indices (e.g., 1 X 1 , 1 X 2 , and 1 X 3 ) for the congruence class are accessed, followed by accessing the entries in the corresponding congruence classes to which these indirect indices point, in order to determine whether the desired real address 106 matches that of the real addresses in any of these entries at step 508 . Clearly, an indirect index might even be a little more specific than a virtual index (e.g., point not only to a congruence class, but also to a specific entry within a congruence class). This is of little concern however because cache directories are usually designed around the notion that a congruence class can be examined very quickly (e.g., in one cycle of a processor time), essentially doing a parallel compare of all of the entries, so having a more specific indirect index doesn't necessarily speed up the ensuing search of the congruence class. Further, by not specifying particular entries in the indirect index, the potential of more than one entry to exist in the congruence with the same real address index value of RX is allowed. This helps make better utilization of the cache directory, especially if there is some correlation between virtual address and real address indexing.
If there is a match at step 510 , this indicates that the real address 106 was found in the cache directory. Appropriate action is taken on the corresponding entry (e.g., returning the corresponding virtual address to the requesting processor) at step 512 . Further processing (for instance, updating the LRU of the found entry, or searching for more entries should the real addresses not be unique) may be performed at step 514 , as appropriate.
If there is no match at step 510 , this indicates a miss, i.e., the real address is not in the cache directory. Appropriate action may then be taken at step 516 , such as letting the processor know that the real address was not found.
In addition to the standard cache directory maintenance, an LRU update also involves an update of the corresponding indirect index that points to this entry. Given the standard nomenclature used above, finding a virtual address VA=VB and VX produces the corresponding real address RA=RB+RX. Looking up the set of indirect indices in congruence class RX (e.g., 408 of FIG. 4 ), one of them must be equal to VX. This particular indirect index is made the MRU indirect index in the indirect LRU for this congruence class.
Inserting a new entry entails a little more work to maintain the indirect indices, for a new indirect index usually must be added, which requires deleting a previous one to make room. Turning now to FIG. 6 , an insertion process for a new entry will now be described. As part of the normal insertion process, the corresponding set of indirect indices (in congruence class RX) is searched at step 602 . If it so happens that there is already an indirect index equal to VX at step 604 , the corresponding LRU is updated to make this index the MRU index at step 606 . Otherwise, a search is performed to find the oldest (LRU) indirect index at step 608 , which is then replaced with VX at step 610 , making this the MRU indirect index in the process. However, replacing the LRU indirect index means that any entries pointed to by it (i.e., all entries in all entries in congruence class IX that share the same real index RX) need to be invalidated at step 612 , lest there be valid entries in the cache directory that have no corresponding indirect indexes pointing to them.
Suppose, for example, the LRU indirect index has the value IX (different than VX), the entries in congruence class IX need to be looked up, and if any of them have real index RX, they need to be invalidated. Normally, there will be no such entry (i.e., the entry it used to point to has aged out of the congruence class), but in some cases there may be an entry (indicating that its indirect LRU caused it to age out before its regular LRU), which needs to be invalidated. Note that since IX cannot equal VX, this invalidation does not take place in the same congruence class as the regular insertion. Though not likely, there is a possibility of even multiple entries in congruence class IX sharing real index RX. In such a case, each of these entries needs to be invalidated
The capabilities of the present invention can be implemented in software, firmware, hardware or some combination thereof.
As one example, one or more aspects of the present invention can be included in an article of manufacture (e.g., one or more computer program products) having, for instance, computer usable media. The media has embodied therein, for instance, computer readable program code means for providing and facilitating the capabilities of the present invention. The article of manufacture can be included as a part of a computer system or sold separately.
Additionally, at least one program storage device readable by a machine, tangibly embodying at least one program of instructions executable by the machine to perform the capabilities of the present invention can be provided.
The flow diagrams depicted herein are just examples. There may be many variations to these diagrams or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.
While the preferred embodiment to the invention has been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.
|
A method, system, and computer program product for implementing a dual-addressable cache is provided. The method includes adding fields for indirect indices to each congruence class provided in a cache directory. The cache directory is indexed by primary addresses. In response to a request for a primary address based upon a known secondary address corresponding to the primary address, the method also includes generating an index for the secondary address, and inserting or updating one of the indirect indices into one of the fields for a congruence class relating to the secondary address. The indirect index is assigned a value of a virtual index corresponding to the primary address. The method further includes searching congruence classes of each of the indirect indices for the secondary address.
| 6
|
FIELD OF THE INVENTION
This invention relates generally to fractionation columns, and more particularly, to apparatus and methods for removing H 2 S and moisture from the naphtha overhead of a fractionator.
BACKGROUND OF THE INVENTION
Hydrocarbon feeds can be reacted in a hydroprocessing zone where a number of reactions take place, including hydrocracking, hydrotreating, hydrogenation, and desulfurization. The hydroprocessing zone is typically followed by a stripper column, where the hydroprocessing zone effluent is separated into a stripper overhead stream and a stripper bottoms stream. In some processes, the stripper column bottoms is sent to a fractionation column, where it is separated into a fractionation column bottoms stream and a naphtha overhead stream. Other streams, such as light gas oil and heavy gas oil streams, can also be separated out in the fractionator, if desired. The naphtha overhead stream is recovered. The naphtha overhead stream includes naphtha, H 2 S, and, in some cases, water.
The H 2 S generated during desulfurization reactions in the hydroprocessing zone is removed predominantly in the stripper column. Although the stripper column is designed to remove H 2 S to the level of parts per billion (ppb) in the stripper bottoms stream, small amounts of H 2 S slip through into the fractionator. The H 2 S becomes concentrated to a level of parts per million (ppm) in the fractionator overhead liquid stream. ASTM D-4952-09 (Doctor Test) is often used as an indicator for the presence of H 2 S in the overhead naphtha stream. An H 2 S level of 1 weight ppm (wppm) can result in the naphtha not meeting the Doctor Test. If the naphtha does not meet the Doctor Test, it cannot be sent directly to the naphtha pool for storage. Consequently, the H 2 S must be removed from the naphtha overhead stream using a secondary processing system.
In many units, the H 2 S is removed using a caustic (NaOH) wash and a sand filter. However, many refiners do not want to use caustic because of the hazards associated with handling it and problems related to disposing of the spent caustic.
Alternatively, the naphtha may be sent to a downstream stabilizer/splitter combination for removal of light petroleum gas. The H 2 S can be removed along with the light petroleum gas. However, this equipment increases the cost of the process.
Therefore, it would be desirable to provide alternative processes for removing H 2 S from naphtha.
SUMMARY OF THE INVENTION
One aspect of the present invention relates to a method of making naphtha substantially free of H 2 S. In one embodiment, the method includes stripping an incoming stream containing naphtha and H 2 S in a fractionator into at least an overhead stream containing the naphtha and H 2 S and a bottoms stream, and introducing the overhead stream from the fractionator into a separator to form a naphtha stream substantially free of H 2 S and an overhead stream containing H 2 S.
Another aspect of the invention is an apparatus for making naphtha. In one embodiment, the apparatus includes a hydroprocessing zone having an inlet and an outlet. The inlet of a stripper column is in fluid communication with the outlet of the hydroprocessing zone. The inlet of the stripping fractionator is in fluid communication with the bottoms outlet of the stripper column. The apparatus includes a separator having an inlet, a product outlet, and an overhead outlet. The inlet of the separator is in fluid communication with the overhead outlet of the stripping fractionator.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates one embodiment of a process utilizing the present invention.
FIG. 2 illustrates another embodiment of a process utilizing the present invention.
DETAILED DESCRIPTION OF THE INVENTION
By installing a separator, including but not limited to, vacuum dryers or coalescers, on the naphtha overhead stream from the fractionator column to the product line, the H 2 S can be removed, and the naphtha can be made substantially free of H 2 S. By “naphtha,” we mean C5 hydrocarbons up to hydrocarbons having a boiling point of about 150° C. (i.e., hydrocarbons having a boiling point in the range of about 30° C. to about 150° C.). By “substantially free of H 2 S”, we mean the H 2 S content is undetectable by ASTM test method UOP 163 and the naphtha passes the Doctor Test, ASTM D4952. This eliminates the need for the caustic/sand filter arrangement or the downstream stripper/stabilizer. In some embodiments where the separator is a vacuum dryer, the liquid portion of the vacuum dryer overhead can be recycled back to the stripper.
The solubility of H 2 S in steam is quite high in columns which are steam stripped. Since this “sour water” remains in the overhead naphtha and is not totally removed, the naphtha may test positive for H 2 S. In this case, the separator can be a coalescer which is installed to remove the water, and hence the H 2 S.
The selection of the type of separator, such as a vacuum dryer or a coalescer, depends on the amount of H 2 S slipping through into the naphtha overhead stream and how low the moisture content needs to be to meet the Doctor Test.
FIG. 1 illustrates one embodiment of a process utilizing the present invention. The feed 5 can be any hydrocarbon feed stream(s) predominantly boiling between about 240° C. and about 600° C. The feed 5 is hydroprocessed in the hydroprocessing zone 10 . The effluent 15 can be subjected to one or more separation processes where at least a portion of the gas is removed and the remaining liquid/gas effluent proceeds, as is known in the art (not shown), if desired. The remaining effluent 15 from the hydroprocessing zone 10 is sent to a stripper column 20 , where it is separated into a stripper overhead stream 25 containing at least one of light naphtha, light petroleum gas, light hydrocarbons, and H 2 S, and a stripper bottoms stream 30 containing light and heavy naphtha, other hydrocarbons heavier than naphtha (e.g., kerosene, diesel, vapor gas oil, unconverted oil, and the like, depending on the feed and the hydroprocessing zone), and H 2 S. The stripper bottoms stream 30 is sent to a fractionator 35 . Stripping medium 40 is introduced into the fractionator 35 . The stripper bottoms stream 30 is separated into a fractionator bottoms stream 45 containing unconverted oil, a heavy gas oil (HGO) stream 50 , a light gas oil (LGO) stream 55 , and a fractionator overhead stream 60 . The HGO stream 50 and LGO stream 55 can be further processed and/or recovered, if desired.
The fractionator overhead stream 60 contains primarily naphtha, and H 2 S. Although most of the H 2 S is removed in the stripper column 20 , the remaining H 2 S is concentrated in the fractionator overhead stream 60 . Fractionator overhead stream 60 is sent to receiver 65 wherein it is separated into a receiver overhead gas stream 70 , a sour water stream 75 , and a liquid naphtha stream 80 . The liquid naphtha stream 80 can contain small amounts of water and H 2 S. The liquid naphtha stream 80 is split into a reflux stream 85 , which is sent back to the fractionator column 35 , and stream 90 , which is sent to a separator. Suitable separators include, but are not limited to, a vacuum dryer 95 , as shown in FIG. 1 , or a coalescer 130 , as shown in FIG. 2 . Sufficient H 2 S is removed in the vacuum dryer 95 so that the naphtha in product stream 100 is substantially free of H 2 S. An overhead stream 105 from the vacuum dryer 95 contains H 2 S.
The vacuum dryer is operated under vacuum. The level of vacuum is not limited; however, it is desirably the lowest level that will remove sufficient H 2 S so that the naphtha in product stream 100 is substantially free of H 2 S. The vacuum dryer can be operated at any suitable temperature. The temperature of operation is related to the level of vacuum generated in the dryer (i.e., the higher the level of vacuum, the lower the temperature needs to be).
The vacuum dryer overhead stream 105 is sent to an ejector receiver 110 , where it is separated into ejector stream 115 , which is condensed steam, a non-condensible vapor stream 120 , and a condensable stream 125 . Ejector stream 115 , non-condensible vapor stream 120 , and condensable stream 125 will have some H 2 S in them. Condensable stream 125 can be recycled to the stripper column 20 , if desired.
When steam is used as the stripping medium 40 , a coalescer 130 could be used, as illustrated in FIG. 2 . The coalescer 130 removes the water as stream 140 from the naphtha product 135 . Because of the high solubility of H 2 S in water, the H 2 S would be removed with the water. Typical operating conditions for the coalescer include operating at the temperature of stream 90 .
While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention. It should be understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims.
|
Methods and apparatus for making naphtha substantially free of H 2 S are described. The method includes stripping an incoming stream containing naphtha and H 2 S in a fractionator into at least an overhead stream containing the naphtha and H 2 S and a bottoms stream, and introducing the overhead stream from the fractionator into a separator to form a naphtha stream substantially free of H 2 S and an overhead stream containing H 2 S.
| 2
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/794,580 filed on Apr. 24, 2006 which is hereby incorporated herein by reference.
TECHNICAL FIELD
[0002] This invention relates to internal combustion engines. More particularly, the invention is concerned with accurately estimating mass airflow to the engine.
BACKGROUND OF THE INVENTION
[0003] The combustion process of homogeneous charge compression ignition (HCCI) engines depends strongly on factors such as cylinder charge composition, temperature, and pressure at the intake valve closing. Hence, the control inputs to the engine, for example, fuel injection mass and timing and intake/exhaust valve profile, must be carefully coordinated to ensure robust auto-ignition combustion. Generally, for best fuel economy, an HCCI engine operates un-throttled and with a lean air-fuel mixture. Further, in an HCCI engine using an exhaust recompression valve strategy, the cylinder charge temperature is controlled by trapping different amount of the hot residual gas from the previous cycle by advancing the exhaust valve close timing from nominal. The opening timing of the intake valve is retarded from nominal to a later time preferably symmetrical to the exhaust valve closing timing about top-dead-center (TDC) intake. Both the cylinder charge composition and temperature are strongly affected by the exhaust valve closing timing. In particular, more hot residual gas from the previous cycle can be retained with earlier closing of the exhaust valve which leaves less room for the incoming fresh air mass. The net effects are higher cylinder charge temperature and lower cylinder oxygen concentration. The negative valve overlap (NVO), defined as the crank-angle period where both intake and exhaust valves are simultaneously closed around TDC intake, is indicative of the trapped amount of hot residuals.
[0004] Robust HCCI combustion has been demonstrated using a variable valve actuation system such as a fully flexible valve actuation (FFVA) system (e.g. electrically variable, hydraulically variable or electro-hydraulically variable valves) or a simplified mechanical two-step valve lift system with a dual cam phasing system. In particular, optimal combustion phasing can be maintained by adjusting both intake and exhaust valve profiles in conjunction with engine control inputs such as injection mass and timing, spark timing, throttle and EGR valve positions. Furthermore, air-fuel ratio control is critical for maintaining robust HCCI combustion especially during transients.
[0005] In conventional gasoline spark-ignition engines, airflow is controlled by the throttle, and the fuel is metered proportional to the measured mass airflow at the throttle body using a MAF sensor. The noise level (i.e. high frequency components) of the MAF signal is low as long as the intake manifold absolute pressure (MAP) is far below the ambient pressure (i.e. throttled engine operation). However, during minimally throttled operation, noise levels can be substantial due to significant coupling of intake dynamics of the cylinders with the intake manifold and MAF sensor. During HCCI engine operations, the throttle is usually kept wide-open to minimize pumping losses, and the airflow is controlled by the exhaust and intake valve profiles (i.e. combinations of lift, duration and phase). Therefore, engines operating in an HCCI mode are also affected by MAF signals which can be substantially noisy. Similarly, in diesel engines, which operate without air throttling, MAF signals can similarly be substantially noisy. Although the high-frequency components in the MAF measurement can be reduced using a low pass filter, a filtered signal produces an undesirable time delay in the MAF measurement. Adapting fuel injection command using a filtered, and hence time delayed, MAF measurement can cause significant air-fuel ratio deviations during engine transient operations resulting in undesirable combustion results including, for example, partial burn, misfires, excessive emissions, combustion phase shifts, etc.
SUMMARY OF THE INVENTION
[0006] In the present invention, model-based estimation and control methodology based on MAF measurement is developed to accurately estimate mass airflow without introducing time delay for robust transient operations.
[0007] A method for unfiltered intake airflow determination in a substantially unthrottled internal combustion engine includes modeling intake airflow using a low-order differential equation. The low-order differential equation includes an estimated airflow term and a desired airflow term, wherein the actual airflow follows the desired airflow as described by the low-order differential equation. The low-order differential equation is tuned in accordance with adaptive parameters operative on the estimated airflow term and the desired airflow term. The tuning minimizes error between the estimated airflow term and the actual airflow.
[0008] An apparatus for unfiltered intake airflow determination in an internal combustion engine includes airflow control means for controlling airflow to engine cylinders without any substantial airflow throttling and an airflow sensor measuring substantially unthrottled airflow. Further included is a closed-loop airflow controller for controlling the airflow control means based on a desired airflow and the measured airflow from the airflow sensor. The controlled airflow follows the desired airflow in such a way that can be described by low-order dynamics. Finally included is an adaptive airflow estimator for providing an undelayed estimate of airflow based on the desired airflow and adaptive parameters.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Embodiments of invention may take physical form in certain parts and arrangement of parts, the preferred embodiment of which will be described in detail and illustrated in the accompanying drawings which form a part hereof and wherein:
[0010] FIG. 1 schematically illustrates an HCCI engine and control system;
[0011] FIG. 2 illustrates measured mass airflow response to a desired mass airflow signal;
[0012] FIG. 3 illustrates measured, filtered and modeled mass airflow in accordance with the present invention; and,
[0013] FIGS. 4A-4D illustrate various data graphs corresponding to an HCCI engine operated in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] The present invention will now be described with respect to a HCCI engine. However, the invention is fully applicable to other engine types, including conventionally throttled spark-ignited engines, diesel cycle engines, or any variety of engines employing measured mass airflow.
[0015] Referring now to FIG. 1 , illustrated is a block diagram showing an engine 12 capable of operating with homogeneous charge compression ignition (HCCI) and a combustion control system 14 and method for controlling combustion in the engine.
[0016] The engine 12 may include various features or devices, including power producing combustion chambers 13 connected with an intake air system 17 and an exhaust system 19 , intake 21 and exhaust 23 valves with some form of variable valve actuation system 15 operative to control intake flow to and exhaust flow from the combustion chambers, an external exhaust recirculation system 25 including an EGR valve 27 connected between the intake and exhaust systems, and fuel injection and spark ignition systems (not separately illustrated) for supplying fuel to and igniting or assisting ignition of combustible mixtures in the combustion chambers.
[0017] The engine 12 is designed to operate on fuel injected gasoline or similar blends, unthrottled with HCCI combustion over an extended range of engine speeds and loads, which may include engine starting where possible. However spark ignition and throttle controlled operation may be utilized with conventional or modified control methods under conditions not conducive to HCCI operation and to obtain maximum engine power. Applicable fueling strategies may including direct cylinder injection, port fuel injection or throttle body fuel injection. Widely available grades of gasoline and light ethanol blends thereof are preferred fuels; however, alternative liquid and gaseous fuels such as higher ethanol blends (e.g. E80, E85), neat ethanol (E99), neat methanol (M100), natural gas, hydrogen, biogas, various reformates, syngases etc. may also be used in the implementation of the present invention.
[0018] The described control system 14 and method are of particular benefit to unthrottled operation of the engine wherein time delays, introduced for example by signal filtering, of a MAF signal are undesirable. The combustion control system 14 includes one or more computers or controllers adapted to carry out a repetitive series of steps or functions in a method of combustion control according to the invention. The main controllers include a feedforward controller and a feedback controller.
[0019] In the present application of the invention, it is assumed that an HCCI engine is operating with exhaust recompression strategy with one of electro-hydraulic, hydraulic, or electric cam phaser, and that mass air flow (MAF) measurement is available with a MAF sensor. The present invention comprises an airflow control using NVO via a variable valve actuation system, and an adaptive airflow model based on the MAF measurement. The overall control structure is shown represented by control system 14 of FIG. 1 .
[0020] Airflow to the engine is measured by a MAF sensor 30 located at the throttle body, and a feedback controller 61 adjusts NVO to achieve desired airflow based on the MAF measurement. The feedback controller is designed such that response of actual airflow to the desired airflow can be approximated by low-order dynamics (e.g. first or second order). Then, closed-loop response of airflow can be modeled using a low-order differential equation.
[0021] An example is shown in FIG. 2 when the feedback controller 61 is designed such that closed-loop dynamics of airflow can be approximated by a 1 st order differential equation as follows:
[0000]
x
.
=
-
1
τ
x
+
1
τ
r
(
1
)
[0022] where x is the airflow measured by a sensor, r is the desired airflow, and τ is the time constant of the closed-loop system. To estimate the airflow into the engine, a 1 st order adaptive airflow model 63 is introduced as follows:
[0000]
x
.
e
=
-
1
τ
e
(
1
+
α
)
x
e
+
1
τ
e
β
r
(
2
)
[0023] where x e is the estimated airflow, τ e is the estimated time constant of the closed-loop system, α and β are control parameters employed by an adaptive controller so that the difference between response of the model and that of actual airflow is minimized. Since from the first order behavior of the airflow under control, the error between the actual and the estimated model airflow is given by the following relationship which relies, in part, upon a desired airflow term:
[0000]
e
.
=
-
1
τ
e
-
(
1
τ
e
+
1
τ
e
α
-
1
τ
)
x
e
+
(
1
τ
e
β
-
1
τ
)
r
(
3
)
[0024] where e=x e −x. Adaptation laws for α and β can be derived using, for example, a Lyapunov function as follows:
[0000]
V
=
1
2
2
+
τ
e
2
γ
(
1
τ
e
+
1
τ
e
α
-
1
τ
)
2
+
τ
e
2
γ
(
1
τ
e
β
-
1
τ
)
2
>
0
,
γ
>
0
(
4
)
[0025] Finally, it can be shown that the following adaptation law guarantees
[0000]
V
.
=
-
1
τ
2
≤
0
,
[0000] and that e →0 as τ→∞ while α and β are bounded:
[0000]
{
α
t
=
γ
x
e
e
β
t
=
-
γ
re
(
5
)
[0026] FIG. 3 shows MAF sensor output from a multi-cylinder HCCI engine operated at constant engine speed of 2000 RPM, with 95 kPa of MAP. In addition, both filtered and adaptive model estimated signals are presented in the figure.
[0027] It can be seen from the FIG. 3 that MAF sensor signal (measured) contains high-frequency components which requires heavy filtering to smooth. Filtering (dashed line), however, introduces a time delay of about 1 sec. The estimated MAF signal from the adaptive model (solid line) show a negligible time delay. With the estimated airflow from the adaptive model, desired air-fuel ratio can be controlled with correct fuel injection command.
[0028] A method in accordance with an embodiment has been tested with a multi-cylinder HCCI engine, and the result is shown in FIGS. 4A-4D . The fueling rate was scheduled based on desired air-fuel ratio and estimated airflow using the present invention. The engine was operating with 95 kPa of MAP, with exhaust recompression valve strategy at constant engine speed of 2000 RPM. The desired MAF was changed from 6.5 to 8.5 g/s, with roughly 2 g/s 2 of change rate. The desired air-fuel ratio was set to be constant at 16:1, and the fueling rate was determined by the estimated airflow from the adaptive model and the desired air-fuel ratio. The FIG. 4C shows that peak-to-peak air-fuel ratio excursion was below 1 during load transients. Also, the combustion phasing, defined as the crank angle position of 50% fuel burned (CA50), is also shown in the figure. FIG. 4D illustrates satisfactory combustion phasing control during transients with the present invention.
[0029] While the invention has been described by reference to certain preferred embodiments, it should be understood that numerous changes could be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the disclosed embodiments, but that it have the full scope permitted by the language of the following claims.
|
A model-based estimation of mass airflow is provided which provides an accurate estimation of mass airflow without introducing undesirable time delays characteristic of filtered mass airflow signals.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority of U.S. provisional application No. 62/168,354, filed May 29, 2015 the contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates beverage transport and dispensing apparatus, and more particularly to an apparatus for transporting, chilling, and dispensing a beverage contained in a bulk storage barrel.
[0003] Currently, there exist dispensing carts for beer and other beverages contained in barrel, however these carts are primarily designed for retail type establishments, or formal environments. Such carts are difficult to be moved over uneven terrain without great effort and their cost makes them prohibitive for most consumers.
[0004] As can be seen, there is a need for an apparatus for conveniently transporting across uneven terrain, quickly chilling, and dispensing beverages from a bulk storage barrel.
SUMMARY OF THE INVENTION
[0005] In one aspect of the present invention, a beverage dispensing cart includes a support platform adapted to support a vessel containing the beverage. The cart has at least one upright member having a first end attached to the support platform and a handle extending from a second end of the at least one upright member; a heat exchanger attached to the at least one upright member, the heat exchanger having an inlet adapted to be coupled to an outlet of the vessel; and a dispensing valve operatively coupled to an outlet of the heat exchanger.
[0006] In other embodiments the cart includes a plurality of ground transport wheels operatively attached to a base portion of the cart. The heat exchanger further includes an insulated container having at least one sidewall defining a cavity therein. The heat exchanger may also include a coiled tube contained within the cavity, the coiled tube having an inlet and an outlet, the inlet extending through the sidewall and terminating in a shank, the outlet operatively coupled to the dispensing valve. The cart may also have a cylinder bracket adapted to receive a cylinder containing a pressurized gas. The ground transport wheels are selectively position able between a transport condition and a stowed condition.
[0007] In other aspects of the invention, a beverage dispensing cart, has a support platform adapted to support a vessel containing the beverage; at least one upright member having a first end attached to the support platform and a handle extending from a second end of the at least one upright member; a cylinder bracket adapted to receive a cylinder containing a pressurized gas; a dispensing valve having an inlet and an outlet: and a delivery tube in fluid communication with the dispensing valve inlet and adapted to be connected to an outlet of the vessel. The cart may also be configured with a heat exchanger means operatively coupled between the dispensing valve and the delivery tube. The heat exchanger means may include an insulated container having at least one sidewall defining a cavity therein. The heat exchanger means may also include a coiled tube contained within the cavity, the coiled tube having an inlet and an outlet, the inlet extending through the sidewall and terminating in a shank, and the outlet operatively coupled to the dispensing valve. The coiled tube may be formed of a metallic material. IN preferred embodiments, the cart is equipped with a plurality of ground transport wheels operatively attached to a base portion of the cart. The ground transport wheels are operable between a transport position and a stowed position.
[0008] In yet other aspects of the invention a beverage dispensing hand cart, includes a hand cart having a support platform adapted to support a barrel containing the beverage, the hand cart having at least one upright member having a first end attached to the support platform and a handle extending from a second end of the at least one upright member, a plurality of ground transport wheels operatively attached to a base portion of the cart; a cylinder bracket adapted to receive a cylinder containing a pressurized gas; a dispensing valve having an inlet and an outlet: a delivery tube in fluid communication with the dispensing valve inlet and adapted to be connected to an outlet of the barrel; and a heat exchanger means operatively coupled between the dispensing valve inlet and the delivery tube. The heat exchanger means may included an insulated container having at least one sidewall defining a cavity therein; and a coiled tube contained within the cavity, the coiled tube having an inlet and an outlet, the inlet extending through the sidewall and terminating in a shank, and the outlet operatively coupled to the dispensing valve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a front perspective view of an embodiment of a beverage transport and dispensing cart of the present invention.
[0010] FIG. 2 is a rear perspective view of the cart.
[0011] FIG. 3 is a front perspective view of the cart shown in open configuration and shown without ice for illustrative clarity.
[0012] FIG. 4 is a section detail view of the cart taken along line 4 - 4 in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0013] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0014] Broadly, an embodiment of the present invention provides a transport and dispensing apparatus for serving beverages contained in a bulk storage vessel. More preferably, the beverage is dispensed in a chilled condition
[0015] As seen in reference to FIGS. 1 and 2 , the beverage transport and dispensing apparatus of the present invention includes a cart 10 adapted to carry a beverage containment barrel 12 , such as a keg of beer. The cart 10 is configured with a support plate 11 extending forwardly from a lower portion of the cart 10 to support the barrel 12 . The barrel 12 is secured to the cart 10 via a clamp 14 , which may include a metallic band camp, nylon or woven fabric strap, a clamp that engages the rim of the barrel 12 .
[0016] The cart 10 is provided with a plurality of ground transport wheels 13 for supporting the cart during transport conditions. The ground transport wheels 13 may be continuously engaged with a ground surface to support the cart 10 or they may be configured to selectively engage the ground during transport and disengaged from the ground during beverage dispensing or storage operations.
[0017] At least one upright member 15 has a first end operatively attached to the lower portion of the cart 10 extends upwardly to a second end proximal to an upper portion of the cart 10 . A handle 17 is defined at the second end of the support member 15 . The handle 17 is configured to provide a gripping location for an operator to manipulate and position the cart 10 via the ground transport wheels 13 . The from
[0018] The cart 10 may further include a dispensing valve 16 , or tap, operatively connected to the barrel 12 via tubing 26 . The tap 16 further includes a handle 32 to operate the tap 16 between a closed position and an open, fluid dispensing condition. For dispensing beverages, such as beer, it is often desirable to dispense the beverage in a chilled condition. According to some embodiments of the invention, the cart 10 may further include a cooling apparatus interposed between the beverage barrel 12 and the dispensing tap 16 .
[0019] As seen in reference to FIGS. 3 and 4 , the cart 10 may further include a cooling apparatus configured to chill the liquid beverage as it is dispensed. In a preferred embodiment the cooling apparatus may include an insulated container 30 having at least one sidewall defining an interior cavity. A heat exchanger 34 may be contained within the interior cavity of the insulated container 30 and interposed between the tubing 26 and the tap 16 .
[0020] Preferably, the heat exchanger 34 is formed as a coiled tube in fluid communication with the tubing 26 and the tap 16 . More preferably the heat exchanger 34 is formed from a coil of thermally conductive material, such as a metal. By way of example, depending on the inner diameter of the tubing, the coil may be formed from a length of tubing having a linear length of about 50 ft. The selected metal should be of a food and beverage grade material and be compatible with beverages being dispensed, such as stainless steel, or copper. A coupling shank 28 is configured to extend a first end of the coil 34 through the side wall of the insulated container 30 and a second end of the coil 34 is operatively coupled to an inlet of the tap 16 . The tap 16 may be attached to the sidewall of the insulated container 30 .
[0021] The interior cavity of the insulated container 30 may be cooled by any suitable means. In a preferred embodiment, the interior cavity is adapted to receive a quantity of ice 36 , which may be water in a frozen condition, dry ice, reusable cold pack materials. More preferably the ice 36 is provided as an ice bath that may surround and chill the heat exchanger 34 .
[0022] As will be appreciated by those of skill in the art, the beverage vessel 12 requires a source of pressure to be conveyed to the beverage contents 38 within the vessel 12 in order to convey the liquid 38 out of the vessel 12 for delivery to the tap 16 . The pressure source may be a hand pump, operatively coupled to an inlet of a barrel fitting 40 disposed at the top of the barrel 12 . Alternatively, the pressure source may be provided via a pressurized gas delivered to the barrel interior via the inlet 41 at fitting 40 . In further reference to FIG. 4 , pressurized, liquids 38 within the barrel are conveyed through a delivery tube 42 extending between an outlet 44 of the fitting 40 and a bottom of the barrel 12
[0023] In a preferred embodiment, the cart 10 of the present invention is configured with a mounting bracket 18 , adapted to receive a pressurized gas cylinder 20 . The pressurized gas cylinder 20 may be charged with, for example CO 2 , or any suitable beverage dispensing gas. The cylinder 20 is operatively connected to the inlet at fitting 40 . The cylinder may include a valve 21 for controlling the pressure and delivery of the gas to pressurize the liquid beverage 38 contained within the barrel 12 . A the cylinder 20 may also include a pressure gauge 22 to permit the operator to set a desired delivery pressure of the gas to the barrel 12 by adjustment of the valve 21 .
[0024] In further reference to FIG. 4 , in order to dispense a liquid beverage 38 from the barrel 12 , the operator would configure the pressurized gas in communication with the fitting inlet 41 , open valve 21 and set a desired delivery pressure by viewing gage 22 . With the tubing 26 connected to the barrel 12 and the heat exchanger shank 28 , the operator would manipulate handle 32 so that the liquid beverage 38 is conveyed through the barrel tube 42 , tubing 26 , the heat exchanger 34 and is dispensed from the tap 16 .
[0025] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
|
A device for beer keg transportation, cooling beer quickly, and dispensing it easily. The dispensing cart combines a handcart for transport of the keg, a heat exchanger for cooling the beer contained in the keg, and a bracket to contain a pressurized gas cylinder for charging the keg.
| 1
|
BACKGROUND
This disclosure relates to antiferroelectric polymer composites, methods of manufacture thereof, and articles comprising the same.
It is desirable in commercial applications, such as spark plug caps for automobiles, to have a high dielectric constant and high breakdown voltage. Spark plug caps are generally manufactured from polymeric composites. High dielectric constants in polymeric composites are generally achieved by using large volume fractions of fillers. This however, reduces mechanical properties such as impact strength and ductility in the spark plug cap.
It is also desirable for energy storage devices, such as DC-link capacitors, that are utilized in high energy density power conversion applications to withstand the high voltage and high temperature environments of electrical devices such as motors and generators. It is therefore desirable for such storage devices to display a high breakdown voltage and corona resistance. In the electronics industry, it is also desirable to have a suitable high dielectric constant material that satisfies the electrical, reliability, and processing requirements for incorporating capacitors into a printed wiring board. In the electronics industry as well as in the automotive industry, there is therefore a need for new polymeric composites having a high dielectric constant and a high breakdown strength as well as good mechanical strength and processability.
It is therefore desirable to have a composition that combines a high dielectric constant and high energy storage capabilities with ease of processing as well as with improved mechanical properties over currently existing high dielectric constant composites.
SUMMARY
Disclosed herein is a composition comprising a polymeric material and a ceramic antiferroelectric particle.
Disclosed herein too is a method of tuning a dielectric constant of a composition comprising subjecting a composition comprising a polymeric material and a ceramic antiferroelectric particle to a biasing electric field; and changing the dielectric constant of the composition.
Disclosed herein too is a method comprising blending a polymeric material with ceramic antiferroelectric particles to form a composition.
Disclosed herein too is a method comprising blending a polymeric material with ceramic antiferroelectric particles to form a composition; applying an electrical field to the composition; and reorienting the ceramic antiferroelectric particles.
DETAILED DESCRIPTION OF FIGURES
FIG. 1 represents a graph of the increase in dielectric constant as a function of the amount of nanosized antiferroelectric particles incorporated into a polymeric material;
FIG. 2 represents a graph of the polarization hysteresis loops triggered when various weight percents of nanosized antiferroelectric particles are incorporated into a polymeric material;
FIG. 3 represents a graph of the field-tunability of the dielectric constant when nanosized antiferroelectric particles are incorporated into a polymeric material;
FIG. 4 represents a graph of the polarization hysteresis loops triggered when micrometer sized antiferroelectric particles are incorporated into a polymeric material; and
FIG. 5 represents a graph of the field-tunability of the dielectric constant when micrometer sized antiferroelectric particles are incorporated into a polymeric material.
DETAILED DESCRIPTION
It is to be noted that the terms “first,” “second,” and the like as used herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “a” and “an” do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. 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). It is to be noted that all ranges disclosed within this specification are inclusive and are independently combinable.
Disclosed herein are compositions comprising a polymeric material and ceramic antiferroelectric particles. The ceramic antiferroelectric particles can be converted to ferroelectric particles upon the application of an activating field. In one embodiment, the activating field can comprise a biasing electrical field. In another embodiment, the activating field can comprise a biasing electric field that is applied in the presence of a source of thermal energy, such as, for example, an oven. Thus, the antiferroelectric particles are field-tunable, nonlinear dielectric particles that can undergo a phase transition from a low dielectric state (antiferroelectric state) to a high dielectric state (ferroelectric state) upon being exposed to a biasing electric field. These advantageous properties of the antiferroelectric particles permit the composition to be field tunable. Field tunable compositions can advantageously have their dielectric properties adjusted upon demand depending upon the application for which they are to be used.
The ferroelectric effect is an electrical phenomenon whereby certain ionic crystals may exhibit a spontaneous dipole moment. There are two main types of ferroelectrics, displacive and order-disorder. For example, the effect in barium titanate, is of the displacive type and is due to a polarization catastrophe, in which, if an ion is displaced from equilibrium slightly, the force from the local electric fields due to the ions in the crystal increase faster than the elastic restoring forces. This leads to an asymmetrical shift in the equilibrium ion positions and hence to a permanent dipole moment. In an order-disorder ferroelectric, there is a dipole moment in each unit cell, but at high temperatures they are pointing in random directions. Upon lowering the temperature and going through the phase transition, the dipoles order, all pointing in the same direction within a domain. As a result of the aforementioned ordering that occurs in ferroelectric materials, these materials have a high dielectric constant of greater than or equal to about 1000. In an antiferroelectric transition individual dipoles become arranged anti-parallel to adjacent dipoles with the result that the net spontaneous polarization is zero. Thus materials in their antiferroelectric states generally have low dielectric constants of about 100 to about 1000.
The antiferroelectric particles can exist in the form of nanoparticles or micrometer sized particles. These antiferroelectric particles generally have a dielectric constant that is similar to the dielectric constant for the polymeric material. This permits a higher field penetration of the particles when compared with ferroelectric particles. As noted above, the antiferroelectric particles intrinsically undergo a phase transition from being antiferroelectric to ferroelectric upon the application of an electric field. The antiferroelectric particles upon being dispersed in a polymer can be triggered to undergo a phase transition from the antiferroelectric state to the ferroelectric state upon the application of an electrical field of less than or equal to about 100 kilovolts/millimeter. As a result, the dielectric constant of the composition would be increased by an amount of greater than or equal to about 500% when compared with a composition that does not contain the antiferroelectric particles.
The antiferroelectric particles can be advantageously dispersed in the polymeric material and can increase the dielectric constant of the composition. The well-dispersed particles within the polymeric material provide improved properties over a polymeric material that does not contain the antiferroelectric particles. These improved properties include a higher dielectric constant, higher energy densities, improved breakdown strength, optical transparency, corona resistance, improved impact strength and ductility, as well as improved ease of processing and a Class A surface finish.
In one embodiment, the composition has a breakdown voltage of greater than or equal to about 200 V/micrometer. The composition advantageously has an energy density of greater than or equal to about 1 J/cm 3 to greater than or equal to about 10 J/cm 3 . Upon being subjected to the biasing electric field, the dielectric constant of the composition can be increased by at least one order of magnitude depending upon the amount of the ceramic antiferroelectric particles in the composition.
The polymeric material used in the compositions may be selected from a wide variety of thermoplastic polymers, thermosetting polymers, blends of thermoplastic polymers, blends of thermosetting polymers, or blends of thermoplastic polymers with thermosetting polymers. The polymeric material can comprise a homopolymer, a copolymer such as a star block copolymer, a graft copolymer, an alternating block copolymer or a random copolymer, ionomer, dendrimer, or a combination comprising at least one of the foregoing. The polymeric material may also be a blend of polymers, copolymers, terpolymers, or the like, or a combination comprising at least one of the foregoing.
Examples of thermoplastic polymers that can be used in the polymeric material include polyacetals, polyacrylics, polycarbonates, polyalkyds, polystyrenes, polyolefins, polyesters, polyamides, polyaramides, polyamideimides, polyarylates, polyurethanes, epoxies, phenolics, silicones, polyarylsulfones, polyethersulfones, polyphenylene sulfides, polysulfones, polyimides, polyetherimides, polytetrafluoroethylenes, polyetherketones, polyether etherketones, polyether ketone ketones, polybenzoxazoles, polyoxadiazoles, polybenzothiazinophenothiazines, polybenzothiazoles, polypyrazinoquinoxalines, polypyromellitimides, polyquinoxalines, polybenzimidazoles, polyoxindoles, polyoxoisoindolines, polydioxoisoindolines, polytriazines, polypyridazines, polypiperazines, polypyridines, polypiperidines, polytriazoles, polypyrazoles, polycarboranes, polyoxabicyclononanes, polydibenzofurans, polyphthalides, polyacetals, polyanhydrides, polyvinyl ethers, polyvinyl thioethers, polyvinyl alcohols, polyvinyl ketones, polyvinyl halides, polyvinyl nitriles, polyvinyl esters, polysulfonates, polysulfides, polythioesters, polysulfones, polysulfonamides, polyureas, polyphosphazenes, polysilazanes, polypropylenes, polyethylenes, polyethylene terephthalates, polyvinylidene fluorides, polysiloxanes, or the like, or a combination comprising at least one of the foregoing thermoplastic polymers.
Exemplary thermoplastic polymers include polyetherimide, polyvinylidene fluoride, polyvinylidine fluoride-trifluoroethylene P(VDF-TrFE), polyvinylidene-tetrafluoroethylene copolymers P(VDF-TFE), polyvinylidine trifluoroethylene hexafluoropropylene copolymers P(VDF-TFE-HFE) and polyvinylidine hexafluoropropylene copolymers P(VDF-HFE), epoxy, polypropylene, polyester, polyimide, polyarylate, polyphenylsulfone, polystyrene, polyethersulfone, polyamideimide, polyurethane, polycarbonate, polyetheretherketone, silicone, or the like, or a combination comprising at least one of the foregoing. An exemplary polymer is ULTEM®, a polyetherimide, commercially available from General Electric Plastics.
Examples of blends of thermoplastic polymers include acrylonitrile-butadiene-styrene/nylon, polycarbonate/acrylonitrile-butadiene-styrene, polyphenylene ether/polystyrene, polyphenylene ether/polyamide, polycarbonate/polyester, polyphenylene ether/polyolefin, or the like, or a combination comprising at least one of the foregoing.
Examples of thermosetting polymers are resins of epoxy/amine, epoxy/anhydride, isocyanate/amine, isocyanate/alcohol, unsaturated polyesters, vinyl esters, unsaturated polyester and vinyl ester blends, unsaturated polyester/urethane hybrid resins, polyurethane-ureas, thermoset polyphenylene ether, silicone, reactive dicyclopentadiene resin, reactive polyamides, or the like, or a combination comprising at least one of the foregoing.
In one embodiment, suitable thermosetting polymers include thermosetting polymers that can be made from an energy activatable thermosetting pre-polymer composition. Examples include polyurethanes such as urethane polyesters, silicone polymers, phenolic polymers, amino polymers, epoxy polymers, bismaleimides, polyimides, and furan polymers. The energy activatable thermosetting pre-polymer component can comprise a polymer precursor and a curing agent. The polymer precursor can be heat activatable, eliminating the need for a catalyst. The curing agent selected will not only determine the type of energy source needed to form the thermosetting polymer, but may also influence the resulting properties of the thermosetting polymer. Examples of curing agents include aliphatic amines, aromatic amines, acid anhydrides, or the like, or a combination comprising at least one of the foregoing. The energy activatable thermosetting pre-polymer composition may include a solvent or processing aid to lower the viscosity of the composition for ease of extrusion including higher throughputs and lower temperatures. The solvent could help retard the crosslinking reaction and could partially or totally evaporate during or after polymerization.
As noted above, it is desirable for the polymeric material to have a glass transition temperature of greater than or equal to about 150° C. In one embodiment, it is desirable for the polymeric material to have a glass transition temperature of greater than or equal to about 175° C. In another embodiment, it is desirable for the polymeric material to have a glass transition temperature of greater than or equal to about 200° C. In yet another embodiment, it is desirable for the polymeric material to have a glass transition temperature of greater than or equal to about 225° C. In yet another embodiment, it is desirable for the polymeric material to have a glass transition temperature of greater than or equal to about 250° C.
In one embodiment, the polymeric material is used in an amount of about 5 to about 99.999 wt % of the total weight of the composition. In another embodiment, the polymeric material is used in an amount of about 10 wt % to about 99.99 wt % of the total weight of the composition. In another embodiment, the polymeric material is used in an amount of about 30 wt % to about 99.5 wt % of the total weight of the composition. In another embodiment, the polymeric material is used in an amount of about 50 wt % to about 99.3 wt % of the total weight of the composition.
The antiferroelectric particles are generally ferroelectric particles that are converted into their antiferroelectric state prior to incorporating them into the composition. It is generally desirable for the antiferroelectric particles in the antiferroelectric state to have a dielectric constant that is as close as possible to the dielectric constant of the polymeric material. In one embodiment, the antiferroelectric particles (in the antiferroelectric state) have a dielectric constant whose value is within 10% of the value of the dielectric constant of the polymeric material. In another embodiment, the antiferroelectric particles (in the antiferroelectric state) have a dielectric constant whose value is within 20% of the value of the dielectric constant of the polymeric material. In yet another embodiment, the antiferroelectric particles (in the antiferroelectric state) have a dielectric constant whose value is within 50% of the value of the dielectric constant of the polymeric material. Examples of antiferroelectric particles are those derived from perovskites.
In one embodiment, the antiferroelectric particle is one that has the formula (I)
Pb(M 1 , M 2 , M 3 , . . . )O 3 (I)
where M 1 , M 2 , M 3 , are transition metals or rare earth metals. Examples of transition metals are those present in groups 3 d , 4 d and 5 d of the periodic table, such as, of example, scandium, iron, titanium chromium, zirconium, or the like, or a combination comprising at least one of the foregoing transition metals. Examples of rare earth metals are lanthanum, cerium, neodymium, gadolinium, samarium, or the like, or a combination comprising at least one of the foregoing rare earth metals.
An example of an antiferroelectric particle is one that comprises lead zirconium titanate (PZT) shown in the formula (II) below:
Pb(Zr x Ti 1-x )O 3 (III)
where x is up to about 1. In one embodiment, x can have a value of about 0.3 to about 1. In another embodiment, x can have a value of about 0.6 to about 1. In yet another embodiment, x can have a value of about 0.9 to about 1. The PZT antiferroelectric particles exist in the form of a solid solution that spans a wide compositional space and, consequently, a wide range of dielectric properties. The phase boundaries and electrical properties of PZT can also be further modified by doping. For example, substitution of La 3+ for Pb 2+ can lead to ferroelectric particles with permittivities up to 7000 that can be converted into antiferroelectric particles. Examples of PZT and PZT derivatives include PbHfO 3 , PbZrO 3 , modified Pb(ZrTi)O 3 , PbLa(ZrSnTi)O 3 , PbNb(ZrSnTi)O 3 , or the like, or a combination comprising at least one of the foregoing antiferroelectric particles. An exemplary antiferroelectric particle is lead zirconate (PbZrO3).
Another example of an antiferroelectric particle is one that comprises lead lanthanum zirconium titanates (PLZT) in formula (III):
Pb 1-x La x (Zr y Ti 1-y ) 1-x/4 O 3 (III)
where x and y can each have a value of up to 1 respectively and wherein x and y are independent of each other. In one embodiment, x can have a value of about 0.1 to about 0.3, while y can have a value of about 0.8 to about 1.
Yet another example of an antiferroelectric particle is one that comprises lead scandium niobates (PSN) in formula (IV) or lead scandium tantalate (PST) in formula (V):
PbSc x Nb 1-y O 3 (IV)
PbSc x Ta 1-x O 3 (V)
Other antiferroelectric particles are PbSc 1/2 Nb 1/2 O 3 —PbLu 1/2 Nb 1/2 O 3 , SrTiO 3 —PbZrO 3 , lead scandium niobium titanate (PSNT) and lead lutetium niobium titanate (PLuNT).
In another embodiment, the antiferroelectric particles are lead-free. Examples of antiferroelectric particles include NaNbO 3 , (K,Na)(Nb,Ta)O 3 , KNbO 3 , BaZrO 3 , Na 0.25 K 0.25 Bi 0.5 TiO 3 , Ag(Ta,Nb)O 3 and Na 0.5 Bi 0.5 TiO 3 —K 0.5 Bi 0.5 TiO 3 —BaTiO 3 or the like, or a combination comprising at least one of the foregoing lead-free antiferroelectric particles.
As noted above, the particles can undergo a phase transition from a low dielectric constant (antiferroelectric state) to a high dielectric constant (ferroelectric state) when subjected to an electrical biasing field. In one embodiment, the antiferroelectric particles can undergo a phase transition from an antiferroelectric (low dielectric constant) state to a ferroelectric (high dielectric constant) state when subjected to an electrical biasing field of greater than or equal to about 4 kilovolts/millimeter (kV/mm). In one embodiment, the antiferroelectric particles can undergo a phase transition from an antiferroelectric (low dielectric constant) state to a ferroelectric (high dielectric constant) state when subjected to an electrical biasing field of greater than or equal to about 60 kilovolts/millimeter (kV/mm). In yet another embodiment, the antiferroelectric particles that can undergo a phase transition from an antiferroelectric (low dielectric constant) state to a ferroelectric (high dielectric constant) state when subjected to an electrical biasing field of greater than or equal to about 200 kilovolts/millimeter (kV/mm).
In one embodiment, the dielectric constant of the composition increases by greater than or equal to 50% upon the phase transition. In another embodiment, the dielectric constant of the composition increases by greater than or equal to 100% upon the phase transition. In another embodiment, the dielectric constant of the composition increases by greater than or equal to 500% upon the phase transition.
As noted above, the antiferroelectric particles can have particle sizes in the nanometer range (10 −9 meter range) or micrometer (10 −6 meter range). In one embodiment, the antiferroelectric particles have particle sizes of about 5 nanometers to about 10 micrometers. In another embodiment, the antiferroelectric particles have particle sizes of about 10 nanometers to about 1 micrometer. In another embodiment, the antiferroelectric particles have particle sizes of about 50 nanometers to about 500 nanometers. In yet another embodiment, the antiferroelectric particles have particle sizes of about 100 nanometers to about 400 nanometers.
In one embodiment, the particles can be surface treated to facilitate bonding with the polymeric material. In one embodiment, the surface treatment comprises coating the particles with a silane-coupling agent. Examples of suitable silane-coupling agents include tetramethylchlorosilane, hexadimethylenedisilazane, gamma-aminopropoxysilane, or the like, or a combination comprising at least one of the foregoing silane coupling agents. The silane-coupling agents generally enhance compatibility of the antiferroelectric particles with the polymeric material and improve dispersion of the antiferroelectric particles within the polymeric material.
As noted above, the antiferroelectric particles have at least one dimension in the nanometer or micrometer range. It is generally desirable for the antiferroelectric particles to have an average largest dimension that is less than or equal to about 10 micrometers. The dimension may be a diameter, edge of a face, length, or the like. The antiferroelectric particles may have shapes whose dimensionalities are defined by integers, e.g., the antiferroelectric particles are either 1, 2 or 3-dimensional in shape. They may also have shapes whose dimensionalities are not defined by integers (e.g., they may exist in the form of fractals). The antiferroelectric particles may exist in the form of spheres, flakes, fibers, whiskers, or the like, or a combination comprising at least one of the foregoing forms. The antiferroelectric particles may have cross-sectional geometries that may be circular, ellipsoidal, triangular, rectangular, polygonal, or a combination comprising at least one of the foregoing geometries. The antiferroelectric particles, as commercially available, may exist in the form of aggregates or agglomerates prior to incorporation into the polymeric material or even after incorporation into the polymeric material. An aggregate comprises more than one particle in physical contact with one another, while an agglomerate comprises more than one aggregate in physical contact with one another.
Regardless of the exact size, shape and composition of the antiferroelectric particles, they may be dispersed into the polymeric material at loadings of about 0.1 to about 85 wt % of the total weight of the composition when desired. In one embodiment, the antiferroelectric particles are present in an amount of greater than or equal to about 1 wt % of the total weight of the composition. In another embodiment, the antiferroelectric particles are present in an amount of greater than or equal to about 10 wt % of the total weight of the composition. In yet another embodiment, the antiferroelectric particles are present in an amount of greater than or equal to about 30 wt % of the total weight of the composition. In one embodiment, the antiferroelectric particles are present in an amount of less than or equal to 85 wt % of the total weight of the composition. In another embodiment, the antiferroelectric particles are present in an amount of less than or equal to about 70 wt % of the total weight of the composition. In yet another embodiment, the antiferroelectric particles are present in an amount of less than or equal to about 60 wt % of the total weight of the composition.
The polymeric material together with the antiferroelectric particles and any other optionally desired fillers may generally be processed in several different ways such as, but not limited to melt blending, solution blending, or the like, or a combination comprising at least one of the foregoing methods of blending. Melt blending of the composition involves the use of shear force, extensional force, compressive force, ultrasonic energy, electromagnetic energy, thermal energy or a combination comprising at least one of the foregoing forces or forms of energy and is conducted in processing equipment wherein the aforementioned forces are exerted by a single screw, multiple screws, intermeshing co-rotating or counter rotating screws, non-intermeshing co-rotating or counter rotating screws, reciprocating screws, screws with pins, barrels with pins, rolls, rams, helical rotors, or a combination comprising at least one of the foregoing.
Melt blending involving the aforementioned forces may be conducted in machines such as, but not limited to, single or multiple screw extruders, Buss kneader, Henschel, helicones, Ross mixer, Banbury, roll mills, molding machines such as injection molding machines, vacuum forming machines, blow molding machine, or then like, or a combination comprising at least one of the foregoing machines. It is generally desirable during melt or solution blending of the composition to impart a specific energy of about 0.01 to about 10 kilowatt-hour/kilogram (kwhr/kg) of the composition. Within this range, a specific energy of greater than or equal to about 0.05, preferably greater than or equal to about 0.08, and more preferably greater than or equal to about 0.09 kwhr/kg is generally desirable for blending the composition. Also desirable is an amount of specific energy less than or equal to about 9, preferably less than or equal to about 8, and more preferably less than or equal to about 7 kwhr/kg for blending The composition.
The particles can be in the antiferroelectric state or the ferroelectric state prior to the incorporation into the polymeric material. The particles that are in the ferroelectric state after incorporation into the polymeric material are converted to the antiferroelectric state prior to use in a particular application. In general, it is desirable to have the particles be in the antiferroelectric state prior to use in a particular application. As noted above, a biasing electric field of less than or equal to about 100 kilovolts/millimeter is generally used to change the state of the antiferroelectric particles (from the antiferroelectric state to the ferroelectric state) that are incorporated into the polymers. This biasing electric field can be accompanied by the application of heat to the sample. Heat may be applied in the form of convection, conduction or radiation to the sample during the application of a biasing electrical field.
In one embodiment, the polymeric material in powder form, pellet form, sheet form, or the like, may be first dry blended with the antiferroelectric particles and other optional fillers if desired in a Henschel or a roll mill, prior to being fed into a melt blending device such as an extruder or Buss kneader. In another embodiment, the antiferroelectric particles are introduced into the melt blending device in the form of a masterbatch. In such a process, the masterbatch may be introduced into the melt blending device downstream of the polymeric material.
When a masterbatch is used, the antiferroelectric particles may be present in the masterbatch in an amount of about 10 to about 85 wt %, of the total weight of the masterbatch. In one embodiment, the antiferroelectric particles are used in an amount of greater than or equal to about 30 wt % of the total weight of the masterbatch. In another embodiment, the antiferroelectric particles are used in an amount of greater or equal to about 40 wt %, of the total weight of the masterbatch. In another embodiment, the antiferroelectric particles are used in an amount of greater than or equal to about 45 wt %, of the total weight of the masterbatch. In one embodiment, the antiferroelectric particles are used in an amount of less than or equal to about 85 wt %, of the total weight of the masterbatch. In another embodiment, the antiferroelectric particles are used in an amount of less than or equal to about 75 wt %, of the total weight of the masterbatch. In another embodiment, the antiferroelectric particles are used in an amount of less than or equal to about 65 wt %, of the total weight of the masterbatch. Examples of polymeric materials that may be used in masterbatches are polypropylene, polyetherimides, polyamides, polyesters, or the like, or a combination comprising at least on of the foregoing polymeric materials. In another embodiment relating to the use of masterbatches in polymeric blends, it is sometimes desirable to have the masterbatch comprising a polymeric material that is the same as the polymeric material that forms the continuous phase of the composition. In yet another embodiment relating to the use of masterbatches in polymeric blends, it may be desirable to have the masterbatch comprising a polymeric material that is different in chemistry from other the polymers that are used in the composition. In this case, the polymeric material of the masterbatch will form the continuous phase in the blend.
The composition comprising the polymeric material and the antiferroelectric particles may be subject to multiple blending and forming steps if desirable. For example, the composition may first be extruded and formed into pellets. The pellets may then be fed into a molding machine where it may be formed into other desirable shapes. Alternatively, the composition emanating from a single melt blender may be formed into sheets or strands and subjected to post-extrusion processes such as annealing, uniaxial or biaxial orientation.
Solution blending may also be used to manufacture the composition. The solution blending may also use additional energy such as shear, compression, ultrasonic vibration, or the like to promote homogenization of the particles with the polymeric material. In one embodiment, a polymeric material suspended in a fluid (e.g., a solvent) may be introduced into an ultrasonic sonicator along with the antiferroelectric particles. The mixture may be solution blended by sonication for a time period effective to disperse the antiferroelectric particles within the polymeric material and the fluid. The polymeric material along with the antiferroelectric particles may then be dried, extruded and molded if desired. It is generally desirable for the fluid to swell the polymeric material during the process of sonication. Swelling the polymeric material generally improves the ability of the antiferroelectric particles to be impregnated with the polymeric material during the solution blending process and consequently improves dispersion.
In another embodiment related to solution blending, the antiferroelectric particles are sonicated together with polymeric material precursors. Polymeric material precursors are generally monomers, dimers, trimers, or the like, which can be reacted into polymeric materials. A fluid such as a solvent may optionally be introduced into the sonicator with the antiferroelectric particles and the polymeric material precursor. The time period for the sonication is generally an amount effective to promote encapsulation of the antiferroelectric particles by the polymeric material precursor. After the encapsulation, the polymeric material precursor is then polymerized to form a polymeric material within which is dispersed the antiferroelectric particles.
Suitable examples of monomers that may be used to facilitate this method of encapsulation and dispersion are those used in the synthesis of polymers such as, but not limited to polyacetals, polyacrylics, polycarbonates, polystyrenes, polyesters, polyamides, polyamideimides, polyarylates, polyurethanes, polyarylsulfones, polyethersulfones, polyarylene sulfides, polyvinyl chlorides, polysulfones, polyetherimides, polytetrafluoroethylenes, polyetherketones, polyether etherketones, or the like, or a combination comprising at least one of the foregoing. In one embodiment, the mixture of polymeric material, polymeric material precursor, fluid and/or the particles is sonicated for a period of about 1 minute to about 24 hours. In another embodiment, the mixture is sonicated for a period of greater than or equal to about 5 minutes. In another embodiment, the mixture is sonicated for a period of greater than or equal to about 10 minutes. In another embodiment, the mixture is sonicated for a period of greater than or equal to about 15 minutes. In one embodiment, the mixture is sonicated for a period of less than or equal to about 15 hours. In another embodiment, the mixture is sonicated for a period of less than or equal to about 10 hours. In another embodiment, the mixture is sonicated for a period of and more preferably less than or equal to about 5 hours.
Solvents may optionally be used in the solution blending of the composition. The solvent may be used as a viscosity modifier, or to facilitate the dispersion and/or suspension of particles. Liquid aprotic polar solvents such as propylene carbonate, ethylene carbonate, butyrolactone, acetonitrile, benzonitrile, nitromethane, nitrobenzene, sulfolane, dimethylformamide, N-methylpyrrolidone (NMP), or the like, or a combination comprising at least one of the foregoing solvents may be used. Polar protic solvents such as water, methanol, acetonitrile, nitromethane, ethanol, propanol, isopropanol, butanol, or the like, or a combination comprising at least one of the foregoing polar protic solvents may be used. Other non-polar solvents such benzene, toluene, methylene chloride, carbon tetrachloride, hexane, diethyl ether, tetrahydrofuran, or the like, or a combination comprising at least one of the foregoing solvents may also be used if desired. Co-solvents comprising at least one aprotic polar solvent and at least one non-polar solvent may also be used. In one embodiment, the solvent is xylene or N-methylpyrrolidone.
If a solvent is used, it may be utilized in an amount of about 1 to about 50 wt %, of the total weight of the composition. In one embodiment, if a solvent is used, it may be utilized in an amount of about 3 to about 30 wt %, of the total weight of the composition. In yet another embodiment, if a solvent is used, it may be utilized in an amount of about 5 to about 20 wt %, of the total weight of the composition. It is generally desirable to evaporate the solvent before, during and/or after the blending of the composition.
After solution blending, the solution comprising the desired composition can be cast, spin cast, dip coated, spray painted, brush painted and/or electrostatically spray painted onto a desired substrate. The solution is then dried leaving behind the composition on the surface. In another embodiment, the solution comprising the desired composition may be spun, compression molded, injection molded or blow molded to form an article comprising the composition.
Blending can be assisted using various secondary species such as dispersants, binders, modifiers, detergents, and additives. Secondary species may also be added to enhance one to more of the properties of the composition. Blending can also be assisted by pre-coating the particles with a thin layer of the polymeric material or with a phase that is compatible with the polymeric material, such as, for example a silane layer.
In one embodiment, a composition comprising a polymeric material and the antiferroelectric particles in random orientations and locations may be subjected to an electrical field in order to orient the antiferroelectric particles. The application of the electrical field can be conducted when the composition is in the melt state or in a solution. Solidification can occur in the presence of the electrical field. Upon being subjected to the electrical field, the antiferroelectric particles can be re-aligned into preferred orientation. In one embodiment, the electric field can be used to align these particles into columnar structure so as to give rise to higher dielectric constant.
A composition comprising a polymeric material and the antiferroelectric particles in a low dielectric constant state has advantages over the polymeric material alone. In one embodiment, the composition has a dielectric constant that is at least 10% greater than a composition comprising polymeric material alone. In another embodiment, the composition has a dielectric constant that is at least 50% greater than the polymeric material alone. In another embodiment, the composition has a dielectric constant that is at least 100% greater than the polymeric material alone.
Upon applying an electrical field for converting the antiferroelectric particles to ferroelectric particles, the composition can have a dielectric constant that is at least 200% greater than the polymeric material alone. In one embodiment, upon conversion, the composition has a dielectric constant that is at least 300% greater than a composition comprising polymeric material alone. In another embodiment, upon conversion, the composition has a dielectric constant that is at least 400% greater than the polymeric material alone. In another embodiment, upon conversion, the composition has a dielectric constant that is at least 500% greater than the polymeric material alone.
A composition comprising a polymeric material and particles in a high dielectric constant state (ferroelectric state) has further advantages over the polymeric material and particles in a low dielectric constant state (antiferroelectric state). In one embodiment, the composition has a dielectric constant that is at least 50% greater than a composition comprising polymeric material and particles in a low dielectric constant state. In another embodiment, the composition has a dielectric constant that is at least 100% greater than the polymeric material and particles in a low dielectric constant state. In another embodiment, the composition has a dielectric constant that is at least 500% greater than the polymeric material and particles in a low dielectric constant state.
The composition also has a breakdown voltage that is advantageously greater than the polymeric material alone. In one embodiment, the composition has a breakdown voltage that is at least 50 kilovolts/millimeter. The breakdown is generally determined in terms of the thickness of the composition. In another embodiment, the composition has a breakdown voltage that is at least 100 kilovolts/millimeter. In another embodiment, the composition has a breakdown voltage that is at least 300 kilovolts/millimeter.
The composition also has a corona resistance that is advantageously greater than the polymeric material alone. In one embodiment, the composition has a corona resistance that is resistant to a current of about 1000 volts to 5000 volts applied for about 200 hours to about 2000 hours. In another embodiment, the composition has a corona resistance that is resistant to a current of about 1000 volts to 5000 volts applied for about 250 hours to about 1000 hours. In yet another embodiment, the composition has a corona resistance that is resistant to a current of about 1000 volts to 5000 volts applied for about 500 hours to about 900 hours.
The composition has a dielectric constant greater than or equal to about 3 when measured at frequencies of about 1 to about 10 6 hertz (Hz). In one embodiment, the composition has a dielectric constant greater than or equal to about 5 when measured at frequencies of about 1 to about 10 6 hertz (Hz). In yet another embodiment, the composition has a dielectric constant greater than or equal to about 10 when measured at frequencies of about 1 to about 10 6 hertz (Hz). In yet another embodiment, the composition has a dielectric constant greater than or equal to about 50 when measured at frequencies of about 1 to about 10 6 hertz (Hz).
In another embodiment, the composition also has an impact strength of greater than or equal to about 5 kiloJoules per square meter (kJ/m 2 ). In another embodiment, the composition has an impact strength of greater than or equal to about 10 kJ/m 2 . In another embodiment, the composition has an impact strength of greater than or equal to about 15 kJ/m 2 . In another embodiment, the composition has an impact strength of greater than or equal to about 30 kJ/m 2 .
Compositions that comprise the nanoparticles may also be optically transparent. In one embodiment, the compositions have a transmissivity to visible light of greater than or equal to about 70%. In another embodiment, the compositions have a transmissivity to visible light of greater than or equal to about 80%. In yet another embodiment, the compositions have a transmissivity to visible light of greater than or equal to about 90%. In yet another embodiment, the compositions have a transmissivity to visible light of greater than or equal to about 95%. In yet another embodiment, the composition also has a Class A surface finish when molded. Molded articles can be manufactured by injection molding, blow molding, compression molding, or the like, or a combination comprising at least one of the foregoing.
The composition can advantageously be used in energy storage and power conversion devices for applications including transient voltage clamping, ripple voltage reduction and waveform correction in resonant circuit. The composition can advantageously be used in spark plug caps, capacitors, defibrillators, xray tubes, or other articles.
The following examples, which are meant to be exemplary, not limiting, illustrate compositions and methods of manufacturing of some of the various embodiments described herein.
EXAMPLES
Example 1
Example 1 illustrates the increase in dielectric constant as a function of increased amounts of nanosized antiferroelectric particles incorporated into a polymeric material. The polymeric material is polyvinylidene fluoride (PVDF) commercially available from Solvay Solexis Inc. The nanosized antiferroelectric particles are NPZ, a rhombohedral-structured lead zirconate. The mean particle size was 100 nanometers. The nanosized antiferroelectric particles were manufactured as follows. Lead oxide and zirconium dioxide were mixed with equimolar mixture of sodium chloride and potassium chloride. The mixture was heated to 900° C. for 6 hours in air in a covered alumina crucible. The reacted mass was then treated with hot water to dissolve off the chloride flux. Fine crystalline lead zirconate was recovered.
The lead zirconate powder was then milled in acetone using a paint shaker for 20 minutes, dried and sieved through a 200-mesh sieve. 0.25 grams of polyvinylidene fluoride (PVDF) was first dissolved in 153 grams of NMP solvent to form a polyvinylidene fluoride (PVDF) solution. The nanosized antiferroelectric particles were added in an amount of about 20 vol % and 40 vol %, based on the total volume of the PVDF as well as the particles. The PVDF solution containing the particles was then cast onto a glass substrate under a clean hood. The solution was dried until films were formed. The composition films were subjected to dielectric constant tests at room temperature at a frequency of 10 2 to 10 5 Hz using a dielectric analyzer HP4285A manufactured by Hewlett Packard. The film thickness is 20 to 150 micrometers, which was sputter coated with platinum. The platinum establishes electrical contact with the electrodes of the dielectric analyzer. The results are shown in the FIG. 1 . From the FIG. 1 it may be seen that 20 vol % of nanosized antiferroelectric particles increased the dielectric constant of the polymeric material alone by about 250%. Addition of 40 vol % of nanosized antiferroelectric particles increased the dielectric constant of the polymeric material alone by about 450%.
Example 2
Example 2 illustrates the polarization hysteresis loops that are obtained when the polarization is measured for compositions comprising nanosized ceramic antiferroelectric particles and a polymeric material. Nanosized antiferroelectric particles similar in composition to those in Example 1 were incorporated into polyvinylidene fluoride (PVDF) at 20 vol % and 40 vol % as detailed in the Example 1. The nanosized antiferroelectric particles have a particle size of 40 nanometers. Polarization was measured using a Precision LC Ferroelectric test system made by Radiant Technologies Inc. at a frequency of 10 hertz. The results are shown in the graph in FIG. 2 . From the graph in the FIG. 2 it may be seen that polarization inside the nanosized particles are switched over by the applied electric field, indicated by the formation of polarization loop. At higher levels of NPZ loading, the polarization switching is more easily triggered.
Example 3
Example 3 illustrates the field-tunability of the dielectric constant when nanosized antiferroelectric particles are incorporated into a polymeric material. The nanosized antiferroelectric particles were lead zirconate that are 40 nanometers in size and incorporated into polyvinylidene fluoride (PVDF) at 20 vol % and 40 vol % in a manner similar to that described in the Example 1. The dielectric constant was calculated based on the polarization switching behavior as shown in FIG. 2 . The dielectric constant was calculated as follows.
Dielectric constant K is defined as shown below in equations (I) and (II)
P =( K− 1)∈ 0 E (I)
D=K∈ 0 E (II)
where P is the polarization (as measured in our experiment), D is dipole displacement, ∈ 0 is the permittivity of the vacuum, and E is applied field.
For materials with a high dielectric constant, P˜D=K∈ 0 E. For nonlinear dielectrics, K(E x ) at a given field E x can be defined as shown below in equations (III):
K ( E x )=( dP/dE )/∈ 0 ( E x ) (III)
K is therefore calculated using equation (III) by taking the derivative of the P˜E curve at a specified field E. To reduce the noise of derivation, the reported K values are the average values of the closest 10 experimental data points. Specifically, K is averaged for polarization data measured in the 100 volts/micrometer field range.
The results are shown as a graph in FIG. 3 . From the FIG. 3 it can be seen that there was an increase of about 50% in dielectric constant under an electric field of about 100 volts/micrometer for the polymeric material having 20 vol % nanosized antiferroelectric particles. For the polymeric material with 40 vol % nanosized antiferroelectric particles, there was a maximum increase of over 200% in dielectric constant under an electric field of about 50 volts/micrometer. This increase in dielectric constant corresponds with a phase transition from an antiferroelectric state to a ferroelectric state.
Example 4
Example 4 illustrates the polarization hysteresis loops triggered when micrometer-sized antiferroelectric particles are incorporated into a polymeric material. The micrometer-sized particles were lead zirconate (PZ) particles. The micrometer sized antiferroelectric particles were 1 to 5 micrometers in size and incorporated into PVDF at 20 vol % and 40 vol % in a manner similar to that described in the Example 1. The polarization hysteresis was measured as described in the Example 2. The results are shown as a graph in FIG. 4 that shows the general behavior of the polarization response of the composites containing 20 vol % PZ under various electric fields. As indicated by FIG. 4 , a higher electric field is needed to trigger the antiferroelectric-ferroelectric phase transition in the sample containing 40 vol % filler than the sample containing the 20 vol % filler.
Example 5
Example 5 illustrates the field-tunability of the dielectric constant when micrometer-sized antiferroelectric particles are incorporated into a polymeric material. The micrometer-sized particles were lead zirconate (PZ) particles. The micrometer sized antiferroelectric particles were 1 to 5 micrometers in size and incorporated into PVDF at 20 vol % and 40 vol % in a manner similar to that described in the Example 1. The dielectric constant was calculated based on the polarization switching behaviors as shown in FIG. 4 . The dielectric constants were calculated as described in Example 3. The results are shown as a graph in FIG. 5 . The dielectric constant of the polymeric material with 20 vol % micrometer-sized antiferroelectric particles did not show significantly different field-tunability than that of the polymeric material alone. However, the dielectric constant of the polymeric material with 40 vol % micrometer-sized antiferroelectric particles showed a significantly different field-tunability than that of the polymeric material alone. For example, FIG. 5 shows about a 100% increase in dielectric constant of the polymeric material with 40 wt % micrometer-sized antiferroelectric particles under an electric field of about 60 volts/micrometer over the polymeric material alone.
From the above examples it may be seen that the dielectric constant of the composition can be increased by at least 50% over a polymeric material that does not contain the antiferroelectric particles. In one embodiment, the dielectric constant of the composition is increased by at least 200% over a polymeric material that does not contain the antiferroelectric particles. In another embodiment, the dielectric constant of the composition is increased by at least 400% over a polymeric material that does not contain the antiferroelectric particles.
In one exemplary embodiment, the composition can have an impact strength of greater than or equal to about 10 kJ/m 2 , a Class A surface finish and a breakdown strength of at least 100 V/micrometer.
In another exemplary embodiment, the composition can have an impact strength of greater than or equal to about 10 kJ/m 2 , a Class A surface finish and a corona resistance of about 1000 volts to 5000 volts applied for about 200 hours to about 2000 hours.
While the invention has been described with reference to 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 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.
|
Disclosed herein is a composition comprising a composition comprising a polymeric material; and a ceramic antiferroelectric particle. Disclosed herein too is a method of tuning a dielectric constant of a composition comprising subjecting a composition comprising a polymeric material and a ceramic antiferroelectric particle to a biasing electric field; and changing the dielectric constant of the composition. Disclosed herein too is a method comprising blending a polymeric material with ceramic antiferroelectric particles to form a composition. Disclosed herein too is a method comprising blending a polymeric material with ceramic antiferroelectric particles to form a composition; applying an electrical field to the composition; and reorienting the ceramic antiferroelectric particles.
| 7
|
FIELD OF THE INVENTION
This invention relates to centrifugal pumps which may be used for pumping water or other fluids.
BACKGROUND OF THE INVENTION
Known centrifugal pumps comprise a rotor having impeller blades which is driven in rotation within a casing having an axial inlet for fluid and a peripheral outlet through which the fluid is discharged under the action of the rotor blades. Such pumps are generally designed to operate using only one direction of rotation of the rotor and the blades are shaped and angled to give an efficient pumping action when the rotor is driven in that direction. These pumps are usually very inefficient if the direction of rotation of the rotor is reversed, so that the blades are moving backwards.
In automatic underwater cleaners for swimming pools and the like, a submerged centrifugal pump is driven by an electric motor and is mounted on a device which is movable in more than one direction. Separate motors are provided for operating the pump and for driving the device in movement, the pump motor being operated in one direction only and the other motor being reversible so that the device can be moved in opposite directions as required.
The present invention is intended to provide a centrifugal pump which can operate efficiently when driven in either direction. Such a pump allows an automatic pool cleaner of the above-mentioned type to be driven by only one motor.
The blades of a centrifugal pump have to be set to particular orientations on the pump rotor to give an efficient pumping action. This orientation may vary according to the pressure against which the pump has to operate and according to the volume of fluid to be pumped. Also when designing a pump for a particular application, determining the optimum orientation of the impeller blades may be a troublesome and expensive operation.
The present invention is also intended to provide a centrifugal pump in which the blade orientation may readily be varied, and the optimum orientation easily determined.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a reversible centrifugal pump comprises a rotor drivable in rotation in both directions about an axis by a motor, the rotor being mounted in a casing having an inlet and a peripheral outlet for fluid to be pumped, the rotor comprising impeller blades which are pivoted to the rotor to rotate relative thereto between two extreme positions, and stop means preventing rotation of the blades beyond said extreme positions.
The stop means may comprise pins extending through the rotor parallel to the rotor axis and positioned to abut the blades. Each blade may be associated with a pair of pins, the pins being a greater distance from the rotor axis than the blade pivots and the blades being between the pins so that the blades may rotate about their pivots between two extreme positions defined by the pins. Under the effect of the pressure of the fluid being pumped the blades will be urged against one pin or the other, depending on the direction of rotation of the rotor, and the pins may be located to give the optimum blade position in both directions of rotation.
The blades may be flexible so that they are capable of bending under the fluid pressure to further optimize the blade orientations during pumping. The blades may be of a flexible plastics material or of a metal such as stainless steel.
According to another aspect of the invention a centrifugal pump which may or may not be reversible comprises a rotor drivable in rotation about an axis, the rotor being mounted in a casing having an inlet and a peripheral outlet for fluid to be pumped, the rotor comprising impeller blades which are pivoted to the rotor to rotate relative thereto and stop means preventing rotation of the blades beyond an extreme position, the stop means being adaptable to vary said extreme position. In this pump the stop means may comprise pins inserted through holes provided in a pair of plates forming the sides of the rotor and a number of pairs of holes in the respective plates may be provided at different locations to define different extreme positions for the blades.
Varying the extreme position of the blades in this way allows the pump to be readily adapted to different pressures and rates of flow. It also allows the blades to be set to their optimum positions empirically, by running a series of tests with the blades in different positions. The blade position may be easily and quickly adjusted by removing the appropriate pins and re-inserting them at a different location. This arrangement may also be used for optimizing the performance of a pump at the design stage.
BRIEF DESCRIPTION OF THE DRAWINGS
A centrifugal pump according to one embodiment of the invention will now be described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a schematic cross-section of a centrifugal pump,
FIG. 2 is a schematic cross-section of the pump perpendicular to the section of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The pump shown in the drawings comprises a casing 1 having one side 2 which is completely open, forming an outlet for discharge of fluid, and an opening 3 forming an inlet for fluid. The casing contains a rotor comprising a circular plate 4 which is drivable in rotation by means of shaft 5 driven by an electric motor (not shown in the drawings). The motor is capable of driving shaft 5 in either direction.
The rotor also comprises a circular plate 6 which is connected to plate 4 by pins 7 which extend parallel to the axis of shaft 5. In the embodiment shown in the drawings the pins are six in number and distributed around the periphery of the rotor discs.
The rotor also comprises spindles 8 which extend between the plates in the axial direction and impeller blades 9, three in number as shown in the drawings, which are pivoted for free rotation about the spindles 8. Pins 7 are further away from the axis of the rotor than spindles 8 so that the rotation of the blades about the spindles is limited by the pins abutting the blades. Pins 7 are positioned around the periphery of the rotor in pairs, one pair corresponding to each blade and the pins of each pair define a pair of extreme positions between which the blade can rotate relatively to the rotor about spindle 8.
The blades 9 are formed of sheets of flexible plastics material which in use can bend to a certain degree under fluid pressure. Alternatively, they may be formed of relatively thin stainless steel which is capable of bending in the same manner.
When the pump is in operation, fluid is fed to it through inlet 3 and the rotor is driven in rotation so that the blades 9 impel the fluid outwardly and the fluid is discharged through the open side 2 of the pump. FIG. 1 shows the rotor rotating in the anticlockwise direction and, against the resistance of the fluid, the blades move to the position shown in FIG. 1 in which they are held by abutment with pins 8. The positions of these pins are chosen so that the angles of the blades in this position are at an optimum for pumping efficiency, this optimum position may vary according to the speed of the rotor and the pressure head against which the fluid is pumped.
If the direction of rotation of the rotor is reversed the blades, under the effect of the fluid resistance, will move to their other extreme position defined by the other one of their pairs of pins, the blades then being angled in the reverse direction. The pins are located so that in this position also, the blades are positioned for optimum pumping efficiency. As the side 2 of the pump casing is completely open the fluid can escape in the same manner whatever the direction of rotation of the rotor.
The pump described is simple, requires little maintenance as it is well adapted to situations in which the motor driving it is required to operate in either direction, for example in underwater devices for cleaning swimming pools. The pump described allows a single motor to be used for pumping and for other operations, including to-and-fro movement, with such a device.
In another embodiment, not shown in the drawings, the pins are removable from plates 4 and 6 and for each pin a number of holes are provided in plates 4 and 6 to receive the pins so that each pin may be located at a choice of positions in the rotor. This feature allows the extreme positions of the impeller blades to be varied at will so that these positions may be set according to the pressure against which the pump has to operate, the volume of fluid to be pumped and the speed of rotation of the rotor. When the pump is installed at a given location, or when the pump is being designed for a given use, it may be operated in a series of trial runs with the pins in different positions and the pin position which gives the optimum efficiency may be adopted for subsequent use. This feature may also be used in centrifugal pumps which are intended to operate in one direction only, in which case the outlet for the fluid may be provided adjacent one side of the rotor only, instead of both sides as shown in the drawings.
|
A centrifugal pump comprises impeller blades which are pivoted at their inner ends to a rotor so that the impeller blades can rotate relatively thereto between two extreme positionss. The extreme positions are defined by stop means in the form of pins. The construction enables the centrifugal pump to be operated efficiently when driven in either direction, the blades being allowed to flex during operation.
| 5
|
FIELD OF TECHNOLOGY
[0001] This disclosure relates generally to paper-based and textile-based materials with associated protective coatings or coverings. In one example embodiment, the disclosure relates to methods, apparatus, and systems to protect a material from weathering, tampering and other outside effects through the use of a surrounding coating or covering such as polyolefin based coating.
BACKGROUND
[0002] Within many fields, notably in paper-based and textile-based materials and more specifically sensitive document materials such as for passports, security and a need for protection is paramount. Documents, such as passports, can incorporate several features designed to ensure that counterfeiters cannot alter the integrity of the documents. Although very secure, modern passports can be flawed due to inherent weaknesses of paper-based or textile-based materials, which includes a potential removal of the cover or associated pages by slicing or splitting the cover off the pages or documents. For example, counterfeiters can take advantage of the weakness in the cover material as it is disproportionally weaker than the inlay layer thus making the adhesive layer between the two layers the point of failure. Also, the nature and thickness of the cover material allows for a partial removal of an element either by slicing or splitting. This allows counterfeiters to remove the sewing in the hinge and add or remove the inner visa pages, which provides an avenue for further counterfeiting.
[0003] FIG. 1 illustrates a prior art document according to some embodiments. A document 100 can have document information printed on a paper (or textile) layer 130 covered by a varnish layer 150 . A polyolefin layer 110 and a paper (or textile) layer 130 can be glued together. e.g., using an adhesive layer 120 , with an adhesive adopted to polyolefin and to paper (or textile). The adhesion between the polyolefin layer 110 and the paper layer 130 may be insufficient and or decrease over time due to the binding of different materials. Thus the layers can be delaminated mechanically 140 along the bonding layer 120 , for example, using a knife or a sharp object. In addition, the paper (or textile) layer 130 can be sliced 145 and split 135 , due to heterogeneous characteristics of the paper or textile material. Moreover delamination can be achieved through application of increased temperatures.
[0004] These described methods are just some of the many methods, with increasing creativity, that counterfeiters enlist that take advantage of the inherent flaws of the current industry standard and common passport design as described in the above embodiment. As such, it becomes clear that within prior designs and known industry practices, including the embodiment described above, a counterfeiter is able to alter documents such as passports in their current design.
[0005] Thus, there is a need for a protective apparatus in secure documents such as government issued identification documents that is both more resistant and durable to outside characteristics and wear, such as tampering and counterfeiting, than the industry standard as described in the above embodiment which is vulnerable to tampering and counterfeiting.
SUMMARY
[0006] Disclosed are methods, apparatus and systems that provide a coating or surrounding matrix of a material, disclosed as a cover material, over a textile-based, paper-based or other material, disclosed as the inlay material or inlay element. Paper-based or textile-based materials are widely used in documents, most notably identification documents such as government issued passports and identification documents. Paper-based materials, such as a polymer-fiber reinforced paper are most widely used as they are easy to process. Polymer-fiber reinforced textile is sometimes used, but less frequently due to the difficulty in processing and higher cost. These documents may also have other inlay elements, such as photos or devices such as biometric identification devices, NEC devices, RFID devices and other electronics and structures which may aid in the use of the identification document.
[0007] The included method, system or invention provides a basis for covering or protecting any type of material or element such as textiles, papers or composites. These covered materials are designated as the inlay material or inlay element, and may be of any type. In a preferred embodiment the inlay material or inlay element may be a document. such as a passport, driver's license, identification card, other printed material such as a story or photo or devices such as a display, RFID or NFC devices. etc. The inlay material or element may be of any paper based, textile based, synthetic, metallic or composite material including wood pulp paper, cotton based paper, textiles including composite textiles, organics or inorganics and may also constitute of formed devices such as electronic devices, semiconductors, antennas and associated micro-electronics such as an RFID tag or NFC devices. In essence, the inlay material or inlay element is an item or items or element or elements to be protected or covered by the covering material.
[0008] The covering material may be of any material such as a composite material or matrix, as well as constitute different layers of differing materials, or in a preferred embodiment, may constitute a monobloc structure of a homogenous material. In a preferred embodiment the material may be polyolefin based and may be designated as a film. The cover material which may be polyolefin, or similar types, may be a microporous matrix composed essentially of an interconnecting porous network of ultrahigh molecular weight, high density polyethylene
[0009] One particular type of polyolefin material that may be used is a polyolefin film as described in U.S. Pat. No. 4,861,644 which is herein incorporated by reference. The structure may be constructed to form a microporous matrix having a network of interconnecting pores communicating throughout the matrix. The average diameter of the pores within the matrix may be any measurement such as between 0.02 and 50 micrometers. The matrix may be formed of any percentage of polyolefin or other materials with an intended characteristic in both volume and mass, and may also include any other materials to provide a different characteristic from the matrix material, such as an additive for coloring, an additive or material for strengthening, an additive for rigidity or an additive for UV protection. As such, the additives may be of any type of material and the microporous matrix may be filled with any filler such as siliceous filler, mica, montmorillonite, kaolinite, asbestos, talc, diatomaceous earth, vermiculite, calcium silicates, aluminum silicates, sodium aluminum silicate, alumina silica gels and glass particles and any other material for any intended purpose.
[0010] The covering material may be of homogenous materials and construction such as in the preferred embodiment of a polyolefin matrix impregnated by silica or another material with a homogenous construction and distribution. The covering material may also be of heterogeneous construction, material and structure, such as using different materials within the construction to make a heterogeneous covering material or matrix, or using the same material throughout the matrix but in the process of applying the material, heat or sonic other process is provided to enact different characteristics to different areas of the material, thus making a heterogeneous matrix structure using the homogenous material. The preferred embodiment uses a homogenous covering material providing a homogeneous matrix with impregnation by an additive.
[0011] The methods above, with using a material such as a polymer material which may be polyolefin, as a protective cover or surrounding layer over inlay materials or elements, can prevent the inlay material or elements, such as a secure document, from being sliced and extracted or tampered with in the same manner as paper or other structure as seen in the Prior Art, thus protecting the secure document pages from counterfeiting. The methods may include using a covering material having a high content of dispersed hard particles, such as silica within the covering material, which can prevent the cover from being melted or sliced without destroying the document itself In some embodiments, the present invention discloses documents that include a siliceous fillers containing microporous polyolefin material as a passport cover material, e.g., replacing paper-based or textile-based materials. The passport documents can include several layers of siliceous fillers containing microporous polyolefin materials, with embedded document elements, such as radio frequency identification (RFID) transponders and printed information.
[0012] The films as taught by the present invention, provide a means to form secure documents, or provide an ability to form a coating on a document or other inlay material or element for any other reason. The documents or product generated from the method may include laminating several layers, such as two or more layers of the above mentioned microporous polyolefin matrix materials which may be filled or impregnated. The lamination of multiple layers can form a structure that, due to the nature of the polyolefin or similar material, is bonded together to form a kind of a monobloc structure, a structure that cannot be sliced or split between the layers without destroying the composite structure. The structure as an improvement on the Prior Art, provides a basis where the covering material fully encompasses the inlay material and as such, with the fully encompassing monobloc structure, provides a characteristic that is hard to tamper or cut as seen in the Prior Art, as a knife or other sharp edge does not have a weakened area between the inlay material and covering material in which to penetrate unlike within the Prior Art.
[0013] In addition, the composite structure can show enhanced durability with a wide range of design opportunities like direct print or coloring for the secure documents or other types of materials needed to be coated or surrounded, such as a document with a RFID, or structures used in manufacturing or otherwise, such as plastics or sheets used within computer devices and supplies. These materials may be a coverstock of a document, such as the cover of passport, or may also be within the inner stock such as a visa page or visa pages of a passport. The material may also be synthetic or any material other than textile-based or paper-based.
[0014] In some embodiments, an adhesive material may be enlisted between the layers of the inlay material or inlay elements and covering material, or between layers of the covering material. The adhesive materials may be selected or optimized to allow for a strong adhesion between various or any components or materials. For example, the adhesive can be elected or optimized for a strong adhesion between two layers of the covering material such as the polyolefin based materials or between the filler portions or a combination thereof. Moreover the adhesive may be optimized to allow for maximum adhesion to the inlay material or elements such as parts of the RFID transponder such as the antenna wire, the RFID chip, the etched or printed elements of the RFID transponder, and a strong adhesion among the other parts of the RFID transponder or other inlay elements.
[0015] In some embodiments, an adhesive material may be enlisted between the layers of the inlaid elements and covering material, or between the pluralities of layers of the covering material. The adhesive materials may be selected or optimized to allow for a strong adhesion between various or any components or materials such as an adhesive that bonds to paper or plastic of which the inlaid elements may be made of and the polyolefin material, or an adhesive that bonds the polyolefin material layers together. Examples of adhesives may be synthetic elastomer-based adhesives, hot melt adhesives, pressure sensitive acrylic co-polymer emulsions, visible light curing adhesives, cyanoacrylates, or reactive (meth) acrylate glues, as well as reactive urethanes. The adhesives may be applied with or without surface treatment. Also in place of adhesives other process or products may be used such as heat, friction, thermal welding, captive designs such as interlocking pieces, etc.
[0016] An additional layer which may be described as varnish and may be of any material, can be added on the internal layer, on the external layer or on any layer of present invention. The varnish can be made of any material such as the industry standard of a combination of a drying oil, a resin and a thinner or solvent. The varnish may be glossy, satin or semi-glossy and of differing levels of transparency. The varnish also may have qualities such as qualities that provide certain outward appearances, such as a tint or that provide tamper evidence such as heat susceptibility using elements such as color changing dyes. These characteristics may be found within the covering material or inlay material or inlay elements as well. The varnish, in a preferred embodiment is provided on the external layer and can provide protection from wear and other characteristics. Having the varnish on the outside layer, provides a basis for both protection from wear due to the characteristics of the material the varnish is made up of but also because the varnish is on the outermost layer, the area between the monobloc or non-monobloc covering material, and inlay element or materials is not structurally differentiated and as such the monobloc covering as aforementioned is held intact. Thus, trying to tamper or penetrate the adhesion, would only result in removing the varnish and would not be successful in reaching the inlay material or elements, as the varnish and associated connection of the varnish layer and covering layer is solely on the external side of the covering material.
[0017] Polyolefin and many other materials used within the covering and identification materials are also highly receptive to reactive adhesives, which offers a tamper-resistant and destruction preventing bond between the layers. The bond between these two components may be excellent even without a glue or adhesive layer between the intended film and the paper. However, an adhesive layer of any thickness may be included to increase the bond strength between the material such as paper and the coating and may provide a basis for providing, since the two components are made of the same material, a final structure that is formed to be a monobloc structure e.g., preventing thermal, stress or strain mismatches, thus reducing warpage issues, for example. The life characteristics can be improved, for example, having better water resistance and wear and tear resistance. These materials, and the adhesive may be configured to complement the paper, or structures, such as the RFID transponder, to aid in both adhesion and other characteristics such as allowing the passing of radio waves.
[0018] Additionally, the present invention may also comprise to have multiple layers of the covering material, in that it may provide intended characteristics, such as multiple layers may provide better wear characteristics or each layer may provide a different materials within the microporous matrix, such as one layer providing UV protection, the next providing scratch resistance, and another layer or the presence of many layers providing further deterrent to the ability to tamper with or counterfeit the inner document or inlay material.
[0019] The methods and systems disclosed herein may be implemented in any means for achieving various aspects. Other features will be apparent from the accompanying drawings and from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Example embodiments are illustrated by way of example and are not limited to the figures of the accompanying drawings, in which, like references indicate similar elements.
[0021] FIG. 1 is a cross sectional view of a Prior Art showing a document with alternate layers of polyolefin, textile or paper as the industry standard and exampling methods of counterfeiting.
[0022] FIG. 2A is a cross sectional view of a document showing the embodiment of the present invention with two polyolefin based film and bonded by an adhesive laver.
[0023] FIG. 2B is a cross sectional view of a document showing an embodiment with an inner layer and outer layer of polyolefin without any adhesive layer and with a monobloc structure.
[0024] FIG. 2C is a cross sectional view of a document showing an embodiment with multiple layers of polyolefin without any adhesive layer and a monobloc structure.
[0025] FIG. 3A-3D illustrate a process for forming a document according to some embodiments.
[0026] FIG. 3A is a cross sectional view of an embodiment. of a provided first polyolefin based film.
[0027] FIG. 3B is a cross sectional view of an embodiment of an identification element formed on a provided first polyolefin based film.
[0028] FIG. 3C is a cross sectional view of an embodiment of an identification element formed on a provided first polyolefin based film with an adhesive layer.
[0029] FIG. 3D is a cross sectional view of an embodiment of an identification element formed on a provided first polyolefin based film with an adhesive layer and second polyolefin layer and adhesive layer.
[0030] FIG. 4A-4C illustrate a process for forming a document according to some embodiments.
[0031] FIG. 4A is a cross sectional view of an embodiment of a provided. first polyolefin based film.
[0032] FIG. 4B is a cross sectional view of an embodiment of an identification element formed on a provided first polyolefin based film.
[0033] FIG. 4C is a cross sectional view of an embodiment of an identification element formed on a provided first polyolefin based film with an adhesive layer and with a monobloc structure.
[0034] FIG. 5A is a systematic diagram of an embodiment in which an identification element is placed between two films and optional adhesive.
[0035] FIG. 5B is a systematic diagram of an embodiment in which an identification element is incorporated in a film and a coating adhesive with laminating a second film.
[0036] FIG. 6A is an example embodiment of a passport or document in which the present invention is enlisted.
[0037] FIG. 6B is an example embodiment of a passport, document or booklet with corresponding cover and inlay pages in which the present invention is enlisted.
[0038] FIG. 6C is an example embodiment of a passport or document or booklet inner page in which the present invention is enlisted.
[0039] Other features of the present embodiments will be apparent from the accompanying drawings and from the detailed description that follows.
DETAILED DESCRIPTION
[0040] Disclosed are methods, apparatus, and systems that may provide a covering or suspension for an inlay material or inlay elements such as a textile or paper based material, document or object that may protect from tampering, counterfeit, wear and other environments. The present invention may be based on the coating being of a polyolefin based material, other microporous materials or other materials, and may be of different structures, including multiple layers, heterogeneous or homogeneous and the inclusion of an adhesive to provide specific characteristics, such as a material that hardens the matrix or provides wear or tamper resistance. These preferred embodiments below are in addition to the features and characteristics described in the above summary and aforementioned figures and description. Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the various embodiments. It should be understood by one of ordinary skill in the art that the terms describing processes, products, element, or methods are industry terms and may refer to similar alternatives. In addition, the components shown in the figures, their connections, couples, and relationships, and their functions, are meant to be exemplary only, and are not meant to limit the embodiments described herein.
[0041] Example embodiments are illustrated by way of example and are not limited to the figures of the accompanying drawings, in which, like references indicate similar elements.
[0042] In one or more embodiments, in addition to the above or below embodiments, the present invention relates to a coating.
[0043] In one or more embodiments, in addition to the above or below embodiments, the present invention relates to a coating such as a polyolefin coating.
[0044] In one or more embodiments, in addition to the above o below embodiments, the present invention relates to a coating such as a polyolefin coating that encompasses an inlay material or object either entirely or on any number of sides.
[0045] In one or more embodiments, in addition to the above or below embodiments, the present invention relates to a coating such as a polyolefin coating that encompasses an inlay material or object such as a passport document, passport page, or other identification material either entirely or on any number or sides.
[0046] In one or more embodiments in addition to the above or below embodiments, the present invention may teach an inlay material that may be of any type, structure, form or composition such as a device, document, printed material, display etc.
[0047] In one or more embodiments in addition to the above or below embodiments the present invention relates to a coating such as a polyolefin coating that encompasses an inlay material or object such as an RFID or other devices such as NFC or biometric identification devices either entirely or on any number of sides.
[0048] In one or more embodiments in addition to the above or below embodiments, the coating material may be of any material such as polyolefin or such as any synthetic, metallic, organic, inorganic or other materials.
[0049] In one or more embodiments, in addition to the above or below embodiments, the present invention may teach that the coating may be of any material such as polyolefin or another synthetic, metallic or organic material, of which provides a microporous matrix with any diameter or volume of pores.
[0050] In one or more embodiments, the present invention may, in addition to the above or below embodiments, have the coating be made of polyolefin or another synthetic, metallic organic, inorganic or other material, of which provides a porous matrix, which may be a micro porous matrix, of which a filling material is impregnated.
[0051] In one or more embodiments, the present invention may, in addition to the above or below embodiments, have the coating be made of polyolefin or another material, of which provides a porous matrix, of which a filling material is impregnated, and of which may be a material such as silica, or any material with a desired characteristic, such as to make the present invention more resistant to tampering by changing the characteristic to be harder, more rigid, etc.
[0052] In one or more embodiments, in addition to the above or below embodiments, the present invention may teach the surrounding material to be of any thickness or any plurality of layers.
[0053] In one or more embodiments, in addition to the above or below embodiments, the present invention may teach the surrounding material to be of any thickness or any plurality of layers to provide for a differing level of hardiness, toughness, tamper resistance or any other aspect. For example, for one type of embodiment, there is only one layer such as a monobloc layer that is comparatively thin, such as 0.1 mm wherein the need of the layer is to protect against water or dust. In another example, the monobloc layer may be 3 mm wherein the monobloc protects the embedded element, such as a document, against dust and water but also intrusion from solid objects such as a knife or from scratches. Additionally, in other embodiments, the single layer may be replaced by a plurality of layers, of which may be formed around, or be attached or formed with an adhesive layer such as with a glue, or other bonds such as being formed together with heat or friction, etc.
[0054] In one or more embodiments, in addition to the above or below embodiments, the present invention may teach the embedded depth of the embedded element in the surrounding material may be of any depth or thickness and may be presented to provide various protections based on the depth or thickness of the layer or layers of material.
[0055] In one or more embodiments, in addition to the above or below embodiments, the present invention may teach to the surrounding material of which may be of different types within different layers, such as having a layer with the polyolefin matrix having a UV reflective material embedded and another layer having silica embedded, providing hardness, rigidity or another characteristic to the structure.
[0056] In one or more embodiments, the present invention may, in addition to the above or below embodiments, enlist the use of an adhesive to bond the different layers of the present invention such as to provide a better bond between the surrounding layer and the inlay layer to reduce tampering. The adhesive may be of any type, and may be chosen due to the characteristics of the materials, such as polyolefin having a desirable characteristic to bond with a certain adhesive, or the adhesive having a characteristic to bond with the inlay material.
[0057] In one or more embodiments, the present invention may, in addition to the above or below embodiments, provide a structure in which the surrounding material is formed as such to provide a monobloc structure
[0058] In one or more embodiments, the present invention may in addition to the above or below embodiments, provide a structure in which the surrounding material is formed as such to fully encompass the material.
[0059] In one or more embodiments, the present invention may, in addition to the above or below embodiments, provide a structure in which the surrounding material is formed as such to encompass the material on any number of sides and may form a monobloc structure. The structure as an improvement on the Prior Art, provides a basis where the covering material fully encompasses the inlay material and as such with the encompassing and monobloc structure, provides a characteristic that is hard to tamper or cut as seen in the Prior Art, as a knife or other sharp edge does not have a weakened area between the inlay material and covering material in which to penetrate unlike in the Prior Art and exampled in FIG. 2B areas 213 and 215 becoming a monobloc structure encompassing the inlay material or element 245 completely.
[0060] In one or more embodiments, the present invention may, in addition to the above or below embodiments provide a structure where a varnish is applied to any of the layers or structures of the covering material, inlay materials or inlay elements. The varnish may be of any type or material as described within the summary and may provide a basis for any and all characteristics such as wear resistance or other physical characteristics such as a desired tint or coloring. Also, the varnish may provide a basis for tamper evident markers such as temperature indicating dyes or other characteristics. As well as this, the varnish, in a preferred embodiment, may be on the external layer of the present invention. This provides a basis that the covering material and inlay materials and inlay elements and their associated protections afforded by the monobloc or other structures as described are still effected as the varnish, on an external layer, does not provide an intrusion into the spaces between the inlay and covering layers and as such the inner structures are held intact and resistant to penetration or other tampering. By a basis of tampering of the varnish, the removal of the varnish does not allow access to the inlay materials, and may actually provide a basis for tamper evidence.
[0061] In one or more embodiments, in addition to the above or below embodiments, the present invention may provide that the surrounding material is made to provide a stratified or layered and monobloc or non-monobloc structure.
[0062] FIGS. 2A-2C illustrate a preferred embodiment of documents using a. covering material which may be polyolefin based according to some embodiments. In FIG. 2A , a document 200 , such as a passport book, can include a covering material such as two polyolefin based films 210 and 212 , and may be bonded by an adhesive layer 220 . An identification element 240 can be placed between the two covering materials such as films of a polyolefin based material 210 and 212 , shown as embedding inside the covering material 210 , but other configurations can also be used, such as embedding inside the covering material such as a polyolefin based material 212 or having a portion embedded in the covering material 210 and a portion embedded in the covering material such as a polyolefin based material 212 . For example, the covering material such as a polyolefin based film 210 can be an inner layer of a passport document, and the covering material such as a polyolefin based film 212 can be an outer cover layer of the passport document or other item. A same adhesive. material can be used to cover the covering material such as polyolefin materials 210 / 212 and the identification element 240 . Alternatively, the adhesive may only cover the covering material such as polyolefin materials 210 / 212 , or different adhesive materials may be used for the polyolefin materials and for the identification element. An optional layer of varnish 250 can be used coat the covering material such as the polyolefin based film layer 212 for protecting the outer cover layer.
[0063] The identification element 240 can be protected in all sides by the covering material such as polyolefin based films 210 and 212 . For example, the identification element 240 can be smaller, e.g., having a smaller lateral surface than that of either the covering material such as polyolefin based films 210 or 212 . In some embodiments, the covering material such as a polyolefin based film 210 and 212 can include a silica filled microporous polyolefin material
[0064] The identification element 240 can include an inlay element such as a RFID transponder, embedded in the bottom covering material which may be a polyolefin based film 210 , e.g., the bottom covering material such as a polyolefin based film 210 can function as a recipient for the RFID transponder or other inlay element. Alternatively, the identification element 240 can include other identification forms, such as printed identification, for example, on an inner surface of the covering material such as polyolefin based film 210 or 212 .
[0065] FIG. 2B shows a document 205 formed by an inner layer of covering material such as a polyolefin based material 214 and an outer cover layer, also of a covering material such as a polyolefin based material 215 , without using an adhesive at position 225 between covering materials. The inner layer 214 can include an inlay of an identification element such as a RED transponder 245 . The cover layer 215 can be protected by a coating of varnish 255 .
[0066] FIG. 2C shows a document 207 formed by multiple layers of covering material such as a polyolefin based material 216 , 217 and 218 . The document 207 is shown without any adhesive layer. Alternatively, an adhesive layer can be provided between any two layers of the covering materials such as polyolefin based materials, for example, to increase the bonding strength. Identification elements can be embedded within the polyolefin based films, e.g., completely covered by the covering materials such as polyolefin based films. For example, an identification element such as a RED transponder 247 can be inlayed in the covering material 216 without any exposure to the outside ambient or environment. An inlay element such as a printed document 248 can also be embedded between the covering material 217 and 218 without any exposure to the outside ambient or environment. The cover layer 218 can be protected by a coating of varnish 257 .
[0067] In some embodiments, the present invention discloses methods, and documents generated from the methods, to coat a covering material such as a polyolefin based film with a protective layer. For example, a varnish layer can be coated on a polyolefin based film to provide protection to a document using polyolefin as Monobloc material Technology and material composition have been developed to form a varnish coating on polyolefin layer with good adhesion.
[0068] In some embodiments, the present invention discloses methods, and documents generated from the methods, to build identification documents or other documents or inlay elements with layers of a covering material such as is polyolefin based material and with or without adhesive in between. The adhesive introduced between two covering layers such as polyolefin layers facilitates very strong interlayer bonds thus preventing the covering layer delamination mechanically. The adhesive layer can be of any thickness and can be very thin, e.g., sub millimeter thickness such as less than 0.5 mm or less than 0.1 mm in order to strictly avoid susceptibility to any kind of tamper actions, be it a knife or organic solvent. Alternatively, layers of the covering material such as polyolefin can be well bonded without the adhesive layer.
[0069] In some embodiments, the present invention discloses secure documents or identification elements, and method to form secure documents or other identification elements, including the construction with two layers of a covering material such as a polyolefin based material, with integrated inlay element such as RFID functionality by using one covering layers such as layer coated with varnish. The construction of documents or elements using multiple layers of a covering material can prevent any tampering such as a delamination attack and can create an additional security feature. The multiple layers of a covering material can be bonded together with or without an adhesive layer.
[0070] For example, when two layers of a covering material are sealed, e.g., bonded together, the adhesive material can flow into the covering material substrate's matrix to create a strong mechanical bond. The mechanical bond can be adequate to cause the composite structure of two bonded layers to be immediately and permanently distort with any attempt to alter it, e.g., slicing or splitting the composite structure.
[0071] The layers of covering material such as a polyolefin based material can include a microporous matrix that produces a cushioning effect that can protect the inlay elements such as RFID chips and other embedded electronics from cracking, chipping and displacement, resulting in more secure data and longer service life. The micropores can absorb polymers and other materials, allowing the use of polymers between two layers of the covering material. For example, materials to be used for bonding layers of the covering material can include polyvinyl chloride (PVC), polyethylene terephthalate (PET), polypropylene (PP), polycarbonate (PC), high-density polyethylene (HDPE), acrylonitrile butadiene styrene (ABS), sheet molding compound (SMC), polyurethane foam, foam rubber, synthetic rubber, fiberglass, and thermoplastic polyolefin (TPO)/
[0072] FIGS. 3A-3D illustrate a process for forming an inlay clement such as a document according to some embodiments. In FIG. 3A , a first covering material such as a polyolefin based film 310 can be provided. The covering material such as a polyolefin based film 310 can include any filled microporous material such as a silica filled microporous polyolefin material. In FIG. 3B , an identification element 340 can be formed on the first covering layer such as a polyolefin based film 310 . The identification element 340 can be formed inside the film 310 , e.g., completely inside the film 310 so that there is no portion of the identification element 340 exposed to the outside ambient or environment. For example, there is a portion 342 of the covering material such as a polyolefin based film 310 around the identification element 340 . Thus the security strength of the document is determined by the film 310 and not affected by the identification element 340 .
[0073] The identification element 340 can include an RFID element or other element, which can be embedded inside a surface of the film 310 , e.g., forming an inlay film. The identification element 340 can include a printed element, such as a printed layer (e.g., paper or textile). Since the identification element is completely covered by the covering material such as a polyolefin based film 310 , the strength of the document can be unaffected by the weakness of the inlay element such as the paper or textile material, e.g., there can be no exposed paper material to allow slicing or splitting. The printed element can also be printed directly on the first covering material which may be a polyolefin based film 310 .
[0074] As shown, the identification element 340 is embedded in the first covering material which may be a polyolefin based film 310 , e.g., the identification element 340 is integrated in the film 310 in its entirety so that the top surface 345 of the identification element 340 is leveled with the top surface 315 of the first covering material 310 . Other configurations can be used, such as a part of the identification element 340 can be above the top surface 315 of the film 310 . For example, the identification element 340 can include a transponder having an RFID chip coupled to antenna wires, and a part of the wires and/or a region of the chip can be above the level of the film 310 , e.g., above the top surface 315 . The position of the identification element 340 with respect to the polyolefin based film 310 can allow for combinations of features with respect to the choice of adhesives 320 .
[0075] In FIG. 3C , a layer of adhesive 320 , e.g., a layer of material that can function to bond two layers of the covering material such as a polyolefin based material, can be coated on the film 310 . The adhesive can coat the identification element 340 and the covering material such as a polyolefin based film 310 or can coat only the covering material 310 , e.g., the portion of the covering material 310 that is not covered by the identification element 340 . Alternatively, different adhesive materials can be used, e.g., one for the covering material 310 and one for the identification element 340 .
[0076] In FIG. 3D , a second covering material which may be a polyolefin based film 312 can be placed or laminated on the adhesive layer 320 , bonding the first covering material 310 to the second covering material 312 , and encapsulate the identification element 340 . An optional layer of varnish 350 can be provided on the second covering material 312 .
[0077] As shown in FIG. 3D , the adhesive layer 320 is coated on the covering material which may be a polyolefin based film 310 . Alternatively, the adhesive layer can be coated on the top covering material which may be a polyolefin based film 312 .
[0078] FIGS. 4A-4C illustrate a process for forming a protective covering over an element such as a document according to some embodiments. In FIG. 4A , a first covering material such as a polyolefin based film 410 can be provided. The covering material 410 can include an impregnated material such as a silica filled microporous polyolefin material. In FIG. 4B , an identification element 440 , such as an RFID element, can be embedded in the first covering material 410 , forming an inlay layer.
[0079] As shown, the identification element 440 is embedded in the first covering material which may be a polyolefin based film 410 , e.g., the identification element 440 is integrated in the film 410 in its entirety so that the topmost surface 445 of the identification element 440 is leveled with the top surface 415 of the first covering material 410 . Other configurations can be used, such as a part of the identification element 440 can be above the top surface 415 of the film 410 . For example, the identification element 440 can include a transponder having an RFID chip 441 coupled to antenna wires 442 , and a part of the wires and/or a region of the chip can be above the level of the film 410 , e.g., above the top surface 415 .
[0080] In FIG. 4C , a second covering material which may be a polyolefin based film 412 can be placed on the first covering material 410 , bonding the first covering material 410 to the second covering material 412 , and encapsulate the identification element 440 . The two first covering material 410 and 412 can be bonded at exposed areas 425 , e.g., bonding without any adhesive layer. An optional layer of varnish 450 can be provided on the covering material 412 .
[0081] Other configuration can be used, such as the addition of printed information, e.g., printing on either one of the two covering materials which may be polyolefin based films 410 and 412 , or adding a printed layer between the two covering materials which may be two polyolefin based films 410 and 412 . In addition, another layer of a covering material which may be a polyolefin based film can be added.
[0082] FIGS. 5A-5B illustrate flow charts for forming an inlay element such as a document according to some embodiments. An identification element can be completely covered between two layers of the covering material which may be siliceous particulate filled microporous polyolefin matrix materials. The covering material which may be polyolefin layers can be bonded together to form a strong seal, protecting the identification element against tampering. A varnish layer can be coated on an outer surface of the composite structure of the covering material such as polyolefin layers and identification element for protection.
[0083] In FIG. 5A , operation 500 places an identification element between two films having similar composition. Each of the two films can include a microporous polyolefin substrate having siliceous fillers. The identification element can have a surface area smaller than that of the two films, so that the identification element can be completely surrounded at all sides by the two films. A protection coating can be placed on a covered film of the two films. The protection coating can include a varnish layer. Operation 510 optionally coats a layer of adhesive on at least one of the opposing surfaces of the two films to allow for increased bonding strength between the layers.
[0084] In FIG. 5B , operation 530 prepares a first film, wherein the first film comprises a microporous polyolefin substrate having siliceous fillers. Operation 540 incorporates an identification element on the first film, wherein the identification element does not cover completely the first film, leaving an exposed portion of the first film. Operation 540 optionally coats a layer of adhesive at least on the exposed portion of the first film. Operation 540 laminates a second film on the first film, wherein the second film comprises a similar material composition as that of the first film.
[0085] FIG. 6A embodies an example passport 601 wherein is a preferred embodiment of the location or the coating and represents the inlay material. The present invention may be used throughout a document such as the passport 601 , on the cover, or on the inlay pages.
[0086] FIG. 6B embodies the front 602 and rear cover 603 of a passport 601 wherein is a preferred embodiment of the use of the present invention coating.
[0087] FIG. 6C embodies a 604 inner page of the passport 604 , where in the coating is provided in the aforementioned embodiments and methods, wherein an identification element is exampled as 605 identification photo, 606 printed information and 607 RFID device are inlay materials covered by the covering of the present invention coating.
[0088] Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the various embodiments. It should be understood by one of ordinary skill in the an that the terms describing processes, products, element, or methods are industry terms and may refer to similar alternatives. In addition, the components shown in the figures, their connections, couples, and relationships, and their functions, are meant to be exemplary only, and are not meant to limit the embodiments described herein. Specifically, the identification element, can be implemented as any inlay material such as a document, RFID chip etc., as described in the entirety of the specification. Also, any material based on polyolefin or the described covering material, may be interchanged to be of any material as described in the specification. The embodiments can be interchanged, connected and ordered to provide any variation of the included elements.
[0089] Example embodiments are illustrated by way of example and are not limited to the figures of the accompanying drawings, in which, like references indicate similar elements.
[0090] The structures and modules in the figures may be shown as distinct and communicating with only a few specific structures and not others. The structures may be merged with each other, may perform overlapping functions, and may communicate with other structures not shown to he connected in the figures. Accordingly, the specification and/or drawings may be regarded in an illustrative rather than a restrictive sense.
|
This disclosure relates generally to paper and textile based materials with associated protective coatings or coverings. Many products, such as identification documents, experience wear and tear as they are subsequently used, scratched, exposed to elements or tampered with. This invention provides methods, apparatuses, and systems to protect an element or product, such as an identification document, from wearing, weathering, tampering and other detrimental outside effects through the use of a surrounding coating or covering such a polyolefin based coating, of which in some embodiments, includes ingenious features such as a monobloc structure, multiple layers, a porous matrix, among others.
| 3
|
This application is a continuation-in-part of our pending design application Ser. No. 29/007,278, filed Apr. 21, 1993 pending, the disclosure of which is incorporated herein by reference thereto.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention broadly concerns an apparel accessory for receiving a garland of fabric therein, and more particularly is directed toward an accessory to be worn as a barrette or hair ornament. The invention includes a framework for receiving a garland of fabric in combination with a clasp whereby the user may custom decorate the accessory with a chosen fabric pulled through the lattice-like framework.
2. Description of the Prior Art
Hair bows, barrettes, ribbons and other decorative accessories of various types are well known in the art and encompass a broad spectrum of designs. Furthermore, pins which decorate articles of clothing are well known to include an ornamental covering secured to the fabric by a hinged pin. Users typically purchase these ornaments largely according to the appearance of the material or emblem carried by the pin.
However, the user frequently changes clothing and as a result, desires a different appearance for the decorative accessories. For example, in the way that a woman would wear a different scarf with different clothing outfits, she may also desire a different decorative accessory with those different outfits. Heretofore, decorative accessories such as hair bows, pins and the like presenting a gathered fabric appearance have been sewed or otherwise permanently affixed to the hardware and thus have been incapable of such adaptation. As a result that the same basic underlying hardware must be repeatedly purchased even though that hardware is largely unseen and immaterial to the decorative desirability of the article.
There has thus arisen a need for a decorative accessory capable of presenting a gathered fabric appearance, which is inexpensive to manufacture, and which may receive different fabrics in substitution.
SUMMARY OF THE INVENTION
These and other objects have largely been met by the garland accessory of the present invention. That is to say, the present invention enables the user to employ a variety of different "looks" by readily substituting different garlands of fabric with the same ornament.
Broadly speaking, the present invention employs a clasp for attachment to the hair or clothing of the wearer, a retaining member associated with the clasp, and a framework of flexible material presenting a plurality of openings sized to receive a portion of a fabric garland therein. As used herein, the term "garland" means a length of fabric material which may be normally flat but when pulled into the openings of the framework presents a gathered or billowing appearance. Exemplary of a fabric garland would be a handkerchief, scarf or the like.
The clasp may include a barrette frame or the hinged jewelry pin framework well known to those skilled in the art, such that the present invention includes applications both for wear in the hair but also could be employed on hats, jackets, sweaters or other articles of clothing. Various different frameworks may be associated with the clasp by simply removing one framework and substituting another. The framework readily attaches to the clasp by positioning the framework over the clasp and bending mounting tabs beneath retaining flanges extending from the opposed end of the clasp. The wearer may readily substitute multiple frameworks each having a different configuration and carrying a different garland selected by the wearer, or alternatively one framework can be removed and different fabric garlands pulled therethrough. The present invention has the further advantage that a garland such as a scarf can be used either in a hair or clothing ornament or as a scarf, thus lending further versatility to the user's wardrobe.
These and other objects of the present invention may be readily perceived by reference to the drawings and the written description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top front perspective view of the garland accessory of the present invention with the fabric garland shown in phantom to better show the positioning of the clasp and framework relative thereto;
FIG. 2 is a top plan view of the garland accessory hereof not including the fabric garland;
FIG. 3 is a bottom view thereof;
FIG. 4 is a right side view thereof;
FIG. 5 is a left side view thereof;
FIG. 6 is a top plan view of an alternate embodiment of the garland accessory hereof not including the fabric garland, showing an alternate framework configuration;
FIG. 7 is a bottom view thereof;
FIG. 8 is a right side view thereof;
FIG. 9 is a left side view thereof;
FIG. 10 is a top plan view of a second alternate embodiment of the garland accessory hereof not including the fabric garland, showing a second alternate framework configuration;
FIG. 11 is a bottom view thereof;
FIG. 12 is a right side view thereof;
FIG. 13 is a left side view thereof;
FIG. 14 is a front elevational view of the garland accessories shown in FIGS. 2, 6 and 10, the back view being a mirror image thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing a garland accessory 10 in accordance with the present invention broadly includes a clasp 12 and a flexible framework 14. The clasp includes a retaining member 16 for holding the framework 14 on the clasp 12. A fabric garland 18 of suitable material such as silk, linen, cotton, or other natural or synthetic material is shown in FIG. 1 and held in position by pulling portions thereof through openings 20 provided in the framework.
In greater detail as best seen in FIG. 14, clasp 12 is of conventional design and includes an elongated arcuate upper beam 22, a spring element 24, a hinge support member 26, a fastening member 28 pivotally mounted thereto; and a catch 30 for holding the fastening member in a position generally parallel to the upper beam 22. Retaining member 16 generally comprises flanges 32 and 34 extending longitudinally in opposite directions from beam 22. The catch 30 may include legs 36 and 38 for holding the remote end 40 of the fastening member 28 therebetween. Such clasps 12 are generally familiar to those skilled in the art and are used as barrettes. Alternatively, jewelers backing pins with hinged or other pin-type members would provide suitable clasps 12 when the garland accessory 10 hereof is used with articles of clothing.
Framework 14 shown in FIGS. 1 through 5 includes a surrounding border 42 and a plurality of transversely extending dividers 44 connected to the border 42 for defining a plurality of openings 20. The framework 14 is preferably made of synthetic resin sheets or film which are easily cut or formed into a desired configuration and a resilient for purposes of mounting to the clasp 10 and holding the fabric garland 18 thereto. At least some and preferably all of the openings are sized to receive portions of the fabric garland 18 therethrough. A ladder-like appearance is thus provided for the framework 14. The openings 20A and 20B at the opposite ends of the framework 14 are provided with longitudinally extending slits 46 extending into the border 42. The slits 46 define tabs 48 and 50 on the framework 14 which is bent into position below flanges 32 and 34 respectively when the framework 14 is mounted to the clasp 12, as seen in FIG. 14.
Garland accessory 10A shown in FIGS. 6 through 9 is substantially the same as garland accessory 10 of FIGS. 1 through 5, with the exception of the configuration of the framework 14A. The framework 14 presents a somewhat different ornamental appearance than that of framework 10 by presenting a circumscribing margin 52 around the border 42 which has a greater transverse dimension, thereby permitting the center opening to have a greater width than those on either side.
Garland accessory 10B shown in FIGS. 10 through 13 is also substantially the same as garland accessory 10, however including a framework 14B of a different ornamental appearance. Framework 14B includes a greater number of dividers 44 which are provided for creating a greater number of smaller openings 20 for receiving the fabric garland 18 therein.
The garland accessories 10, 10A and 10B as shown herein are particularly useful as hair ornaments in the manner of a barrette. In use, the wearer typically detaches the desired framework 14 and positions a fabric garland above the framework 14. By pulling desired portions of the fabric garland 18 through the openings 20, that part of the fabric garland 18 positioned above the framework 14 takes on a gathered or billowing appearance. No fasteners are needed to hold the fabric garland 18 in place as the compressed fabric bears against the border 42 and dividers 44 of the framework and is held therein. The user may easily attach the framework 14 to the clasp 12 after the fabric garland 18 has been attached by locating tabs 48 and 50 beneath the flanges 32 and 34. The resiliency of the synthetic resin framework 14 conforms over the arcuate surface of beam 22 as shown in FIG. 14 and the tabs 48 and 50 hold the framework 14 and the fabric held therein against longitudinal, lateral and vertical movement relative to the clasp 12. The wearer then opens the clasp in the conventional manner and clamps a portion of her hair between the spring 24 and the fastening member 28 as is well known to users of barrettes.
If the wearer maintained a set of different frameworks 14, 14A and 14B, the framework 14 can be easily removed without tools as the flanges have no fastening members to secure the tabs 48 and 50. The fabric garland 18 is easily removed from the framework 14 by simply pulling the garland 18 away from the framework. A new garland may then be substituted on the framework 14 and then reinstalled on the clasp. As the garland 18 substantially completely covers the framework 14 and the clasp 12, an ornamental appearance selected by the wearer may be readily and inexpensively achieved.
Although preferred forms of the invention have been described above, it is to be recognized that such disclosure is by way of illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
The inventors hereby states their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of their invention as pertains to any apparatus not materially departing from but outside the liberal scope of the invention as set out in the following claims.
|
A garland accessory for permitting a wearer to custom decorate her apparel is provided which includes a framework detachably mounted to a clasp. The framework is a thin flexible sheetlike material presenting a plurality of openings for receiving a fabric garland therein. Multiple frameworks may be used with the same clasp to permit ready substitution of different fabric garlands as desired by the user.
| 0
|
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a method, apparatus and software for collecting usage data for one or more data feeds. Specifically, the present invention relates a computer system comprising a set of client computers connected via a network to a server computer wherein the server computer and the client computers may be arranged in conjunction with software for providing data feeds from the server computer to any of the client computers over the network and wherein the usage data for one or more data feeds may be determined and logged.
[0002] Data feeds are a mechanism that enables data users or subscribers to receive periodically updated data from a data source or publisher. Data feeds enable a data publisher to disseminate regularly updated data to a large number of data subscribers in an efficient manner. The data may, for example, comprise news, message or financial data and be provided over a network such as the Internet. Data feed protocols commonly operate by the data subscriber or client periodically polling the data feed source for updates to a given data feed. A number of protocols exist for data feed services such as the Really Simple Syndication (RSS) protocol, the Atom Syndication Format (ATF) protocol, or the Resource Description Framework (RDF) Feeds protocol. Data feeds may also be implemented in other network protocols such as the Hypertext Transfer Protocol (HTTP).
[0003] Current data feed mechanisms enable subscribers to subscribe to a given feed anonymously. Furthermore, the same data feed subscriber may repeatedly poll the same data feed source regardless of whether or not the user has not viewed the data feed. Thus, it is difficult for a data feed publisher to determine usage statistics for a given data feed.
BRIEF SUMMARY OF THE INVENTION
[0004] A data feed server configured for tracking usage of a data feed includes a data feed server configured to respond to polls from client computers and transmit a data feed in response to a poll from a client computer. The data feed server is further configured to received usage data from a client computer that indicates usage of the data feed at the client computer.
[0005] A client computer for accessing a data feed includes a client computer configured to communicate with at least one data feed server that publishes a data feed. The client computer selectively polls the data feed server for the data feed. The client computer is further configured to record usage data indicating usage of the data feed at the client computer and, in a subsequent polling of the data feed sever, report the usage data for the data feed to the data feed server.
[0006] A method of determining usage of a data feed includes collecting information with a data server that indicates whether a data feed provided by the data server was accessed by a user at a client computer to which the data server had transmitted the data feed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0007] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
[0008] FIG. 1 is a schematic illustration of a computer network in which data feeds are provided by a data feed server computer to data feed client computers according to an embodiment of the present exemplary system and method.
[0009] FIG. 2 is a schematic illustration of data feed client and server software systems in the computer system of FIG. 1 according to an embodiment of the present exemplary system and method.
[0010] FIG. 3A is a flow chart illustrating processing performed by the data feed server of FIG. 2 according to an embodiment of the present exemplary system and method.
[0011] FIG. 3B is a flow chart illustrating processing performed by the data feed server of FIG. 2 according to another embodiment of the present exemplary system and method.
[0012] FIG. 4 is a flow chart illustrating processing performed by the data feed client of FIG. 2 according to an embodiment of the present exemplary system and method.
DETAILED DESCRIPTION OF THE INVENTION
[0013] As will be appreciated by one skilled in the art, the present invention may be embodied as a method, system, or computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, the present invention may take the form of a computer program product on a computer-usable storage medium having computer-usable program code embodied in the medium.
[0014] Any suitable computer usable or computer readable medium may be utilized. The computer-usable or computer-readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a non-exhaustive list) of the computer-readable medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a transmission media such as those supporting the Internet or an intranet, or a magnetic storage device. Note that the computer-usable or computer-readable medium could even be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via, for instance, optical scanning of the paper or other medium, then compiled, interpreted, or otherwise processed in a suitable manner, if necessary, and then stored in a computer memory. In the context of this document, a computer-usable or computer-readable medium may be any medium that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The computer-usable medium may include a propagated data signal with the computer-usable program code embodied therewith, either in baseband or as part of a carrier wave. The computer usable program code may be transmitted using any appropriate medium, including, but not limited to, the Internet, wireline, optical fiber cable, RF, etc.
[0015] Computer program code for carrying out operations of the present invention may be written in an object oriented programming language such as Java, Smalltalk, C++, or the like. However, the computer program code for carrying out operations of the present invention may also be written in conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
[0016] The present invention is described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0017] These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function/act specified in the flowchart and/or block diagram block or blocks.
[0018] The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0019] With reference now to FIG. 1 , a computer system ( 101 ) comprises a set of client computers ( 102 ) connected to, for example, a wide area network (WAN) ( 103 ), in the form of the Internet, to a server computer ( 104 ). The server computer ( 104 ) is also connected to a storage device ( 105 ). The server computer ( 104 ) and the client computers ( 102 ) are arranged with software for providing data feeds from the server computer ( 104 ) to any of the client computers ( 102 ) over the network ( 103 ).
[0020] FIG. 2 shows the software provided on the computers ( 102 , 104 ) in further detail. The server computer ( 104 ) comprises a data feed server application program ( 201 ) which enables a data feed provider to create or collect data feed content and to publish the content as a data feed file. In the present embodiment, the data feed file format and protocol is the Really Simple Syndication (RSS) protocol and the RSS file format is Extensible Mark-up Language (XML). In the present embodiment, the RSS XML file for a given data feed is published by posting the Universal Resource Locator (URL) of the respective RSS XML file on a website. When the data feed provider or publisher needs to update a data feed, the updates are made to the corresponding RSS XML file. The data feeds may generally comprise three parts: a title, a summary, and a message body. The title and the summary are entered directly in the RSS XML file, along with an entry date. The message body is a Hypertext Mark-up Language (HTML) file that is referenced in the RSS XML file. In the present embodiment, the data feed server is further arranged to collect usage data ( 202 ) for the data feeds that it provides to the client computers ( 102 ). In the present embodiment, the usage data ( 202 ) comprises an indication of the number of instances of a supplied data feed that have been viewed by their respective users. The mechanism by which the usage data ( 202 ) is collected is described in further detail below.
[0021] The client computer ( 102 ) comprises a data feed reader application program ( 203 ) in communication with a data feed client application program ( 204 ). The data feed reader ( 203 ) enables a user to select or subscribe to one or more data feeds, for example, by selecting links from browsed web pages. The data feed are then displayed to the user via a display window of the data feed reader ( 203 ). The data feed subscription process is performed with the data feed client ( 204 ). Once a data feed has been subscribed to, the data feed client ( 204 ) is arranged to periodically check or poll the URL corresponding to the given data feed. Data feed polls are made via HTTP requests to the data feed server ( 201 ) using a given data feed URL. Updated data is uploaded to the data feed reader ( 203 ) for display to the user. Once uploaded, the data feed reader ( 203 ) enables the user to select and view the data provided by a given data feed.
[0022] Thus, once the data feed client ( 204 ) has been subscribed to a given data feed, it is arranged to poll the data feed server ( 201 ) periodically for updates to the content of the given data feed. In the present embodiment, when a data feed has been viewed by the user, the data feed reader ( 203 ) is arranged to provide a corresponding indication to the data feed client ( 204 ). The data feed reader ( 203 ) is arranged to treat a given data feed as “viewed” once it has been selected for viewing by the user. In response to such an indication for a given data feed, the data feed client ( 204 ) is arranged to add a flag to the subsequent poll of the corresponding data feed URL. For example, the data feed client ( 204 ) may be given a data feed URL of:
http://www.ibm.com/rss/latestnews
If the data feed has been viewed by the user via data feed reader ( 203 ), the data feed client ( 204 ) is arranged to append a “viewed” flag, resulting in the following modified polling of the corresponding data feed URL:
http://www.ibm.com/rss/latestnews?<viewed>
[0025] In response to each data feed poll, the data feed server ( 201 ) is arranged to inspect the requested URL for a “viewed” flag. If no such flag is present, the data feed request is handled as normal. If, however, a “viewed” flag has been appended, then a record of the data feed URL along with a time stamp is entered in the data feed usage statistics ( 202 ). The data feed request is then handled as normal.
[0026] The processing performed by the data feed server ( 201 ) when publishing a data feed will now be described in further detail with reference to the flow chart of FIG. 3A . At step 301 , the data feed server ( 201 ) is started up and processing moves to step 302 where the data feed publisher creates an RSS XML file for the data feed content. Processing then moves to step 303 where the data feed URL is published on a web site to enable users to identify and select the feed. Processing then moves to step 304 where any updates to the data feed are made to the RSS XML file so as to provide updated data to any subscribed users. The processing of step 304 repeats for as long as the data feed remains in a published state so as to enable repeated updates of the data feed data.
[0027] The processing performed by the data feed server ( 201 ) in response to data feed polls will now be described in further detail with reference to the flow chart of FIG. 3B . At step 305 , processing is initiated in response to a data feed poll in the form of an HTTP request identifying a data feed. Processing then moves to step 306 where the received URL is inspected to determine whether or not a “viewed” flag has been appended. If no “viewed” flag has been appended then processing moves to step 307 where the requested data feed data is provided and processing returns to step 305 to await a further poll. If, at step 306 , a “viewed” flag is identified then processing moves to step 308 where the data feed URL and a time stamp are recorded in the data feed usage statistics ( 202 ). Processing then moves to step 307 and proceeds as described above.
[0028] The processing performed by the data feed client ( 204 ) when polling a data feed will now be described in further detail with reference to the flow chart of FIG. 4 . At step 401 , processing is initiated when a user subscribes to a data feed via data feed reader ( 203 ). Processing then moves to step 402 where the data feed reader ( 203 ) informs the data feed client ( 204 ) of the new data feed and processing moves to step 403 . At step 403 , the data feed client ( 204 ) starts a poll timer for a predetermined time interval. When the poll timer time interval expires, processing moves to step 404 . At step 404 , the data feed client ( 204 ) is arranged to interrogate the data feed reader ( 203 ) to determine whether the data feed for which a poll is about to be made has been viewed. If the data feed has not been viewed, then processing moves to step 405 . At step 405 , the data feed URL is polled and the data feed updated accordingly. Processing then returns to step 403 and proceeds as described above. If, at step 404 , the data feed reader ( 203 ) indicates that the respective data feed has been viewed, then processing moves to step 406 where a “viewed” flag is appended to the data feed URL. Processing then moves to step 405 where the data feed URL is polled using the URL with the appended “viewed” flag. Processing then proceeds as described above where the data feed is updated accordingly and its “viewed” status reset by the data feed reader ( 203 ).
[0029] In another embodiment, the data feed client is arranged to upload the data for a given data feed only if the data is new or has been updated since the last poll. In a further embodiment, the data feed server is arranged to collect further data from data feed readers, such as the originating URL. The data feed client may be arranged to provide further data feed usage data in addition to a “viewed” flag. In another embodiment, the data feed client is arranged to maintain the “viewed” status for a given data feed for a predetermined period that may exceed the data feed polling period.
[0030] In a further embodiment, the data feed client is arranged only to poll a given data feed if the data feed has been viewed by the user within a predetermined period. The predetermined period may correspond to or exceed the polling period. In another embodiment, the data feed server is arranged to record only the most recent “viewed” status for given data feed. In a further embodiment, the data feed reader is arranged to update a data feed client poll table with “viewed” flag to remove the need for the data feed client to interrogate the data feed reader prior to each poll. The data feed client is arranged to reset the table entry for a given data feed on each respective poll. In another embodiment, the usage data is used by the data feed server to remove or deactivate redundant or unused feeds. In still another embodiment, the usage data may be collected by the data feed server to indicate to a data feed provider that the data feeds may need to be amended. Thus, the data feed provider may be made aware that a particular data feed is not being read or viewed for some reason and may need to be updated to increase subscription to the data feed or increase the use of a particular data feed.
[0031] As will be understood by those skilled in the art, the data feed reader may be a stand-alone application or form part of another suitable application program such as a web browser or email client application program. Furthermore, part or all of the functions of the data feed client and reader as described above may be provided by one or more application programs.
[0032] Further, as will be understood by those skilled in the art, other suitable protocols are available for providing data feeds and may be arranged or adapted to provide the facilities described above. Also, the functions of the client computer described herein may be provided by any suitable device and may connect to the data feed server via any suitable means such as a wireless, mobile, or peer-to-peer (P2P) network.
[0033] The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
[0034] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0035] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
[0036] Having thus described the invention of the present application in detail and by reference to embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.
|
A data feed server configured for tracking usage of a data feed includes a data feed server configured to respond to polls from client computers and transmit a data feed in response to a poll from a client computer. The data feed server is further configured to received usage data from a client computer that indicates usage of the data feed at the client computer. A client computer for accessing a data feed includes a client computer configured to communicate with at least one data feed server that publishes a data feed. The client computer selectively polls the data feed server for the data feed. The client computer is further configured to record usage data indicating usage of the data feed at the client computer and, in a subsequent polling of the data feed sever, report the usage data for the data feed to the data feed server. A method of determining usage of a data feed includes collecting information with a data server that indicates whether a data feed provided by the data server was accessed by a user at a client computer to which the data server had transmitted the data feed.
| 7
|
FIELD OF THE INVENTION
[0001] This invention relates to the field of post-transcriptional gene silencing (PTGS) or RNA interference (RNAi), a mechanism widely found in plant and animals cells, which produces silencing or inhibition of a gene homologous to a double-stranded RNA (dsRNA) introduced into the cell. More particularly, this invention relates to methods and constructs for selecting dsRNAs and/or targets for utilization in dsRNA-mediated RNAi.
BACKGROUND OF THE INVENTION
[0002] Double-stranded RNAs are known to trigger silencing of a target gene having a nucleotide sequence complementary to one strand of the double-stranded RNA structure, believed to involve degradation of the mRNA transcribed from the target gene. This phenomenon, termed post-transcriptional gene silencing (PTGS) or RNA interference (RNAi), is probably an evolutionarily conserved defense mechanism against viruses and the mobilization of transposons, and is found in plants, invertebrates including C. elegans and Drosophila , and in vertebrates, e.g., fish, mammals, including humans. RNAi promises broad applicability to reduce or eliminate the generation of abnormal and/or undesired gene products, including those from transgenes, endogenous genes, and pathogen genes. Introducing dsRNA into cells having the required molecular machinery triggers processing of the dsRNA into short segments which associate with cellular proteins to initiate degradation of homologous mRNAs. PTGS presents a new and exciting approach for down-regulating or silencing the expression of genes.
[0003] RNAs having a double-stranded sequence as short as about 19 nucleotides in length may be effective to produce gene silencing, but, in general, longer dsRNAs, e.g., several hundred to several thousand nts in length are more effective. While there is no real upper limit, maximum length is determined primarily as a matter of convenience and practicality, involving such matters as synthesis and delivery of the desired dsRNAs. Currently, however, there are no rules for selection of optimal targets and effectors for RNAi and there is a need for efficient methods for evaluating target sequences and potential dsRNA effector molecules.
SUMMARY OF THE INVENTION
[0004] The assay method of the invention provides a rapid, efficient assay for evaluating potential mRNA targets for dsRNA-mediated silencing or degradation, as well as effector dsRNA molecules for utilization in such silencing mechanisms. The method utilizes a reporter-target sequence fusion message construct, comprising an mRNA encoding a reporter sequence linked to a target sequence. The target sequence is selected to determine its amenability to dsRNA-associated degradation. The reporter sequence and the target sequence to be evaluated are present within a capped and polyadenylated mRNA transcript capable of being translated within an appropriate cell line or other system. Translation of the mRNA will result is production of a detectable reporter. In a preferred embodiment, the target sequence is present within the 3′ untranslated region of the mRNA. The target sequence may also be located within the translated region, in which case a fusion protein is produced, so long as the reporter is still functional within the fusion protein. The mRNA fusion construct is contacted with an RNA molecule(s) having a double-stranded portion complementary to at least a portion of the target sequence, under conditions in which dsRNA-associated degradation of the corresponding mRNA sequence can occur. If cleavage of the mRNA transcript does occur, translation of the reporter cannot occur and there will be a detectable elimination, diminution, or modulation of the reporter gene product. EGFP is a particularly preferred reporter for use in such a screening assay because its modulation can be directly monitored in situ, without the need for tedious and time-consuming analytical steps, such as cell lysis, recovery of reporter, etc. Other GFP variants are also suitable, as are other reporters capable of convenient detection, particularly chemiluminescent, fluorometric, and calorimetric reporter systems.
[0005] The invention also provides mRNA reporter-target fusion constructs, cells transfected with such mRNA constructs, expression constructs which express mRNA reporter-target fusion constructs, cells transiently transfected with such expression constructs, cells stably transfected with such expression constructs, and cells containing both an mRNA reporter-fusion construct of the invention and an RNA having a double-stranded sequence homologous to at least a portion of the target sequence.
BRIEF DESCRIPTION OF FIGURES
[0006] FIG. 1 is a depiction of the EGFP-fusion mRNA assay.
[0007] FIG. 2 depicts plasmid pEGFP-N3, which encodes a red-shifted variant of wild-type GFP (1-3) which has been optimized for brighter fluorescence and higher expression in mammalian cells. (Excitation maximum=488 nm; emission maximum=507 nm.) pEGFP-N3 encodes the GFPmut1 variant (4) which contains the double-amino-acid substitution of Phe-64 to Leu and Ser-65 to Thr. The coding sequence of the EGFP gene contains more than 190 silent base changes which correspond to human codon-usage preferences (5). Sequences flanking EGFP have been converted to a Kozak consensus translation initiation site (6) to further increase the translation efficiency in eukaryotic cells. The MCS in pEGFP-N3 is between the immediate early promoter of CMV (P CMV IE ) and the EGFP coding sequences. Genes cloned into the MCS will be expressed as fusions to the N-terminus of EGFP if they are in the same reading frame as EGFP and there are no intervening stop codons. SV40 polyadenylation signals downstream of the EGFP gene direct proper processing of the 3′ end of the EGFP mRNA. The vector backbone also contains an SV40 origin for replication in mammalian cells expressing the SV40 T-
[0008] FIG. 3 depicts a fusion mRNA structure in upper left hand corner. The sense strand of siRNA#1 is represented in the HBVsAg target sequence. Fluorescent micrographs of transfections A, B, and C are shown.
[0009] FIG. 4 shows HBVsAg levels as determined by ELISA for: (left panel) cells transfected with HBVsAg expression vector and siRNA#2, (middle panel) cells transfetced with HBVsAg expression vector and siRNA#1 and (right panel) cells transfected with HBVsAg and no siRNA. All measurements were made at 18 hrs post-transfection. Duplicate measurements for each experiment are shown.
DETAILED DESCRIPTION OF THE INVENTION
[0010] All of the reverences cited within this disclosure are hereby incorporated by reference in their entirety.
[0011] The assay method of the invention provides a rapid, efficient assay for evaluating potential mRNA targets for dsRNA-mediated silencing or degradation, as well as effector dsRNA molecules for utilization in such silencing mechanisms. Although there has been considerable discussion and debate about the relative merits of short dsRNAs (siRNAs) vs. long dsRNAs, exogenously introduced vs. endogenously expressed dsRNAs, there has been little consideration of other factors that may be important in selection of gene targets particularly amenable to RNAi, or, on the other hand, selection of particularly effective dsRNAs for use in dsRNA-mediated gene silencing. Accordingly, there is a great need for rapid, efficient assay methods designed to enable evaluation of target sequences as well as dsRNA effector molecules for use in PTSG.
[0012] As to factors of importance in the efficiency of PTGS, the RNA sequence of the dsRNA effector molecule selected and of its corresponding mRNA target are expected to significantly impact the efficiency of PTGS. It has been shown that not all potential target sequences will be equally amenable to silencing. Similarly, not all dsRNA effector molecules will be equally efficient in producing the desired effect. In part this is due to the variable three-dimensional structure associated with different RNA sequences. Since RNAs are known to fold according to nearest neighbor rules, they assume various secondary structures as they are synthesized. The particular three-dimensional structure formed and the strength of the bonds holding an RNA molecule in a particular conformation will be dependent upon the sequence of the molecule. Protein-binding to various regions of RNAs and other currently unrecognized factors may also be relevant. A particular RNA strand may therefore vary greatly in its availability to hybridize with a complementary oligonucleotide strand to form a double-stranded structure, or for inverted repeat sequences within a single oligonucleotide strand to form a stem-loop structure. This is particularly true when it is desired to transcribe two complementary RNAs from one or more expression vector(s) with the intent that they hydridize to form a dsRNA, or to express a single RNA strand with inverted repeats or self-complementary regions, capable of forming a stem-loop or hairpin dsRNA structure. This obstacle to forming dsRNAs may also be encountered when complementary RNA strands are synthesized in vitro and brought together under conditions designed to permit hybridization into dsRNAs. In addition, the different siRNA molecules which are processed from the larger input dsRNA molecules may interact with different affinities with proteins/complexes involved in gene silencing, influencing their ability to achieve silencing.
[0013] The screening assay of the invention utilizes a reporter-target fusion message construct, comprising an mRNA encoding a reporter sequence linked to a target sequence. The target sequence is selected to determine its amenability to dsRNA-associated degradation. The reporter sequence and the target sequence to be evaluated are present within a capped and polyadenylated mRNA transcript capable of being translated within an appropriate cell line or other system. Accordingly, the functional mRNA will comprise either a 5′ cap or an IRES element, a suitable 5′ untranslated region (UTR), a coding sequence for a selected reporter, a PTGS target sequence, a 3′ untranslated region, and a poly (A) tail at the 3′ end. The 5′ UTR will contain the regulatory elements required for translation in the selected assay system, e.g., a Kozak sequence flanking the translation start codon. Translation of the mRNA will result in production of a detectable reporter. The target sequence may conveniently be placed within the 5′ UTR in a position which does not interfere with initiation of translation, or within the 3′ UTR. In a preferred embodiment, the target sequence is present after the translation stop codon of the reporter sequence, within the 3′ untranslated region of the mRNA. The target sequence may also be located within the translated region, in which case a fusion protein is produced, so long as the reporter is still functional within the fusion protein. In some instances, by using “wobble” codons, with alterations in the third nucleotide of a codon, the target sequence could actually be included within the sequence encoding the reporter. The mRNA fusion construct is contacted with an RNA molecule(s) having a double-stranded portion complementary to at least a portion of the target sequence, under conditions permitting dsRNA-associated degradation of the corresponding mRNA sequence. If there is cleavage of the mRNA transcript anywhere between the cap and the polyA tail, translation of the reporter cannot occur and there will be a detectable elimination, diminution, or modulation of the reporter gene product. A chemiluminescent or fluorometric reporter will be advantageous in the methods of the invention. EGFP is a particularly preferred reporter for use in such a screening assay because its modulation can be directly monitored real time and in situ, obviating the need for tedious and time-consuming analytical steps, such as cell lysis, recovery of reporter, etc. Other GFP variants are also suitable, as are other reporters capable of convenient detection.
[0014] The target sequence can represent virtually any target (or targets) including without limitation of prokaryotic, eukaryotic, plant, animal, invertebrate, vertebrate origin, selected for potential dsRNA-mediated down regulation, e.g., any pathogen of plant or animal, e.g., fungal, bacterial, viral, or prion pathogen sequence(s), e.g., a sequence from HIV, HSV, HBV, HCV, HPV, smallpox, anthrax, etc.; an endogenous gene associated with pathology or disease, such as TNF, a cancer-associated gene, or a host gene responsible for entry or infection by a pathogen; or a transgene, e.g., a gene introduced for gene therapy purposes, to be modulated or down-regulated. Among cancer-associated genes are included cancers of any type, in any species, e.g., developmental genes, cytokines/lymphokines and their receptors, growth/differentiation factors and their receptors, neurotransmitters and their receptors, oncogenes, the BCR-abl chromosomal sequences, tumor suppressor genes, enzymes, etc. (see the teaching of e.g., U.S. Pat. No. 6,506,559 B1). Among viral genes selected for evaluation using the method of the invention are included, without limitation, viruses of the species Retrovirus, Herpesvirus, Hepadnavirus, Poxvirus, Parvovirus, Papillomavirus, and Papovavirus. Specifically, some of the more desirable viruses to evaluate with this method include, without limitation, HIV, HBV, HCV, HSV, CMV, HPV, HTLV and EBV. In particular, a viral polynucleotide sequence necessary for replication and/or pathogenesis of the virus in an infected mammalian cell is selected. Among such target polynucleotide sequences are protein-encoding sequences for proteins necessary for the propagation of the virus, e.g., the HIV gag, env and pol genes; the HPV6 L1 and E2 genes; the HPV11 L1 and E2genes; the HPV16 E6 and E7 genes; the HPV18 E6 and E7 genes; the HBV surface antigens, the HBV core antigen, HBV reverse transcriptase; the HSV gD gene, the HSV vp16 gene, the HSV gC, gH, gL and gB genes, the HSV ICP0, ICP4 and ICP6 genes; Varicella zoster gB, gC and gH genes; and non-coding viral polynucleotide sequences which provide regulatory functions necessary for transfer of the infection from cell to cell, e.g., the HIV LTR, and other viral promoter sequences, such as HSV vp16 promoter, HSV-ICP0 promoter, HSV-ICP4, ICP6 and gD promoters, the HBV surface antigen promoter, the HBV pre-genomic promoter, among others.
[0015] The target sequence can be any heterologous sequence from about 19 nucleotides in length, up to about 8,000 nts, and may advantageously include sequences representing two or more epitopes from a single target, i.e., a single gene of interest, or different genes from the same organism, or one or more sequences from a number of different targets, such as different viruses, e.g., HIV, HBV, HCV, smallpox, etc.
[0016] The fusion mRNAs of the invention can be transiently or stably expressed in cells capable of carrying out PTGS. Alternatively, the fusion mRNAs can be transcribed in vitro and introduced into such cells by any of a number of known delivery mechanisms, such as injection, electroporation, transfection with one or more of the many known RNA or DNA delivery agents (also suitable for delivery of plasmid expression vectors expressing fusion mRNAs), (e.g., Lipofectamine™; Fugene™; cationic lipids; cationic amphiphiles; local anesthetics such as bupivacaine, as in U.S. Pat. No. 6,217,900; complexes comprising a cationic polyamine and an endosome disruption agent, as in U.S. Pat. Nos. 5,837,533 and 6,127,170; calcium phosphate, etc.).
[0017] Similarly, the effector dsRNAs can be synthesized using known methods or they can be transcribed and assembled in vitro and introduced by similar means into the test cells or expressed within such cells from a vector(s) (e.g., DNA plasmid or viral vector). The effector dsRNAs can be short (with a double-stranded region of at least about 19 nts) or long (50, 100, 200, e.g., several hundred to several thousand nts), comprised of separate complementary single strands, or of a single strand with inverted complementary regions and optionally a spacer region which will form a stem-loop or hairpin structure with a double-stranded region or regions (of at least 19 nts, or longer regions of 50, 100, several hundred to several thousand nts) complementary to at least part of the target sequence in the fusion mRNA to be evaluated. The effector dsRNAs can advantageously be any at least partially double-stranded RNA molecule having a double-stranded region of at least about 19 nucleotides homologous to a target sequence and otherwise capable of mediating RNAi, including RNA/DNA duplexes, circular RNAs with self-complementary regions that hybridize to form a partially-double-stranded structure, lariat structures, single-stranded hairpin structures, double-stranded structures, etc., described in detail, including synthetic methods, in WO 0063364 A2, “Methods and Compositions for Inhibiting the Function of Polynucleotide Sequences”, C. Pachuk, and C. Satishchandran; still other dsRNA effector molecules desirable for use in the methods of this invention and methods for making them are described in U.S. Provisional Application 60/399,998, filed 31 Jul. 2002, incorporated herein by reference.
[0018] The dsRNA effector molecules to be evaluated may be made in vitro by conventional enzymatic synthetic methods using, for example, the bacteriophage T7, T3 or SP6 RNA polymerases according to the conventional methods described by such texts as the Promega Protocols and Applications Guide , (3rd ed. 1996), eds. Doyle, ISBN No. 1-882274-57-1. See also: http://www.promega.com/guides. Alternatively, the shorter dsRNA molecules (e.g., less than about 300 nts) may be made by chemical synthetic methods in vitro [see, e.g., Q. Xu et al., Nucl. Acids Res., 24(18):3643-4 (September 1996); N. Naryshkin et al., Bioorg. Khim., 22(9): 691-8 (September 1996); J. A. Grasby et al, Nucl. Acids Res., 21(19):4444-50 (September 1993); C. Chaix et al., Nucl. Acids Res., 17(18):7381-93 (1989); S. H. Chou et al., Biochem. 28(6):2422-35 (March 1989); O. Odal et al., Nucl. Acids Symp. Ser., 21:105-6(1989); N. A. Naryshkin et al., Bioorg. Khim, 22(9):691-8 (September 1996); S. Sun et al, RNA, 3(11):1352-1363 (November 1997); X. Zhang et al., Nucl. Acids Res., 25(20), 3980-3 (October 1997); S. M. Grvaznov et al., Nucl. Acids Res., 26 (18):4160-7 (September 1998); M. Kadokura et al., Nucl. Acids Symp. Ser, 37:77-8 (1997); A. Davison et al, Biomed. Pept. Proteins. Nucl. Acids, 2(I):1-6(1996); and A. V. Mudrakovskaia et al., Bioorg. Khim., 17(6):819-22 (June 1991)]. In addition, short dsRNAs are commercially available from sources including Dharmacon, Lafayette, Colo.
[0019] The effector dsRNA molecules of this invention can also be made in a recombinant microorganism, e.g., bacteria and yeast or in a recombinant host cell, e.g., mammalian cells, and isolated from the cultures thereof by conventional techniques. See, e.g., the techniques described in Sambrook et al, Molecular Cloning: A Laboratory Manual , 3rd Ed.; Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., 2000, which is exemplary of laboratory manuals that detail these techniques, and the techniques described in U.S. Pat. Nos. 5,824,538; 5,877,159; 5,643,771, and US Published Application 20020132257 A1, incorporated herein by reference.
[0020] Alternatively, the dsRNA effector molecules to be evaluated in the present invention may be co-expressed together with the reporter-target fusion message in vivo within the same cell in which the assay is carried out. Any suitable vector(s), the same or different, known to those of skill in the art may be used to express the dsRNA effector molecule, and/or the reporter-target fusion message, including a DNA single-stranded or double-stranded plasmid or vector. In a preferred embodiment, the agent which delivers the dsRNA effector and/or the reporter-target fusion message is a double-stranded DNA plasmid “encoding” the desired RNA molecule(s). See, e.g., the teaching of Sambrook et al., Molecular Cloning: A Laboratory Manual , 3 rd Ed.; Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., 2000, incorporated herein by reference. The fusion message RNAs are designed to be capped, and, if desired, cytoplasmic capping may be accomplished by various means including use of a capping enzyme such as a vaccinia capping enzyme or an alphavirus capping enzyme. The DNA vector is designed to contain one of the promoters or multiple promoters in combination (mitochondrial, RNA poll, II, or poIII, or viral, bacterial or bacteriophage promoters along with the cognate polymerases). Such plasmids or vectors can include plasmid sequences from bacteria, viruses, or phages. Such vectors include chromosomal, episomal and virus-derived vectors, e.g., vectors derived from bacterial plasmids, bacteriophages, yeast episomes, yeast chromosomal elements, and viruses, vectors derived from combinations thereof, such as those derived from plasmid and bacteriophage genetic elements, cosmids and phagemids. Thus, one exemplary vector is a single or double-stranded phage vector. Another exemplary vector is a single or double-stranded RNA or DNA viral vector. Such vectors may be introduced into cells as polynucleotides, preferably DNA, by well known techniques for introducing DNA and RNA into cells. The vectors, in the case of phage and viral vectors may also be and preferably are introduced into cells as packaged or encapsidated virus by well known techniques for infection and transduction. Viral vectors may be replication competent or replication defective. In the latter case, viral propagation generally occurs only in complementing host cells. In another embodiment the delivery agent comprises more than a single DNA or RNA plasmid or vector. As one example, a first DNA plasmid can provide a single-stranded RNA sense polynucleotide sequence as described above, and a second DNA plasmid can provide a single-stranded RNA antisense polynucleotide sequence as described above, wherein the sense and antisense RNA sequences have the ability to base-pair and become double-stranded. Such plasmid(s) can comprise other conventional plasmid sequences, e.g., bacterial sequences such as the well-known sequences used to construct plasmids and vectors for recombinant expression of a protein. However, it is desirable that the sequences which enable protein expression, e.g., Kozak regions, etc., are included in these plasmid structures only for expression of the reporter-target fusion message but not for expression of the dsRNA RNAi effector molecules.
[0000] Screening Assay
[0021] The inventors have developed a high throughput screening assay which enables the rapid screening of both target RNA sequences and effector dsRNA molecules. The basis of this assay is the use of a fusion mRNA, comprising a sequence encoding a reporter moiety linked to a sequence to be evaluated as a potential target for dsRNA-mediated gene silencing. In a preferred embodiment, utilization of an EGFP (Enhanced green fluorescent protein) fusion mRNA permits monitoring the “real-time” loss of expression of a targeted mRNA. The structure of such a fusion mRNA is depicted in FIG. 1 . Briefly, the fusion mRNA expresses EGFP due to the location of the EGFP coding region at the 5′end of the mRNA. The 3′UTR (untranslated region) includes a variable region in which different target sequences will be cloned. These target sequences can be derived from endogenous genes, transgenes, pathogen genes, etc., or any sequence desired to be evaluated as a target for dsRNA-mediated degradation. Induction of PTGS directed against the target sequences will result in cleavage and thus non-translatability of the fusion mRNA: EGFP expression will be lost. We have demonstrated the ability to include target sequences as large as 3.5 Kb in the 3′UTR and thus large regions of viral genomes or other sequences can initially be assayed for their ability to be targeted by RNAi.
[0022] Target RNA screen: It has been demonstrated that not all regions of a target mRNA can be successfully targeted for PTGS ( ). Presumably this has to do with inaccessibility of certain regions of mRNA molecules to gene silencing machinery and is likely caused by protein binding to the RNA and/or structure of the RNA. It is therefore important to be able to screen for mRNAs that can be efficiently targeted for PTGS. Constructs expressing the reporter-target fusion mRNAs of the invention can be co-transfected individually with constructs that express effector dsRNA molecules (see Effector RNA Screening below). Alternatively, stable cell lines expressing the fusion mRNA can be created and these cell lines can be transfected with vectors expressing effector dsRNAs, or the effector dsRNAs can be prepared in vitro or in another cell line, and delivered through known means to such cell lines. The time course and magnitude of silencing will be monitored through EGFP expression.
[0023] Effector dsRNA Screening: Prior work has demonstrated that not all dsRNAs are equally efficient in degrading target mRNAs. Some are much more efficient at inducing silencing and the onset of silencing can vary from molecule to molecule. Although the rules involved are not defined, structure of the target mRNA and the dsRNA species are believed to play a role. The EGFP screening system of the invention can be utilized to identify an efficient and rapid acting dsRNA(s) against each desired target.
[0024] It will be recognized that the EGFP reporter gene and the EGFP-N3 vector present certain advantages for practicing the methods of the invention, but that any vector than includes a detectable reporter can be utilized as described herein. Chemiluminescent, fluorometric, and colorimetric reporter systems are especially convenient for use in the assay methods of the invention, including, e.g., a luminescent □-galactosidase reporter system, EGFP and Luciferase reporter systems, (Clontech); the FluorAce beta-glucuronidase Reporter Kit Assay (Bio-Rad); Phospha-Ligh™ Secreted Alkaline Phosphatase Reporter Gene Assay System (Applied Biosystems). Many other known reporters or drug resistance genes could readily be adapted to use in the described assay, including acetohydroxyacid synthetase (AHAS), alkaline phosphatase (AP), secreted alkaline phosphatase (SEAP), beta galactosidase (LacZ), beta glucuronidase (GUS), chloramphenicol acetyltransferase (CAT), horseradish peroxidase (HRP), luciferase (Luc), nopaline synthetase (NOS), octopine synthetase (OCS), as well as a variety of selectable markers that confer resistance to antibiotics such as ampicillin, chloramphenicol, gentamicin, hygromycin, kanamycin, lincomycin, methotrexate, phosphinothricin, puromycin, and tetracycline. In addition, any gene product which can be detected can serve as the reporter, since dsRNA-induced cleavage of the mRNA construct will result in detectably modulated or decreased production of the gene product.
[0025] Cells or cell lines useful for carrying out the methods of the invention must be capable of supporting dsRNA-mediated RNAi; in general, however, most cells or cell lines have this capability. In addition to cellular machinery for carrying out RNAi, the methods of the invention require a system capable of supporting translation of the mRNA fusion construct, and, in those cases where it is desired to express the dsRNAs rather than providing exogenously formed dsRNAs, also the capacity to transcribe the effector dsRNA molecules. It is convenient to carry out the methods in a readily available and well characterized cell line such as Human RD (rhabdomyosarcoma), HuH7, HeLa, NIH3T3, and HepG2; however, most cell lines are RNAi competent, including a great variety of cell lines available from, e.g., ATCC (American Type Culture Collection—see ATCC.org). In addition, primary cells isolated from a tissue or an organism can be utilized. In general, it may be desirable to utilize cells, such as RD cells or Huh7 cells, capable of exhibiting a dsRNA-mediated stress response, particularly when the dsRNA effector molecules, e.g., long exogenously introduced dsRNAs, tend to induce such responses. This is less important when using dsRNA effectors such as expressed long dsRNAs, which do not induce a dsRNA-mediated stress response. Some cell lines, such as HeLa cells, which are capable of supporting RNAi, but are not competent with respect to exhibiting dsRNA-induced stress responses, may be preferred in some instances.
[0026] While the utilization of a chemiluminescent or fluorometric reporter makes it highly efficient to carry out the methods of the invention with in situ or real-time monitoring in various cell lines, if desired, the assay can also be carried out in a cell lysate. Additionally a cell-free system utilizing an in vitro transcription-translation kit (e.g., TNT Quick Coupled Transcription/Translation System, Promega, Madison, Wis.) can also be used, together with a Dicer or Dicer-type protein that cleaves longer dsRNAs into siRNAs, e.g., the Dicer siRNA Generation Kit available commercially from Gene Therapy Systems, Inc. (see genetherapysystems.com/catalog).
EXAMPLES
Example 1
[0000] Construction of an mRNA Fusion Vector
[0027] Vector preparation: pEGFP-N3 ( FIG. 2 ) a commercially available vector obtained from Clontech [(BD Biosciences Clontech, 1020 East Meadow Circle, Palo Alto, Calif. 94303) GenBank Accession #: U57609, Clontech Catalog #6080-1, See Catalog PR 08395, published 30 Aug. 2000, which provides a restriction map and detailed information about the vector, including the following: pEGFP-N3 encodes a red-shifted variant of wild-type GFP, which has been optimized for brighter fluorescence and higher expression in mammalian cells. pEGFP-N3 encodes the GFPmut1 variant which contains the double amino acid substitution of Phe-64 to Leu and Ser-65 to Thr. The coding sequence of the EGFP gene contains more than 190 silent base changes which correspond to human codon-usage preferences. Sequences flanking EGFP have been converted to Kozak consensus translation initiation site to further increase the translation efficiency in eukaryotic cells.
[0028] EGFP-N3 vector was restricted with Not I which cleaves after the EGFP stop codon. Following Not I digestion, the ends of the vector were blunted according to standard techniques (See, Molecular Cloning: A Laboratory Manual , Cold Spring Harbor Laboratory Press, 3 rd Ed, December 2000. Eds., Sambrook et al.)
[0029] HBV target sequence: The HBV derived target sequence is derived from HBV strain G2.27246, GenBank Accession # AF090839 and maps from coordinates 1849 to 2888 of this sequence.
[0030] Cloning of target HBV sequence into pEGFP-N3: A blunt-ended DNA fragment comprised of the HBV target sequence, was ligated into the vector pEGFP-N3 prepared as described above. The resultant construct EGFP/HBVsAg is pEGFP-N3 with the HBV target sequence encoded in the 3′UTR of the EGFP mRNA. Note that the Not 1 site, into which the HBV target sequence was cloned in downstream from the EGFP stop codon but upstream from the polyadenylation site ( FIG. 2 ).
Example 1A
[0000] Human RD Cells, Transfections and Summary of Results
[0031] Human RD cells (Rhabdomyosarcoma/Human Embryonal Rhabdomyososarcoma) (available from ATCC, as well as other sources) were co-transfected with:
[0000] A) EGFP/HBVsAg (Enhanced green fluorescent protein/Hepatitis B virus surface Ag) fusion mRNA construct and an siRNA derived from HBV (siRNA#1)[note that siRNA#1 maps to a subset of the HBV derived sequences cloned into the 3′UTR of EGFP/HBVsAg];
[0032] B) EGFP/HBVsAg fusion mRNA construct and a control siRNA (siRNA#2); or C) EGFP-N3 (EGFP plasmid without HBVsAg sequences) and siRNA#1. EGFP expression was monitored by fluorescent microscopy for 7 days. EGFP expression was down-regulated from 2-7 days post-transfection only in those cells co-transfected with the EGFP/HBVsAg fusion mRNA construct and siRNA#1. Levels of fluorescence were not down-regulated in cells transfected with EGFP-N3 plus siRNA#1, EGFP/HBVsAg fusion mRNA construct plus siRNA#2, EGFP-N3 plasmid alone (data not shown), or EGFP/HBVsAg fusion mRNA construct alone (data not shown). This demonstrates that the selected HBVsAg sequence inserted into the mRNA fusion construct constitutes a suitable target sequence for dsRNA-mediated gene silencing. By constructing a vector expressing an mRNA comprising the HBsAg target sequence alone, without the reporter sequence, and carrying out an analogous experiment with the same siRNA and other dsRNAs comprising a sequence complementary to the HBVsAg target, it was demonstrated (See Example 1B, below) that cleavage of the HBVsAg mRNA will also occur when presented in a more native conformation (not as a fusion mRNA), and that translation and generation of the protein product will be prevented or decreased.
[0000] Reagents:
[0000] HBV siRNA sequence (siRNA#1): maps to coordinates 2172-2196 of
[0000] GenBank Accession # AF090839
[0000] Top strand: 5′ccuccaaucacucaccaaccuccug3′
[0000] Bottom strand: 3′ggagguuagugagugguuggaggac5
[0000] Control siRNA sequence (siRNA#2): not derived from HBV sequences
[0000] Top Strand: 5′ agcuucauaaggcgcaugcuu3′
[0000] Bottom Strand: 3-uuucgaaguauuccgcguacg 5′
[0033] Note: siRNAs were chemically synthesized by Dharmacon (Lafayette, Colo.). Top strand and bottom strand of each siRNA set were annealed using standard techniques. Alternatively, siRNAs can also be prepared enzymatically using commercially available siRNA transcription kits such as the one available from Ambion.
[0000] HBVsAg Fusion Vectors and siRNAs were Constructed as Described in FIG. 1 Above
[0000] Human RD Cells, Transfections and Summary of Results:
[0034] Human RD cells were seeded into six-well plates such that they were between 80-90% confluency at the time of transfection. All transfections were performed using Lipofectamine (InVitrogen, Carlsbad, Calif.) according to manufacturer's directions. Nucleic acid concentrations were held constant at 4.3 ug for each transfection. The following nucleic acids were transfected in the indicated transfections:
[0000] Transfection A) 300 ng EGFP/HBVsAg, 2 ug siRNA#1 and 2 ug pGL3-basic vector (an inert DNA plasmid used as filler DNA for transfection);
[0000] Transfection B) 300 ng EGFP/HBVsAg, 2 ug siRNA #2 and 2 ug pGL3-basic;
[0000] Transfection C) 300 ng EGFP-N3 and 2 ug siRNA#1.
[0035] Transfection mixes were made using Lipofectamine and Opti-Mem (a serum-free medium available from InVitrogen), according to manufacturer's directions. The day after transfection, transfection mixes were removed from cells and replaced with DMEM (containing 10% FBS). This was designated one-day post-transfection. At days two-seven post-transfection, cells were visualized daily by both phase contrast microscopy and fluorescent microscopy. Cells belonging to the Transfection A group were significantly down-regulated for EGFP expression whereas cells belonging to Transfection B and Transfection C groups were not ( FIG. 3 ). No significant differences were observed in EGFP expression amongst not only the B and C transfection groups but also no differences were seen when B and C were compared to the fluorescence seen when cells were transfected in the same manner with the EGFP/HBVsAg fusion vector alone and/or the EGFP-N3 vector alone (data not shown). These results demonstrate that the EGFP/HBVsAg mRNA is specifically targeted by RNAi in cells transfected with the HBV siRNA#1, but not in cells transfected with the irrelevant siRNA#2. Also, as expected, the parental vector, PEGFP-N3, which does not contain any HBV sequences gave rise to an mRNA that was not targeted by either of the siRNAs. This experiment indicated that the selected HBV sequence utilized in the EGFP/HBVsAg construct is amenable to being targeted by RNAi and that siRNA#1 can effect RNAi of this target sequence.
Example 1B
[0036] To demonstrate that siRNA#1 can also target HBV sequences in a more native conformation, i.e., in the absence of EGFP mRNA sequences, the following experiment was done. An HBVsAg expression vector was constructed. This vector contains HBVsAg sequences derived from the HBV target sequence contained in the EGFP/HBVsAg fusion vector including those sequences corresponding to siRNA#1. The construct is designed to express middle sAg. Expression is directed by the HCMV promoter and the SV40 polyadenylation signal. Construction of such a vector can be easily accomplished by one skilled in the art.
[0000] In this experiment, RD cells were transfected with:
[0000] A) the HBVsAGg expression vector and siRNA#1;
[0000] B) the HBVsAg expression vector and siRNA#2; and
[0000] C) the HBVsAg expression vector alone.
[0037] All transfections were performed as described for the fusion mRNA vector transfections using Lipofectamine. Transfection A contained 300 ng HBVsAg expression vector, 2 ug siRNA#1 and 2 ug pGL3-basic vector; Transfection B contained 300 ng HBVsAg expression vector, 2 ug siRNA#2 and 2 ug pGL3-basic vector; and Transfection C contained 300 ng HBVsAg expression vector and 2 ug pGL3-basic vector. At 18 hrs post-transfection, media was collected from transfected cells and assayed for the presence of HBVsAg by ELISA. ELISA kits for the detection of HBVsAg are commercially available through Abbott Labs in Chicago. The results are shown in FIG. 4 . Briefly, siRNA#1 but not siRNA#2 was able to downregulate HBVsAg expression. Control levels of HBVsAg expression vector generated in transfections not containing any added siRNA is also shown.
Example 2
[0000] Evaluation of Effector Molecules
[0038] After a suitable target region for PTGS has been identified, the assay of the invention can be utilized to evaluate the relative effectiveness of selected effector molecules which include a region of dsRNA complementary to the target mRNA. For example, a series of overlapping sequences complementary to a region of the HBVsAg in the EGFP-HBVsAg fusion mRNA construct described above is mapped out. The double-stranded region of such dsRNAs can be as short as 19 nts in length or as long as several thousand nts, but will preferably be 100, 200, up to 500 nts in length. The HBV derived target sequence utilized in the EGFP/HBVsAg Fusion Construct described above maps from coordinates 1849 to 2888 of the HBV strain G2.27246, GenBank Accession # AF090839, and thus represents a sequence of 1039 nts. Thus, e.g., the HVB derived target sequence can be divided up into overlapping stretches of approximately 200 nts, e.g., coordinates 1849-2050 (A), 1949-2150 (B), 2049-2250 (C); 2149-2349 (C); 2249-2450 (D); 2349-2550 (E); 2449-2649 (F); 2549-2749 (G); and 2649-2888 (H). Double stranded RNAs having one strand complementary and one strand homologous to this sequence are then synthesized, or, alternatively, are expressed as described herein, either as two separate strands synthesized individually and annealed under appropriate conditions, or as a single RNA strand having one such sequence in the sense orientation and another in the antisense orientation, preferably with a suitable linking region, e.g., a linking region of suitable length, e.g., 9 to 30 nucleotides, preferably consisting of a sequence of the same base, such as poly C, poly A, poly U, or poly G.
[0039] Human RD cells are transfected as described in Example 1 above with the EGFP/HBVsAg fusion vector and one of the dsRNA effector molecules to be evaluated, e.g., dsRNA A, dsRNA B, dsRNA C, dsRNA D, dsRNA E, dsRNA F, dsRNA G, or dsRNA H, or, alternatively, transcribed as described in Example 1 above with the EGFP/HBVsAg fusion vector and a vector designed to express one of the dsRNA effector molecules to be evaluated, e.g., dsRNA A, dsRNA B, ds RNA C, dsRNA D, dsRNA E, dsRNA F, dsRNA G, or dsRNA H. In each case, cells are visualized daily as described in Example 1A by both phase contrast microscopy and fluorescent microscopy, to determine the efficacy of each such dsRNA in eliciting RNAi and the relative efficacy of the eight dsRNAs.
Example 3
[0040] In a further experiment, dsRNA effector molecules representing overlapping sequences of variable length, e.g., 20 nts, 30 nts, 50 nts, 100 nts, 150 nts, 200 nts, 300 nts, 400 nts, to 500 nts, mapping to the HBVsAg target sequence of the EGFP/HBVsAg Fusion Construct are designed and constructed, and delivered as described in Example 1 above, either as a synthesized dsRNA or as a vector expressing such a dsRNA, to appropriate cells such as Human RD or Huh7 cells, together with the EGFP/HSVsAg Fusion Construct. In each case, cells are visualized daily as described by both phase contrast microscopy and fluorescent microscopy, to determine the efficacy of each such dsRNA in eliciting RNAi and the relative efficacy of the various dsRNAs.
|
Methods and constructs for selecting double-stranded RNA molecules capable of post-transcriptional gene silencing (PTGS) or RNA interference (RNAi); and methods of selecting targets susceptible to double-stranded RNA mediated PTGS or RNAi.
| 2
|
BACKGROUND OF THE INVENTION
[0001] This invention generally relates to a drive axle assembly, and specifically to a drive axle assembly configured to reduce the amount of required lubricant.
[0002] Typically, an axle housing includes a shaft suspended for rotation within the housing and driven by a drive mechanism also disposed within the housing. The housing is hollow throughout. A lubricant, such as oil, contained within the housing lubricates the drive mechanism. Further, lubricant within the housing lubricates bearing assemblies used to support drive axles within the housing. The amount of lubricant contained within the housing is dictated by the size and location of the drive mechanism and placement of the bearing assemblies.
[0003] One example of an axle housing that requires a significant amount of lubricant is an inverted portal drive axle housing. In an inverted portal axle, the shaft and drive hub rotate about different axes spaced a distance apart. This configuration allows a vehicle floor to be much lower than would otherwise be possible with conventionally configured axles. Typically, an inverted portal axle includes a drive mechanism disposed on one end of the axle housing and a drop gearbox on either end immersed in lubricant. Lubricant must cover the drive mechanism and helical gears to a required depth. The entire hollow interior of the housing must be filled with lubricant in order to obtain a proper level at the drive mechanism and both drop gearboxes. Much of the lubricant included within the housing is not in contact or near the drive mechanism. A large amount of lubricant is simply provided to ensure that a proper level of lubricant is present at the drive mechanism and drop gearboxes. Accordingly, much of the lubricant contained in the housing is not near the drive mechanism, drip gearboxes, or the bearing assemblies and is present only to ensure the proper level of lubricant in specific critical areas.
[0004] Typically, an inverted portal axle housing contains approximately 25 to 27 liters of lubricant to attain the proper level relative to the drive mechanism. This is periodically changed in order ensure that the desired lubrication properties are maintained within specified parameters. The lubricant removed from the axle housing during an oil change must be disposed. The sheer quantity of lubricant required to fill an axle housing causes disposal problems and increases operation and maintenance costs.
[0005] Accordingly, it is desirable to develop an axle assembly that reduces the amount of required lubricant while maintaining sufficient levels for proper lubrication of the drive mechanism and the bearing assemblies.
SUMMARY OF INVENTION
[0006] An embodiment of this invention is an axle housing including web structures defining an internal chamber containing lubricant only in critical areas requiring lubrication.
[0007] The axle housing supports a shaft driven by a drive mechanism. A web member defines a lubricant containment chamber within the axle housing. The web member cooperates with the housing to form the lubricant containment chamber and prevent lubricant from being dispersed throughout the entire hollow interior of the housing. A shaft seal is provided within each web member to prevent lubricant leakage through a shaft web member interface.
[0008] The axle housing includes an internal cavity that runs the entire length of the axle housing from a first end to a second end. The web members are disposed at each end to define the lubricant containment chambers. The remaining areas within the axle housing do not receive lubricant and remain dry. Typically, an inverted portal axle assembly requires approximately 25 to 27 liters of lubricant, much of this lubricant dispersed in sections not requiring lubrication. The containments chambers defined within the axle housing assembly of this invention reduce the amount of required lubricant to approximately 17 to 19 liters.
[0009] Accordingly, this invention provides an axle housing containing lubricant only in areas requiring lubrication, reducing the quantity of lubricant required to maintain proper levels for the drive mechanism and bearing assemblies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:
[0011] FIG. 1 is a cross-sectional view of an inverted portal drive axle including web members of this invention;
[0012] FIG. 2 is a cross-sectional view of a web member at the shaft interface; and
[0013] FIG. 3 is an enlarged cross-sectional view of an end of the axle housing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] Referring to FIG. 1 , an axle assembly 10 includes rotating shafts 11 , 12 . The rotating shafts 11 , 12 are supported within a housing 14 by bearings 40 and is driven by a drive mechanism 16 . The housing 14 includes web members 22 disposed within the housing 14 to define lubricant containment chambers 30 . The lubricant containment chambers 30 are filled with lubricant 42 to a desired level to partially immerse the drive mechanism 16 . Lubricant is prevented from being dispersed throughout a middle section 18 of the axle housing 14 . By confining lubricant within the containment chambers 30 , the amount of lubricant required to properly lubricate the drive mechanism 16 is reduced.
[0015] The axle housing 10 of this invention is an inverted portal axle having the shafts 11 , 12 rotating about a first axis 34 and a drop gearbox 32 with an output member rotating about a second axis 36 . The first and second axes 34 , 36 are disposed parallel to each other and are spaced apart a distance 38 . The drive mechanism 16 is preferably a gearbox that transmits torque from a drive shaft to the axle shafts 11 , 12 . The axle shafts 11 , 12 transmit torque from the drive mechanism 16 to the drop gearboxes 32 . A drop gearbox 32 is disposed at first and second ends 26 , 28 of the housing 14 . The specific configuration of the drive mechanism is as known to worker skilled in the art. The lower profile of the axle housing 14 allows the floor of a vehicle to be lowered below a driven wheel. Inverted portal axles are most often used in mass transit vehicles to allow the use of a lowered floor in order to aid entry and exit of passengers. As appreciated, the inverted portal axle is just one example of an axle housing configurations that may benefit from this invention.
[0016] The web members 22 define the lubricant containment chambers 30 at the drive mechanism 16 and the bearing assemblies 40 disposed at distal ends of the housing 14 . The web members 22 are preferably an integrally cast part of the housing 14 . Each web member 22 is a plate dividing a portion of the hollow interior of the housing 14 . The web members 22 are positioned relative to the area within the housing 14 that requires lubricant. The containment chambers 30 defined by the web members 22 reduce the amount of lubricant required to obtain required lubricant levels for lubrication of the drive mechanism 16 and bearings assemblies 40 .
[0017] Referring to FIG. 2 , the web member 22 includes a shaft seal 24 surrounding each shaft 11 , 12 . The shafts 11 , 12 extend through the web member 22 to the drive mechanism 16 ( FIG. 1 ). The drive mechanism 16 rotates the shaft 12 . The seal 24 prevents lubricant from migrating past the web member 22 into the dry center section 18 of the housing 14 .
[0018] Referring to FIG. 3 , an enlarged view of the first end 26 of the axle assembly 10 is shown. The axle housing 14 includes the web member 22 and the shaft seal 24 that define the containment chambers 30 . Lubricant 42 within the containment chamber 30 is filled to a desired level in order to provide proper lubrication of the drive mechanism 16 and drop gearboxes 32 . This invention reduces the total amount of lubricant 42 required to immerse the drive mechanism 16 and drop gearbox 32 to the desired level.
[0019] Axle assemblies designed according to this invention reduce the amount of lubricant 42 required to lubricate the drive mechanisms 16 , drop gearbox 32 , and bearing assemblies that support rotation of the axle shafts 12 . The web members 22 define the lubricant containment chambers 30 within the housing 14 such that only a portion of the housing contains lubricant. This feature reduces the amount of lubricant 42 by confining lubricant 42 to these portions of the housing 14 requiring lubrication.
[0020] The foregoing description is exemplary and not just a material specification. The invention has been described in an illustrative manner, and should be understood that the terminology used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, one of ordinary skill in the art would recognize that certain modifications are within the scope of this invention. It is understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For that reason the following claims should be studied to determine the true scope and content of this invention.
|
An axle housing assembly includes web members that define lubricant containment chambers within an interior space of a housing. Each lubricant containment chamber contains a fixed amount of lubricant. The containment chambers defined within the housing confine lubricant to critical areas to reduce the amount of lubricant required within the housing to properly lubricate internal components.
| 8
|
BACKGROUND OF THE INVENTION
The present invention concerns an unwinding device for twin warp beams in weaving looms, providing important advantages in loom construction.
It is known that, in order to facilitate the warping operation in double-width weaving machines, it is often preferred to use, instead of a single warp beam, two side-by-side beams, called "twin beams". The unwinding of such beams is either carried out by a single unwinding device, equipped with a differential between the two beams, or by two separate unwinders.
Both solutions are meant to guarantee a constant equal tension for the two beams, so as to obtain a perfect working and to exhaust the two beams simultaneously. The tension should moreover be uniform and it should be possible to efficiently regulate the damping action of the yarn carriers and to easily operate any adjustments.
The solution of a single unwinder with a differential, because of the high transmission ratios and torques involved in the operation, is subject to intolerable slacks which determine oscillations in the beams and an anomalous behaviour. It is therefore not suited for application on modern weaving machines, with high performances and working at very fast speeds.
The solution with two separate unwinders is more interesting, as it reduces slacks and halves the torques, dividing them between the two unwinders. Furthermore, it provides the advantages of an easier installation of the beams, which are free from kinematic connections. Nevertheless, in its practical accomplishments known so far, also this solution is not suited for a rational application on modern looms with high speeds and performances.
The object of the present invention is to propose a modern and satisfactory solution for an unwinding device for twin beams.
SUMMARY OF THE INVENTION
For this purpose, the present invention provides an unwinding device for twin beams, with two separate unwinders, characterized in that the adjustment of the two unwinders is carried out according to the inclinations, detected by sensors, which the two yarn carriers of the beams take up under the different tensions of the warp yarns.
Preferably, in said device, the yarn carriers are carried by an oscillating bar and are mounted, with their inward ends, on ball joints allowing rotation and inclination thereof in respect of said bar, and with their outward ends on supports--rotating and tilting on ball joints--carried by levers supporting said bar and causing the oscillation thereof, calibrated return means opposing the oscillations of said levers and of said supports according to the tensions of the warp yarns; moreover, said sensors detect the position of said supports carried by the levers, in order to adjust said unwinders.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is now described in further detail with reference to the accompanying drawings, which represent preferred embodiments thereof and in which:
FIG. 1 is a general plan view, seen from the top, of a pair of twin warp beams with their respective yarn carriers, controlled by an unwinding device according to the invention.
FIG. 2 is a detailed side view showing the unwinding device in a first working step;
FIG. 3 is a view similar to that of FIG. 2, but showing a different working step;
FIG. 4 shows a structural modification of the return means for the levers and for the supports of the device according to the invention, shown in the previous figures;
FIG. 5 shows a possible balancing connection between said return means; and
FIG. 6 shows a different embodiment of the arrangement according to the invention, applied in the case of a single beam replacing the twin beams.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The arrangement according to the invention, illustrated in FIG. 1, comprises two twin beams 1 and 2, the slow rotation of which is controlled by two separate unwinders 3 and 4, and two separate yarn carriers 5 and 6, onto which press and partially wind the warp yarns fed from the beams 1 and 2 and leading to the loom healds.
The yarn carriers 5 and 6 consist of two hollow metal rollers, mounted freely rotating and tilting on a bar 7 which is carried by two end levers 8 and 9 and by a central lever 10, said levers being mounted respectively on supports 12, 13 and 14 of the loom casing, so as to oscillate on a common axis 11.
At their inward facing ends the two yarn carriers 5 and 6 are mounted on the bar 7 by way of ball joints 15 and 16 allowing the free rotation and inclination thereof; whereas, at their outward far ends said yarn carriers are mounted on supports 17 and 18 carried by the levers 8 and 9, so as to oscillate with said levers on the axis 11; also in this case the yarn carriers are mounted by way ov ball joints 19 and 20, allowing the free rotation and inclination of the supports 17 and 18 in respect of the levers 8 and 9, and consequently the rotation of the yarn carriers and their inclination in respect of the bar 7.
From FIGS. 2 and 3 it appears evident that the levers 8 and 9 (only the lever 9 being shown) are stressed by return means, in the form of a spring 21, opposing the oscillations of said levers and the consequent oscillations of the bar 7 and thus of the yarn carriers 5 and 6 (only the yarn carrier 6 being shown); whereas the oscillations of the supports 17 and 18 (only the support 18 being shown), in respect of said levers 8 and 9, are in turn opposed by springs 22.
FIGS. 1 to 3 finally show sensors 23 and 24 (FIGS. 2 and 3 showing only the sensor 24) which detect the oscillations of the levers 8 and 9 and/or of the supports 17 and 18, and accordingly operate the unwinders 3 and 4 (FIGS. 2 and 3 showing only the unwinder 4).
In operation, when the shed is being formed, there is an increase in the tension of the warp yarns which overcomes the calibrated action of the return means (springs 21) and causes the counterclockwise oscillation (dashed lines in FIG. 2) of the levers 8 and 9 on the axis 11. Said oscillation is detected by the sensors 23 and 24, which provide to suitably adjust the unwinders 3 and 4.
In the event, instead, that the two twin beams 1 and 2 should unwind unevenly, thereby varying the tensions in the warp yarns pressing and winding onto the yarn carriers 5 and 6, the supports 17 and/or 18 will oscillate, and said oscillations will be detected by the sensors 23 and/or 24 so as to suitably adjust the unwinders 3 an 4. These oscillations, opposed by the springs 22, are obtained thanks to the fact that the yarn carriers 5 and 6, and the supports 17 and 18, are mounted by way of ball joints (15, 16, and respectively 19, 20).
It will thus be seen from the foregoing description and the accompanying drawings that the unwinders 3 and 4 are drives for rotating the beams 1 and 2 on which the warp yarns f are wound, and that the speed with which they rotate the beams 1 and 2 is controlled by the sensors 23 and 24. The yarn carriers 5 and 6 thus serve as tension rollers, the warp yarns f being partially trained about them and bearing thereagainst. The members 5 and 6 are freely rotatable on the ball joints 15, 16 and within ball joints carried by supports 17 and 18 that can be seen in FIG. 1.
The shape of the levers 8 and 9 is that of lever 9 as seen in FIGS. 2 and 3, mounted for rotation about axis 11 on a stub shaft which in turn is rotatable within the support 12 or 13. This stub shaft also carries the ball joint 19 or 20; and the levers 8, 9 are connected to supports 17, 18, respectively, by the springs 22 which yieldably permit relative swinging movement of 8 relative to 17 and 9 relative to 18. Springs 21 thus are compression springs which oppose counterclockwise movement of levers 8, 9, and springs 21 are likewise compression springs which oppose counterclockwise movement of 18 relative to 9 (and 17 relative to 8, not shown) all as seen in FIGS. 2 and 3.
FIGS. 4 to 6 show some modified embodiments of the arrangement according to the invention.
FIG. 4 shows how the return means for the levers 8 and 9 may comprise--instead of a spring 21--a positive control, consisting of a pair of toggle-joint levers 25 and 26 and of a cam 27 acting on said pair of levers. Whereas, the supports 17 and 18 (see FIGS. 4 and 5) can be controlled by means of hydraulic cylinders 28 and 29, the action of which is balanced thanks to their connection to a central cylinder 30 which regulates the strength of said action. In this case, unwinding takes place merely thanks to the changes of inclination of the yarn carriers 5 and 6.
FIG. 6 shows finally the system according to the invention, applied in the case of using a single beam 1: there are again two yarn carriers 5 and 6, mounted as in the previous arrangement, and two sensors 23 and 24, the signals of which are caused to interact in an electronic circuit 31, so as to obtain signals for controlling the single unwinder 3 of the beam 1. This arrangement allows operating with high warp yarn tensions.
The efficiency of the heretofore described and illustrated arrangements will appear quite evident to the experts in the field, said arrangement allowing operating with a very uniform and constant tension in the warp yarns, while making if possible to regulate the damping action of the yarn carriers and to carry out the various adjustments in a very simple, easy and reliable manner.
|
Unwinding device for twin warp beams, with two separate unwinders, wherein the adjustment of the two unwinders (3, 4) is carried out according to the inclinations, detected by sensors (23, 24), which the two yarn carriers (5, 6) of the beams (1, 2) take up under the different tensions of the warp yarns (f).
| 3
|
TECHNICAL FIELD
[0001] The invention relates to the general technical field of chemical vapor deposition reactors.
[0002] Such reactors are for example used for manufacturing semi-conductor materials based on elements of columns 13 and 15 of the periodic table—such as gallium nitride GaN.
[0003] The invention notably relates to a chemical vapor deposition reactor for the manufacturing of wafers of element 13 nitride by injection of gas precursors.
[0004] These wafers may be intended for the manufacturing of semi-conductor structures such as light-emitting diodes (LED) or laser diodes (LD).
PRESENTATION OF THE PRIOR ART
[0005] Present methods for manufacturing semi-conducting materials based on element 13 nitride are based on chemical vapor deposition techniques, such as deposition techniques:
by MetalOrganic Vapor Phase Epitaxy (MOVPE), by Hydride Vapor Phase Epitaxy (HVPE), by Close-Spaced Vapor Transport (CSVT), etc.
[0009] In order to apply these different techniques, a chemical vapor deposition reactor is generally used.
[0010] This reactor comprises a support—or “a susceptor”—intended for receiving one (or several) initial substrate(s) on which the semi-conducting material(s) is (are) manufactured.
[0011] In order to form semi-conducting material(s), precursor gases are injected into an enclosure of the reactor so as to sweep the surface of the substrate(s). These precursor gases react to the surface of the substrate(s) in order to form one (or several) layer(s) of semi-conducting material.
[0012] In order to guarantee performances of good quality in the thereby formed semi-conducting material(s), it is necessary to control the composition. Notably, the making of a uniform layer is conditioned by a laminar flow of the precursor gases on the substrate(s).
[0013] Now the precursor gases may react together and be deposited in unsuitable areas of the reactor, such as the walls of the enclosure, or the outlet of the nozzles for supplying precursor gases.
[0014] Such depositions may induce partial or total blocking of the supply nozzles, which makes the control of the flows of precursor gases difficult and therefore degrades the quality of the obtained semi-conducting materials.
[0015] Document US2008/0163816 describes a reactor including a system for injecting precursor gases for producing an AlN layer by a chemical vapor deposition method in order to homogenize the pressure exerted by the film formed on the substrate. The injection system includes an “injection shower” (referenced as 15) positioned above the substrate. The shower with a frustoconical shape is supplied via a conduit in an upper portion (reference 14). It comprises a large number of injectors (referenced as 15b) in the lower portion. However such a reactor is not adapted to depositions of gallium nitride because of the strong reactivity of the precursor gases (i.e. gallium chloride and ammonia) used for forming a layer of gallium nitride.
[0016] Document EP 0 687 749 describes a device wherein two precursor gases are injected separately just above the substrate in order to promote the homogeneity of the mixture of precursor gases and to obtain a layer of gallium nitride of good quality. These gases are in particular tri-ethyl gallium or tri-methyl gallium and ammonia. The thereby described device includes a cooling chamber (referenced as 20) which gives the possibility of avoiding a too strong reaction before the deposition. This configuration aims at improving the control of the homogeneity of the mixture of precursor gases (cf. page 4 column 6 lines 3 to 25 of EP 0 687 749). Such a device including a cooling chamber is:
difficult or even impossible to apply when the injection device is in an area of the chamber at a very high temperature (>700° C.), expensive, and energy consuming.
[0020] Another injection device is described in WO 2008/064083. The document proposes to make a GaN layer by HVPE on a substrate heated to 1,000° C. A sweeping gas, in this case nitrogen, is propelled laterally relatively to the substrate. A first precursor gas—i.e. gallium chloride—is provided as a dimer in a first tubing (referenced as 323) and opens into a funnel (referenced as 325) filled with silicon carbide beads SiC for which the temperature is of the order of 800° C. for decomposing the first precursor gas into a monomer. The first precursor gas decompose into a monomer is then maintained at a temperature above 600° C. in order to avoid the reformation of dimers, and is transported as far as a slot (referenced as 329) (cf. last paragraph of page 23 and first paragraph of page 24; FIGS. 4 to 6). A second precursor gas, in this case ammonia, is injected separately through a tubing (referenced as 519). The precursor gases are blown so as to follow non-turbulent conditions and at a sufficiently large distance from the substrate so that their temperature is of the order from 400 to 500° C. in order to avoid a sparse deposition in the injection device. A drawback of such an injection device is that the control of the temperature of the precursor gases is delicate, notably in the case of producing semi-conducting materials of large dimensions.
[0021] Document FR 2 957 939 describes a device for injecting gases into a treatment chamber. The injector comprises at least two adjacent injectors. Each injector comprises a diffusion plate comprising a plurality of openings for letting through the gas. A first gas wave is introduced into a first injector. In the treatment chamber, the first gas wave reacts with a substrate before being purged from the chamber by means of a discharge device. A second gas wave is then introduced into a second injector, which reacts with the deposits left by the first gas injection.
[0022] The precursor gases are therefore injected separately, it is not possible to directly proceed with the deposition of a layer of a mixture of precursor gases. The pulse/purge steps therefore have to be repeated as many times as necessary in order to obtain the desired thickness of the thin layer, which causes a relatively low production capacity.
[0023] Therefore there exists a need for a device which is still more productive giving the possibility of producing in a more stable way very homogeneous slices of a semi-conducting material, notably slices of a material nitride of element 13 of the periodic classification, more particularly slices consisting of GaN, of large size (four inches, six inches or eight inches).
SUMMARY OF THE INVENTION
[0024] For this purpose, the invention proposes a chemical phase deposition reactor from first and second precursor gases, the reactor comprising:
an enclosure including upper and lower walls and a side wall connecting the upper and lower walls, a support intended to receive at least one substrate, mounted inside the enclosure, and at least one system for injecting precursor gases, the system including an injection head including at least one nozzle for supplying the first precursor gas along a main direction of axis A-A′, said at least one nozzle including:
a precursor gas supply conduit, and an outlet member generating a vortex flow of a substantially annular shape around the axis A-A′.
[0030] Within the scope of the present invention, by “vortex flow with a substantially annular shape”, is meant a generally toroidal vortex wherein the flow of fluid is mainly a rotation around a curved loop itself and extending around the axis A-A′. Such a closed loop is not necessarily planar and may have different radii of curvature piece wise.
[0031] The generation of a vortex flow with a substantially annular shape around the axis A-A′ allows recirculation of the precursor gas in the vicinity of the outlet of the nozzle in order to avoid the deposition of material in the vicinity of the outlet of the nozzle by reaction of the first and second precursor gases.
[0032] Indeed, unlike what may be expected, the local recirculation of the first precursor gas does not produce any Venturi effect tending to suck up the second precursor gas.
[0033] On the contrary, in practice, the “recirculation loop” of the first precursor gas pushes back the second precursor gas and thereby avoids a reaction between both gases in the close vicinity of the outlet of the nozzle.
[0034] Preferred but non-limiting aspects of the reactor according to the invention are the following.
[0035] The outlet member may comprise an upstream end facing the precursor gas supply conduit and a downstream end opposite to the upstream end along the main direction, the sectional dimensions of the upstream end being less than the sectional dimensions of the downstream end.
[0036] The variations of sections between the upstream and downstream end portions of the outlet member give the possibility of generating a vortex flow around the outlet of the supply nozzle. Alternatively, the upstream and downstream ends of the outlet member may have equal sections, the outlet member including an annular striction (or shrinkage) between the upstream and downstream ends, this striction generating local acceleration of the ejected gas just before passing at the annular striction and generating a vortex flow just after the striction.
[0037] The outlet member may consist in a part connected to the outlet of the gas supply conduit. Alternatively, the outlet member and the gas supply conduit may be in a single piece. Notably, the outlet member may comprise a coaxial recess with the gas supply conduit.
[0038] This gives the possibility of obtaining a supply nozzle wherein the downstream end of the outlet member is flushed with the surface of the injection head.
[0039] Advantageously, the recess may comprise a cylindrical counterbore, the diameter of the counterbore being greater than the diameter of the precursor gas supply conduit.
[0040] This gives the possibility of facilitating the manufacturing of the injection head, a simple piercing of the nozzles at their free end giving the possibility of forming the outlet members.
[0041] The recess may comprise a flared portion outwards along the main direction A-A′.
[0042] This gives the possibility, in the supply nozzle, of limiting the regions which may induce pressure losses for the vortex flow.
[0043] In an alternative embodiment, the recess may also include a frustoconical portion.
[0044] This gives the possibility of obtaining a vortex wherein the flow velocities of the fluid are uniformly distributed around the outlet of the nozzle.
[0045] In another alternative embodiment, the recess may include a concave portion, notably with the shape of a piece of a torus.
[0046] This gives the possibility of accelerating the velocities of rotation of the fluid so in the vortex.
[0047] The recess may also comprise a combination of portions of different shapes.
[0048] In an embodiment, the walls of the outlet member comprise a molybdenum coating. This gives the possibility of protecting the walls of the outlet member against deposition of gallium nitride.
[0049] The injection head may be used for introducing a single one of the precursor gases required for the deposition reaction. Alternatively, the injection head may be laid out so as to allow the introduction of different precursor gases. In this case, it may comprise:
a plurality of first nozzles for supplying a first precursor gas, a plurality of second nozzles for supplying a second precursor gas,
the first and second nozzles being alternatively distributed in the injection head.
[0052] By distributing the first and second nozzles alternatively gives the possibility of ensuring a more homogeneous distribution of the precursor gases at the surface of the substrate on which the deposition has to be applied.
[0053] Preferably, the largest dimension in section of the outlet member is greater than the largest dimension in section of the gas supply conduit, and the ratio between the largest dimension in section of the outlet member and the depth of the outlet member is comprised between 0.1 and 10. These dimensions are more particularly adapted for the manufacturing of semi-conducting materials including one (or several) layer(s) of gallium nitride.
[0054] The invention also relates to a method for manufacturing a semi-conducting material in a chemical vapor deposition reactor as described above, the method comprising an applied epitaxial growth step:
by MetalOrganic Vapor Phase Epitaxy (MOVPE), by Hydride Vapor Phase Epitaxy (HVPE), or by Close-Spaced Vapor Transport (CSVT).
[0058] The invention also relates to a method for manufacturing a chemical vapor deposition reactor from first and second precursor gases, the reactor comprising:
an enclosure including upper and lower walls and a side wall connecting the so upper and lower walls, a support intended to receive at least one substrate, mounted inside the enclosure, and at least one system for injecting precursor gases, the system including an injection head including at least one nozzle for supplying the first precursor gas along a main direction of axis A-A′, said at least one nozzle including a precursor gas supply conduit,
remarkable in that the method comprises a phase for dimensioning an outlet member of the nozzle, for determining the geometry of the outlet member allowing the generation of a vortex flow with a substantially annular shape around the axis A-A′.
[0062] Preferred but non-limiting aspects of the manufacturing method described above are the following:
the dimensioning phase may comprise a step for selecting a set of geometrical characteristics of the supply nozzle allowing the obtaining of a vortex flow for which the diameter is substantially equal to the depth of the outlet member, the dimensioning phase may also comprise the following steps:
receiving parameters relating to:
operating conditions of the supply nozzle, physico-chemical characteristics of the gas intended to be ejected,
defining a set of geometrical characteristics of the supply nozzle, numerical modelling of the injector from received parameters and from the defined set of geometrical characteristics; estimating from the modelling, geometrical characteristics of the vortex flow generated by the outlet member; comparing the diameter H of the vortex flow and of the depth P of the outlet member.
SHORT DESCRIPTION OF THE DRAWINGS
[0072] Other advantages and features of the reactor according to the invention will still emerge from the description which follows, of several alternative embodiments, given as non-limiting examples, from appended drawings wherein:
[0073] FIG. 1 illustrates an example of a chemical vapor deposition reactor according to the invention,
[0074] FIG. 2 illustrates an example of a supply nozzle from the prior art,
[0075] FIG. 3 illustrates an example of a supply nozzle according to the invention,
[0076] FIG. 4 schematically illustrates various alternatives of an outlet member of a supply nozzle,
[0077] FIG. 5 is a perspective view of an injection head according to the invention,
[0078] FIG. 6 is a sectional view of an injection head and of a reactor support,
[0079] FIG. 7 is a schematic sectional illustration of an outlet member,
[0080] FIG. 8 schematically illustrates steps of a method for dimensioning an outlet member of an injection head.
DETAILED DESCRIPTION OF THE INVENTION
[0081] Various examples of chemical vapor deposition reactors will now be described in more details with reference to the figures. In these different figures, the equivalent elements bear the same numerical references.
[0082] In the following, the invention will be described with reference to the manufacturing of gallium nitride GaN wafers.
[0083] However, it is quite obvious for one skilled in the art that the reactor described below may be used for growing a material other than gallium nitride GaN.
1. General
[0084] With reference to FIG. 1 , an example of a chemical vapor deposition reactor is illustrated, wherein gas precursors are injected in order to allow the growth of GaN on a substrate for example of sapphire.
[0085] The reactor comprises an enclosure 1 housing a support 2 and an injector 3 .
[0086] The enclosure 1 is a chamber in which the deposition is applied. It may be of a parallelepipedal or cylindrical shape (or other shape) and comprises an upper wall 11 , a lower wall 12 and one (or several) side wall(s) 13 .
[0087] The support 2 comprises a susceptor intended to receive one (or several) substrate(s) used for growing the layer(s) of gallium nitride GaN. This growth is obtained by reacting together two so called “gas precursors” gases—at the surface of the substrate 21 .
[0088] The injector 3 opens into the inside of the enclosure 1 through an inlet orifice. The injector 3 gives the possibility of transporting the gas flow inside the enclosure 1 , and notably of at least of the gas precursors required for forming the gallium nitride layer.
[0089] The injector 3 comprises one (or several) duct(s) 31 for transporting the gas flow and one (or several) injection head(s) 32 . The injection head(s) 32 give the possibility of sweeping the substrate positioned on the support 2 with one (or several) chemical agent(s) in a gas phase.
[0090] The injection head 32 may be positioned above the outlet support 2 so that the gas flow is projected in a substantially perpendicular direction to the upper face of the support 2 . Alternatively (or additionally), the (or one) injection head 33 may be positioned beside the support 2 so as to project the gas flow in a direction substantially parallel to the upper face of the support 2 .
2. Particularities of the Reactor According to the Invention
[0091] 2.1. Problem of the Existing Injectors
[0092] A drawback of the injectors of the prior art is that the gas precursors 41 , 42 tend to react together at the supply nozzles 421 . As illustrated in FIG. 2 , this reaction induces the formation of a film 43 on the supply nozzles 421 , this film partly obstructing or totally obstructing the supply nozzles 421 . This may compromise the manufacturing of high quality components in the reactor, since it becomes difficult to control the injection parameters (such as the flow rate, the concentration, etc.) of the precursor gases 41 , 42 in the enclosure 1 .
[0093] 2.2. Proposed Solution
[0094] In order to solve this drawback, it is necessary to avoid the reaction of the precursor gases 41 , 42 at the supply nozzles of the injection head 32 , 33 .
[0095] To do this, the formation of an outlet member 322 - 328 in each supply nozzle is proposed. The function of this outlet member 322 - 328 is to prevent the reaction of the gas precursors 41 , 42 at the supply nozzles.
[0096] In the embodiment illustrated in FIG. 3 , each supply nozzle thereby consists in:
a gas supply conduit 321 extending along an axis A-A′, and an outlet member 322 connected to the end of the gas supply conduit 321 , the outlet member 322 generating a vortex flow with a substantially annular shape around the supply conduit 321 .
[0099] Thus, if the supply nozzle ejects a first precursor gas 41 into the enclosure 1 of the reactor, the outlet member 322 generates a vortex 44 of the first precursor gas 41 , this vortex 44 having the shape of a torus and extending around the outlet of the supply nozzle (axis A-A′).
[0100] The fact that each injection nozzle comprises an outlet member 322 generating a toroidal flow 44 of the ejected species 41 gives the possibility of generating a recirculation of the first ejected gas precursor 41 at the outlet of the nozzle. Thus locally, the atmosphere of the enclosure 1 is enriched (i.e. in proximity to the outlet of the supply nozzle) with the ejected precursor gas 41 .
[0101] This gives the possibility of preventing the formation of a film at the outlet of the supply nozzle.
[0102] Indeed, the inventors have discovered that the formation of a film of gallium nitride requires the presence of two gas precursors 41 , 42 in substantially equivalent proportions: notably at concentrations of the same order of magnitude.
[0103] In this case, the fact of generating a turbulent vortex 44 of the first ejected precursor gas 41 , induces a local enrichment of the atmosphere with the first ejected precursor gas 41 (and therefore local depletion of the atmosphere with the second precursor gas 42 ). The local concentrations of the first and second precursor gases 41 , 42 being very different, the latter no longer react together at the outlet of the supply nozzle.
[0104] The risks of obturation of the supply nozzles is thereby avoided. Of course, the first and second precursor gases 41 , 42 continue to react together, but in an area 43 sufficiently far from the outlet of the supply nozzle for limiting any risk of blocking the latter.
3. Outlet Member
[0105] 3.1. Alternatives for the Outlet Member
[0106] The outlet member 322 - 328 may consist in a part mounted at the end of the gas supply conduit 321 . In this case, the outlet member 322 - 328 extends by protruding outwards from the injection head 32 .
[0107] Alternatively, the outlet member 322 - 328 and the supply conduit 321 may be in one piece. This gives the possibility of limiting the number of parts making up the injection head 32 , and thereby facilitates its manufacturing.
[0108] The outlet member 322 - 328 may for example consist in a recess made at the free end of the gas supply conduit 321 . An outlet member 322 - 328 is thereby obtained opening and flushed with the injection head 32 is thereby obtained. This gives the possibility of limiting the number of walls on which an undesired film 43 of gallium nitride may be deposited.
[0109] For example in the embodiment illustrated in FIG. 3 , the outlet member 322 consists in a substantially cylindrical counterbore. This counterbore is obtained by making a bore in the gas supply conduit, for example by piercing.
[0110] When the outlet member consists in a shoulder, its shape may vary, notably depending:
on the type of machining applied for making the outlet member, on the shape of the gas supply conduit 321 .
[0113] With reference to FIG. 4 , the outlet member may for example consist in:
a recess of a concave shape, for example as a sphere portion 324 , a recess of a parallelepipedal or cylindrical shape 325 , a recess of a frustoconical shape 326 , a recess of a complex shape consisting in a combination of the previous shapes, for example consisting of a cylindrical portion 327 and of a frustoconical portion 328 .
[0118] Preferably the cross-sectional profile of each supply nozzle has a sudden variation in section between the supply conduit and the outlet member. This gives the possibility of promoting the generation of a turbulent vortex at the outlet of each supply nozzle. Thus, outlet members will be preferred with the shape of a step or a square wave in a longitudinal section.
[0119] Advantageously, the walls of the outlet member may be treated for limiting the risks of nucleation on the latter. For example, in an embodiment, the outlet member is covered with one (or several) molybdenum layer(s) (alternatively, the outlet member may consist of molybdenum). The molybdenum has actually the particularity of preventing nitridation and therefore protecting the outlet member against the risks of formation of a gallium nitride film.
[0120] 3.2. Dimensions of the Outlet Member
[0121] The dimensions of the outlet member depend on different parameters, and notably on relative parameters:
to the geometry of the injector, to the type of ejected precursor gas by the supply nozzle, to the conditions of use of the injector (flow rate of the ejected precursor gas, temperature, . . . ), etc.
[0125] With reference to FIG. 8 , the steps of a method for dimensioning an outlet member of a supply nozzle have been illustrated. This dimensioning method may advantageously be applied within the scope of a method for manufacturing the chemical vapor deposition reactor described above.
[0126] The dimensioning method consists of determining the geometry of the outlet member allowing the generation of a sufficient vortex flow in order to avoid the deposition of material in the vicinity of the outlet of the supply nozzle.
[0127] Notably, the dimensioning method gives the possibility of defining the geometrical characteristics of the outlet member allowing the obtaining of a vortex flow for which the diameter is substantially equal to the depth (i.e. the dimension of the outlet member along the axis A-A′) of the outlet member.
[0128] The dimensioning method may comprise the following steps:
a) receiving ( 410 ) parameters relating to:
operating conditions of the supply nozzle, such as the pressure, the temperature and the mass flow rate(s) of the ejected gas(es) (notably the precursor gas, the carrier gas, etc.), physico-chemical characteristics of the ejected gas(es) (pyrolysis, viscosity, etc.);
b) defining ( 420 ) a set of geometrical characteristics of the injection head, and notably of the relevant supply nozzle, the geometrical characteristics for example relating to
the section S 1 of the gas supply conduit, the length—i.e. the largest dimension along a direction perpendicular to the axis A-A′—(or section S 2 in the case of a counterbore) of the outlet member, the depth P of the outlet member,
c) numerical modeling ( 430 ) of the injector in its environment from parameters received in step a) and from the set of geometrical characteristics defined in step b); d) estimating ( 440 ), from the modeling, the geometrical characteristics of the vortex flow generated by the outlet member; e) comparing ( 450 ) the diameter H of the vortex flow and the depth P of the outlet member, and
If the diameter H is equal to the depth P, the selection ( 460 ) of the set of geometrical characteristics defined in step b), and the stopping of the method, If the diameter H is different from the depth P, repeating steps b) to e) of the method for a new set of geometrical characteristics different from the set of current geometrical characteristics.
[0141] Thus, the dimensions of the outlet member may vary depending on the type of ejected precursor gas by the supply nozzle, and/or on the ejection velocity of the gas, and/or on the concentration of the gas, etc.
[0142] This is why when the injection head is adapted for injecting two different gas precursors into the enclosure, the latter may comprise outlet members of different dimensions, as illustrated in FIGS. 5 and 6 .
[0143] In this embodiment, the injection head comprises:
a plurality of first supply nozzles for a first precursor gas 41 , a plurality of second supply nozzles for the second precursor gas 42 ,
[0146] Each supply nozzle from the plurality of first supply nozzles comprises a supply channel 321 and a first outlet member 322 . Each supply nozzle from the plurality of second supply nozzles comprises a supply channel 321 and a second outlet member 323 .
[0147] The first and second outlet members 322 , 323 are cylindrical counterbores and have different dimensions. Notably, the diameter and the depth of each first outlet member 322 are respectively less than the diameter and less than the depth of each second outlet member 323 .
[0148] Preferably, the first and second supply nozzles are alternately positioned on the injection head. Thus, each first supply nozzle is adjacent to two second supply nozzles along a diameter of the injection head as illustrated in FIG. 5 . This gives the possibility of a better distribution of the two precursor gases at the surface of the substrate(s) positioned on the support of the reactor.
[0149] 3.3. Dimensioning of the Outlet Member
[0150] The tests and modellings give the possibility of dimensioning each outlet member in an optimal way. In particular, in the case of an outlet member consisting in a cylindrical recess, the depth P and the section S 1 of the recess may be estimated notably by taking into account:
the section S 2 of the supply conduit 321 , the dynamic viscosity of the precursor gas to be ejected, and the flow rate of each gas under the temperature and pressure conditions of the reactor.
[0154] Thus for a hole for injecting gallium chloride diffused in a hydrogen carrier gas, one has the following relationship:
[0000] P =(2.95×10 −3 *(18* D GaCl +D H2 )−0.35)*[( S 1/ S 2) 2 −S 1/ S 2]
[0155] Wherein:
D GaCl is the mass flow rate of gallium chloride in the injector of section S 2 and D H2 is the mass flow rate of hydrogen in the injector of section S 2 .
[0158] For a hole for injecting ammonia, diffused in a hydrogen carrier gas, one has the following relationship:
[0000] P =(3.80×10 −3 *(8.33* D NH3 +D H2 )−0.45)*[( S 1/ S 2) 2 −S 1/ S 2]
[0159] Wherein:
D GaCl is the mass flow rate of gallium chloride in the injector of section S 2 , and D H2 is the mass flow rate of hydrogen in the injector of section S 1 .
[0162] Thus for example, it is possible to generate for a mixed flow rate of 30 sccm of ammonia and of 10 sccm of hydrogen an optimal recirculation of gas with an injector for which the supply conduit is of a circular section with a diameter of 2 mm, enlarged to a section of 4 mm at the outlet member by selecting a depth of 4 mm, the chamber temperature being comprised between 850 and 1,000° C.
[0163] Preferably in the case of a circular counterbore, the outlet member is with a diameter comprised between 2 and 10 millimeters and a depth comprised between 4 and 20 millimeters when the gas supply conduit 321 has a diameter comprised between 1 and 5 millimeters.
[0164] The reader will have understood that many modifications may be made to the reactor described above.
[0165] For example, the shape of the outlet member is not limited to a cylinder or a shape having axisymmetry, the latter may notably be rectangular or elliptical, etc.
|
The invention concerns a reactor for chemical vapour deposition from first and second precursor gases, the reactor comprising: —a chamber including top and bottom walls and a side wall linking the top and bottom walls, —a support intended for receiving at least one substrate, mounted inside the chamber, and —at least one system for injecting precursor gases, the system comprising an injection head including at least one nozzle for supplying the first precursor gas ( 41 ) in a main direction of axis A-A′, the at least one nozzle including: a precursor gas supply conduit ( 321 ), and an outlet member ( 322 ) generating a substantially annular 43 vortex flow ( 44 ) around axis A-A′.
| 2
|
This application is a continuation of U.S. patent application Ser. No. 09/972,340 filed Oct. 5, 2001 now U.S. Pat. No. 6,605,769, entitled “Musical Instrument Digital Recording Device With Communications Interface”, which was a continuation-in-part of U.S. patent application Ser. No. 09/346,053 filed Jul. 7, 1999 abandoned, entitled “Musical Instrument Digital Recording Device With Communications Interface”, the disclosures of each of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates generally to audio recording and playback devices. More particularly, this invention pertains to recording and playback devices for use in conjunction with musical instruments that are external to the device.
Musicians frequently have a need or desire to record the music that they create on their instruments. In some cases, the recording is made for personal enjoyment. In other circumstances, a recording will be made for more commercial purposes, such as to make a record of a song writing session to create a song demo recording, to create a musical instrument track for editing or mixing, or for archival purposes. Generally, musicians who want to record their music while playing an instrument will have to make special arrangements in a recording studio or use amateur tape recording equipment of their own. While in the recording studio, the musician has access to a variety of sophisticated post-production recording, mixing, and editing equipment. In a home recording setting, editing options are usually far more limited. In either case, the musician must plan the recording session in advance including gathering and connecting sophisticated, bulky recording equipment. During the recording session, the musician is often distracted from the actual playing of the instrument because he must use his hands to control the recording equipment and/or to change or reload the recording media. Even if a musician uses a portable cassette or mini-disc recorder for convenience, neither is specifically adapted for connection directly to an instrument such as a guitar. Moreover, existing portable recording devices have limited functionality and versatility in terms of editing and external connectivity.
U.S. Pat. No. 5,837,912, issued to Eagen, describes an apparatus for digitally recording music from a guitar. The apparatus also allows the user to replay the digitally recorded music. However, the Eagen device does not allow a user to edit the digitally recorded music or to access selected portions of the digitally recorded music.
Conventional portable recording and playback devices from Sharp Corporation and Diamond, such as the Sharp MD-MT821 and the RIO PMP300, provide the ability to digital record music from compact discs or from the Internet for time periods ranging from 1 hour to 8 hours. They do not provide the ability to edit the recorded music or record for longer periods of time. Moreover, these devices are not adapted for recording music directly from a guitar or other musical instrument.
Thus, there is a need for an audio recording and playback device that may be conveniently carried and operated by a musician to record the music he or she creates with a musical instrument. Preferably, such a device will have both internal storage that can easily be cued and reviewed as well as an interface to an external storage and editing device.
SUMMARY OF THE INVENTION
The musical instrument direct recording and playback device of the present invention comprises an input stage including an audio signal format converter having two analog inputs and outputs, an output stage including two digital outputs, a digital signal processor; a control input device: an application software storage device; an application software program, an operating system storage device; an operating system software program, a digital storage device; and a display. The device can connect directly to the output jack of an external musical instrument for purposes of receiving analog audio signals as the instrument is played. On commands entered by a footswitch connected to the device, the device converts the received signals to digital format, compresses the digital signals, and stores and indexes the digital audio signals on an internal mass storage device. On receipt of further commands, the device can retrieve selected portions of the digital signals, decompress the retrieved signals, converts the retrieved signals to analog signals, and output the analog signals as a monaural or stereo audio signal. The device includes an external communications port and interface, such as from a Universal Serial Bus, to a personal computer. This allows the stored digital audio data to be up-loaded for storage and editing and/or new or updated software to be downloaded.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing of the musical instrument direct recording and playback device of this invention.
FIG. 2 is a plan view of a typical SHARC (Super Harvard ARChitecture) Digital Signal Processor device and circuit board that can be used in one embodiment of the device of the present invention.
FIG. 3 is a block diagram of the SHARC DSP device and circuit shown in FIG. 2 .
FIG. 4 is a flow chart showing the functional steps implemented by the software in one embodiment of the device of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , the present invention of a musical instrument recording and playback device 10 includes a recording input stage 12 and playback output stage 17 connected to a digital signal processor 14 , a control input device 16 , an application software storage device 18 , an application software program 19 , an operating system storage device 20 , an operating system software program 21 , a re-writable digital mass storage device 22 , and a display 24 .
The input stage 12 includes a first analog input 26 connected to a first digital input 42 on the processor 14 through a first analog data converter 27 , and a second analog input 28 connected to a second digital input 44 on processor 14 through a second analog data converter 29 . Optionally, first and second buffer amplifiers 37 and 39 can be used between the analog inputs 26 and 28 and corresponding analog data converters 27 and 29 . The converters 27 and 29 and be conventional A/D converters or CODEC devices capable of providing additional standard or proprietary format encoding on the input signals as they are converted to digital format at converter outputs 34 and 36 .
The analog inputs 26 and 28 are conventional female audio jacks adapted to connect directly to the output of a conventional external musical instrument 5 . The musical instrument 5 can be an electric guitar, keyboard, or other instrument that generates electrical analog and/or digital audio signals when the instrument is played by a musician. In a preferred embodiment, auxiliary audio output jacks 13 and 15 are hardwired directly to the analog inputs 26 and 28 so that an external connection can be made to other audio devices. In another embodiment of the invention, the device 10 can include digital signal inputs for direct connection to a musical instrument having a digital output. In this embodiment, the converters 27 and 29 would not need to perform an analog-to-digital conversion but would simply perform an encoding and/or decoding function to provide digital audio signals in the proper format.
The audio output stage 17 includes first and second digital outputs 64 and 66 on processor 14 , connected at converter inputs 30 and 32 to corresponding first and second digital data converters 41 and 43 . The outputs 38 and 40 of converters 41 and 43 can be buffered by buffer amplifiers 45 and 47 to provide analog audio output signals at first and second channel analog outputs 49 and 51 . Optionally, separate first and second auxiliary digital outputs 53 and 55 can be connected to processor outputs 64 and 66 for connection to external digital audio devices. The digital converters 41 and 43 are conventional type D/A converters or CODEC devices.
In a preferred embodiment of the device 10 , the converters 27 , 29 , 41 , and 43 can be integrated into a single CODEC integrated circuit and package.
The primary function of the input and output stages 12 and 17 is to convert analog signals generated by the musical instrument 5 to digital format during recording, and to convert the recorded digital audio signals back to analog format during playback.
The digital signal processor 14 includes a first digital input 42 , a second digital input 44 , a control input 46 , an application software storage input 48 , an application software storage output 50 , an operating system storage input 52 , an operating system storage output 54 , a display output 56 , a computer communications port 58 , a digital storage input 60 , a digital storage output 62 , a first digital output 64 , and a second digital output 66 . The processor 14 is of a conventional type found in the art such as the SHARC digital signal processor.
The primary function of the processor 14 is to compress the converted digital signals for storage purposes, store the compressed digital signals in files on the digital storage device 22 , control and manage the digital storage device 22 , receive inputs from the control input device 16 , retrieve stored digital signals from the digital storage device 22 , decompress retrieved digital signals, and send the decompressed digital signals to the converter 12 for conversion to analog signals. The processor 14 accomplishes all of the above tasks by using application software loaded on the application software storage device 18 . The application software is described in detail below.
The digital signals are compressed to ensure that the digital signals use up a minimum amount of space on the digital storage device 22 . In one embodiment of the device 10 , the digital storage device can be a conventional low profile IDE hard disk drive, and the processor 14 can communicate and control the digital storage device 22 through a conventional IDE disk controller interface.
The processor 14 compresses the digital signal received through the first digital signal input 42 and the digital signal received through the second digital signal input 44 . A compression algorithm is used to perform the compression. The compression algorithm is of the type commonly found in the art such as MPEG audio compression.
An external data port 48 , such as a USB port of the conventional type found in the art, is used to transfer stored audio data and programming from the device 10 to a remote computer (not shown). The digital audio data that is uploaded from the device 10 can then be stored, edited, mixed, etc. and, if desired, downloaded back to the device 10 .
FIGS. 2 and 3 illustrate one physical embodiment of the device 10 shown in block diagram form in FIG. 1 , and particularly using a conventional SHARC DSP circuit board as the microprocessor 14 with onboard non-volatile memory (not-shown). A standard RS-232 serial communications port 48 is used to communicate with external devices in this embodiment, rather than a USB port. A UART (Universal Asynchronous Receiver Transmitter) and RS-232 Drivers convert the data as needed by the processor 14 and external device (not shown) in conventional fashion.
In accordance with one novel feature of the invention, the control input device 16 can be a momentary contact or multiple position footswitch that is capable of sending electrical signals or commands to the processor 14 by a wired or wireless connection to control input 46 . The control input device 16 generates control inputs to the processor 14 to control the operation of the device 10 . For example, when the control input device 16 is pressed one time, a control input is generated and sent to the processor 14 . The application software on the processor interprets this control input as a command to start and stop recording or to playback audio stored at a specific memory location.
Although the use of a footswitch that is hardwired to the device 10 is convenient for use by musicians who otherwise have their hands occupied, other conventional switches can be used, including switches operably connected to the device 10 by infrared or other conventional wireless means. Alternatively, a PC connected through a USB port can provide control commands to the device 10 .
FIG. 4 is a flowchart describing the sequence of commands and responsive operations that are implemented by the software controlling the microprocessor 14 in one embodiment of the present invention. As seen on FIG. 4 , the device can operate in one of multiple modes based on the Select Mode, Select Record Mode, and/or Select Play Mode prompted by the processor 14 and entered by use of the control input device (footswitch) 16 . The primary modes include Select Record Mode, Select Play Mode, and File Dump Mode.
The record modes can include Record On Demand, Continuous Record, and Search. The Record On Demand mode requires further switch input by the user which, when received, initiates storage of audio signals along with generation of marker and indexing data. The Continuous Record mode activates recording, indexing, and marking whenever audio signals are present at a device input 26 , 28 . The play modes include Index Play mode causes the device to begin playback of recorded signals located at specified index numbers. Additional detail is shown in FIG. 4 and described below. A programmer familiar with the programming language/instruction set associated with a particular microprocessor 14 would create and store the corresponding instructions and commands in the program storage device, such as the PROM 18 , 19 on FIG. 3 .
The control input device 16 also controls the primary mode in which the device 14 is operating. When the control input device 16 is pressed five times in rapid succession, for example, the processor 14 enters a “Mode Setting Mode.” The display indicates this mode by displaying a “555” on the display 24 .
In a preferred embodiment, there are three recording modes for the musical instrument direct recording and playback device 10 . The first recording mode is the Continuous Record Mode that is selected when the user presses the control input device 16 six times. In the Continuous Record Mode, the device 10 records whenever an analog signal is present on analog inputs 26 and 28 .
The second preferred recording mode is the Record on Demand Mode that is selected when the user presses the control input device 16 seven times. In the Record on Demand Mode, the device 10 begins recording when the control input device 16 is pressed one time. The recording ends when the control input device 16 is pressed a second time. In one embodiment of the device, the processor is programmed to store audio data in six minute increments. If the control input device 16 is pressed when the device 10 is recording in the middle of a six minute recording increment, then a reduced mount of storage on storage device 22 will be used. For example, if a user records for three minutes and presses the control input device 16 , the device 10 will stop recording. When the user presses the control input device 16 to start a new recording, the device 10 will skip the remaining three minutes of the preceding six minute increment and start recording at the beginning of the next six minute increment.
A third recording mode is the Search Record Mode, selected when the user presses the control input device 16 eight times. In the Search Record Mode, the device 10 will not record over certain specified memory locations that the user has designated as protected. For example, the user may have several hours of recorded audio stored on storage device 22 . Within the second hour, and specifically, the first eighteen minutes of that hour, is recorded material that the user would like to keep stored at a specific memory location. The user designates this memory location as protected using the application software.
At some future time, the user may be recording over a memory location immediately preceding the memory location that the user would like to protect. When the device 10 reaches the protected material, the device 10 skips over the protected memory location and continues recording at the next available memory location.
In a preferred embodiment, there are four play modes for the device 10 . The Play Next Index Mode allows the user to replay the audio data stored at the next index number. This mode is selected when the user presses the control input device 16 one time. The Play Back Last Index Mode allows the user to replay the audio stored at the last index number. This mode is selected when the user presses the control input device 16 two times. The Play Back Last Marker allows the user to replay musical sounds stored at the last marker. This mode is selected when the user presses the control input device 16 three times. The Play Back Search Marker Mode allows the user to replay musical sounds stored at a given marker. This mode is selected when the user presses the control input device 16 four times.
An additional File Dump Mode can also be used. This mode is selected when the user presses the control input device 16 nine times. In the File Dump Mode, the device 10 transfers audio files stored on storage device 22 to a separate computer using external communications port 58 . The transferred data can include the corresponding index numbers and markers.
The application software storage device (ASSD) 18 is coupled to the processor 14 . The ASSD 18 contains the application software program 19 that responds to and causes processor 14 to execute user commands.
The operating system storage device (OSSD) 20 is electrically connected to the processor 14 . The OSSD contains the operating system software program 21 used to implement the compression of digital signals, store digital signals, retrieve stored digital signals, and transmit the retrieved digital signals to the output stage 17 .
Th operating system software 21 , application software 19 , and processor 14 cooperate such that the input stage 12 and output stage 17 can work concurrently, whereby new audio can be recorded and stored during the playback mode.
The digital storage device (DSD) 22 is electrically connected to the processor 14 . The DSD 22 is of the type commonly found in the art such as an optical or magnetic disk drive. It should be noted that many other mass storage devices could be substituted for the hard disk drive. Examples of substitutes include non-volatile FLASH memory cards, etc. In one embodiment of the invention, the processor 14 is programmed to overwrite the first recorded digital audio data stored on the DSD 22 when the DSD 22 is full. Flash Memory is used for easy and fast information storage in such devices as digital cameras and home video game consoles. It is used more as a hard drive than as RAM. In fact, Flash Memory is considered a solid-state storage device. Known examples of Flash Memory include a PC's BIOS chip, CompactFlash (most often found in digital cameras), SmartMedia (most often found in digital cameras), Memory Stick (most often found in digital cameras), PCMCIA Type I and Type II memory cards (used as solid-state disks in laptops), and memory cards for video game consoles.
More particularly, Flash Memory is a type of EEPROM chip. It has a grid of columns and rows with a cell that has two transistors at each intersection. The two transistors are separated from each other by a thin oxide layer. One of the transistors is known as a floating gate and the other one is the control gate. The floating gate's only link to the row, or wordline, is through the control gate. As long as this link is in place, the cell has a value of “1”. To change the value to a “0” requires a curious process called Fowler-Nordheim tunneling. Tunneling is used to alter the placement of electrons in the floating gate. An electrical charge, usually 10-13 volts, is applied to the floating gate. The charge comes from the column, or bitline, enters the floating gate and drains to a ground. This charge causes the floating gate transistor to act like an electron gun. The excited electrons are pushed through and trapped on other side of the thin oxide layer, giving it a negative charge. These negatively charged electrons act as a barrier between the control gate and the floating gate. A special device called a cell sensor monitors the level of the charge passing through the floating gate. If the flow through the gate is greater than fifty percent of the charge, it has a value of “1”. When the charge passing through drops below the fifty percent threshold, the value changes to “0”. A blank EPROM has all of the gates fully open, giving each cell a value of “1”.
The electrons in the cells of a Flash Memory chip can be returned to normal (“1”) by the application of an electric field, a higher voltage charge. Flash Memory uses in-circuit wiring to apply the electric field to the entire chip, or to predetermined sections known as blocks. This erases the targeted area of the chip, which can then be rewritten. Flash Memory works much faster than traditional EEPROMs because instead of erasing one byte at a time, it erases a block or the entire chip, and then rewrites it.
The CompactFlash and SmartMedia types of removable storage, as well as PCMCIA Type I and Type II memory cards, adhere to standards developed by the Personal Computer Memory Card International Association (PCMCIA). Because of these standards, it is easy to use CompactFlash and SmartMedia products in a variety of devices. Standard adapters are available that allow the microprocessor 14 to access these cards through a standard floppy drive, USB port or PCMCIA card slot. SmartMedia cards erase, write and read memory in write and read memory in small blocks (256 or 512 byte increments).
In an embodiment of the device 10 where an external FLASH memory device is used for DSD 22 , the digital storage input 60 and output 62 can be in the form of a second USB connector with an adaptor to connect to a SmartMedia or CompactFlash card, or a standard PCMCIA card connector with a PCMCIA FLASH memory device, all of which are conventional devices well known in the art. The microprocessor 14 reads and writes data to the FLASH memory type DSD 22 using the standards developed by the Personal Computer Memory Card International Association (PCMCIA).
The DSD 22 stores each digital audio signal as an individual file in six minute increments. It should be noted that the choice of six minute increments is arbitrary and may vary depending on the needs of the user. In addition, the DSD 22 may also combine each individual digital signal and store both digital signals as one stereo file. Preferably, the DSD 22 can hold up to 20 hours of musical sounds.
In accordance with a preferred embodiment, each six minute data increment results in the generation of an index number corresponding to that increment. For example, a six minute recording would have a 00 for an index number. A twelve minute recording would have two index numbers: 00 and 01. The index number 00 would represent the first six minutes of the recording and the index number 01 would represent the second 6 minutes of the recording.
The user of the device 10 can also insert electronic marker numbers at his or her discretion, using the input device (footswitch) 16 . These markers would be time stamped and would be numbered beginning with the number 1. The user of the device 10 can issue a command (also using input device 16 ) to move directly to each marker. The application software program 19 controls this function of the device 10 .
File names are created by using the date of the recording in month, day, and year format and the index number of the file. For example, a twelve minute recording created on Jan. 1, 1999 would result in two files having the file names 010199.000 and 010199.001.
A display 24 is electrically connected to a display output 56 on processor 14 . The display 24 can be a three or four digit LED display typically found in the art. The display 24 displays the index number for the current file that is being recorded or being played. For example, when the recording and playback device 10 has been recording for 26 minutes (and thus the current index number is 04) the number 04 is displayed on the display 24 . Likewise, when the recording and playback device 10 has been playing back a recording for two minutes, the number displayed on the display 24 is 00. Thus, the display can be used by the musician to locate and playback a specific portion of the recorded audio, using the displayed index numbers and/or markers. The display can also be used to provide visual command prompts to the user when a primary, record, or playback mode needs to be selected.
Thus, although there have been described particular embodiments of the present invention of a new and Musical Instrument Digital Recording Device with Communications Interface, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.
|
A portable device is used for recording, editing, and replaying musical sounds generated by a musical instrument external to the device. The musical sounds are converted from analog to digital format, compressed for minimum storage usage, and stored in a digital storage medium. The stored signals are filed according to an indexing scheme that allows selection and retrieval of selected portions of the musical sounds. The selected portions are retrieved from storage, decompressed, converted back to analog signals, and output to a sound generating device. The operation of the device is controlled by application software and operating system software.
| 6
|
TECHNICAL FIELD
The invention relates to a vehicle-sensitive sensor for a belt retractor for vehicle safety belt systems.
BACKGROUND OF THE INVENTION
Belt retractors are widely known components of vehicle safety belt systems. The retractors have a belt spool rotatably mounted in a frame and a blocking mechanism in order to block the belt spool against an unwinding of belt webbing in the case of an impact of the vehicle. The blocking mechanism is controlled by means of the vehicle-sensitive sensor responding to accelerations of the vehicle. Known vehicle-sensitive sensors have a coupling pawl in the form of a one-sided lever, under which a steel ball is arranged. The coupling pawl lies on the steel ball with a depression in the form of a spherical segment. If an intense acceleration occurs in the case of a vehicle impact, then the steel ball moves so that the depression in the form of a spherical segment and hence the coupling pawl are raised. The vehicle-sensitive sensor is arranged here beneath the clutch disc, so that on raising the coupling pawl, the end of the latter is guided into the clutch toothing and hence the blocking mechanism is activated. Conventional vehicle-sensitive sensors are only adaptable in a limited manner to various arrangements in the belt retractor. A further disadvantage of conventional vehicle-sensitive sensors lies in that an installation of the belt retractor which is inclined with respect to the structurally given installation position is not possible, because the gravity then engaging obliquely on the steel ball causes a permanent displacement of the steel ball Connected with a permanent blocking of the belt spool.
BRIEF SUMMARY OF THE INVENTION
Through the invention, a greater flexibility is to be achieved with the arrangement and construction of the vehicle-sensitive sensor for a belt retractor. This is achieved in a sensor which comprises an inertia body displaceable in case of decelerations and accelerations of the sensor, and a two-armed lever. A first arm of the two-armed lever forms a coupling pawl, and a second arm of the two-armed lever is able to be engaged by the inertia body such that, in case of a displacement of the inertia body, the lever is pivoted so that the coupling pawl is directed into a clutch toothing. The provision of a two-armed lever makes possible a substantially more flexible construction of the vehicle-sensitive sensor compared with the prior art. Thus, for example, the distance covered by the end of the coupling pawl, the size and weight of the inertia body and the spatial arrangement of the inertia body in the belt retractor can be easily varied, without having to accept restrictions in the operating reliability.
As a further step, provision is made that the sensor has a housing on which the lever and the inertia sensor are mounted and which is arranged in relation to a reference so as to be pivotal about an adjustment axis, with a nose of the coupling pawl, able to be guided into the clutch toothing, lying on the adjustment axis. Such a construction of the vehicle-sensitive sensor provides the precondition for an adjustment of the vehicle-sensitive sensor on differently inclined installation positions of the belt retractor. The sensor can be pivoted as a unit in the belt retractor, without its release values, i.e. the values which are necessary for a displacement of the inertia body, or the distance covered on displacement of the inertia body from the nose of the coupling pawl changing. Furthermore, the installation angle of inclination may now be adjusted in a simple manner.
In further development of the invention, provision is made that the nose of the coupling pawl, able to be directed into the clutch toothing, a point on the rotation axis of the lever, and the center of gravity of the inertia body lie on the adjustment axis in the state of rest of the sensor. Thereby, a compact sensor unit results, which only has a small space requirement on a rotation about the adjustment axis.
Advantageously the housing is provided with an adjustment cylinder, which is rotatably arranged. The sensor can be arranged for example in a bore of a covering hood before its being fastened to a frame of a belt retractor. An adjustment cylinder also makes possible a rotatable arrangement of the sensor which is simple to produce and in so doing reliable in operation.
Furthermore, provision is made that a display- and adjustment device is provided for the pivot position of the housing in relation to the clutch disc. Owing to these steps, a single type of belt retractor can be adjusted to various installation inclinations, for example for various vehicle types. The display- and adjustment device can be arranged here such that the adjustment can be carried out and detected from the exterior.
Provision is made that the second arm of the lever lies against the inertia body in the state of rest of the sensor. Each displacement of the inertia body is thereby converted directly into a movement of the coupling pawl, whereby a rapid response of the sensor is achieved. As the second arm of the lever lies against the inertia body, in driving operation also no rattling of the lever can occur.
Alternatively, provision is made that the second arm of the lever in the state of rest of the sensor is arranged at a predetermined distance from the inertia body. Here, it is advantageous that the initial displacement of the inertia body is not influenced by friction between the second arm of the lever and the inertia body. The exact adherence to the structurally given acceleration threshold, after which a displacement of the inertia body takes place, is thereby ensured.
As a further step, provision is made that the sensor has a housing with a stop in which an arm of the lever abuts in the state of rest. In this way, a constant predetermined distance can be ensured between the arm of the lever and the inertia body.
It is advantageous if the inertia body is formed by a ball and the second arm has a ring which surrounds a segment of the ball. The provision of a ring which surrounds a segment of the ball makes it possible that the second arm of the lever engages in the lower region of the ball, in which region the ball also sits on a support. Thereby, further design possibilities are opened up for the vehicle-sensitive sensor.
It is advantageous here that the ring has a contact surface facing the ball, which contact surface has substantially the form of a circular conic frustum surface, the generatrix of which is inclined to the central axis of the ring about an angle of approximately 40°. Such a construction of the ring makes possible a low-friction running of the ball onto the ring, so that the acceleration values necessary for guiding the coupling pawl are only negligibly influenced by friction between ball and ring.
It is advantageous if the sensor has a housing with a bearing support to support the lever and a ball support to receive the ball. The ball support is formed here advantageously by a circular cylinder with a conical depression in an end face, so that an annular support surface is produced for the ball. Through an annular support surface, the ball remains at rest as long as an acceleration value given by the structural design is not exceeded. As only an annular surface is in contact with the ball, the ball support is not liable to contamination.
In further development of the invention, the lever can have at least one bearing edge or two bearing points along its rotation axis. These constructions both make possible a low-friction bearing of the lever and, in so doing one that is simple to produce for example by injection molding. Bearing edges can be mounted in a V-shaped depression, whereas bearing points can be constructed in a conical shape and arranged in likewise conical depressions with a greater taper angle than the bearing points.
In an embodiment of the invention, provision is made that the ring arranged on the second arm of the lever is arranged beneath the central point of the ball. A displacement of the ball thereby leads to a downward movement of the second arm and an upward movement of the coupling pawl, so that the sensor can be arranged beneath the clutch disc of the belt retractor. It is advantageous here if the center of gravity of the lever in relation to the rotation axis of the lever lies on the side of the first arm. The ring is thereby urged by gravity in the direction of the ball, so that in the state of rest of the sensor, the abutment of the ring against the ball or, in connection with a stop, a constant distance of the ring from the ball is ensured.
Alternatively, provision is made that the ring arranged on the second arm of the lever is arranged above the central point of the ball. Here, a displacement of the ball leads to an upwards movement of the second arm and a downward movement of the coupling pawl, so that a sensor with these features can be arranged above the clutch disc. In order to ensure also here a constant distance from the ring to the ball or an abutment of the ring against the ball, the center of gravity of the lever in relation to the rotation axis of the lever advantageously lies on the side of the second arm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective partial view of a sensor according to the invention in accordance with a first embodiment;
FIG. 2 shows a partial view, partially in section, of the sensor of FIG. 1;
FIG. 3 shows a view similar to FIG. 2 on the occurrence of an intense vehicle acceleration;
FIG. 4 shows a view similar to FIG. 2 with an intense vehicle deceleration;
FIG. 5 shows a perspective partial view of the sensor of FIG. 1 from a different angle of view;
FIG. 6 shows a partial view of a vehicle-sensitive sensor of a second embodiment; and
FIG. 7 shows a side view, partially in section, of the sensor illustrated in FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a perspective partial view of a belt retractor 10 comprising a sensor according to a first embodiment. The belt retractor 10 has a frame 12 and a conventional belt spool (not shown) rotatably mounted in the frame 12 . Of a conventional blocking mechanism for the selective, non-rotatable blocking of the belt spool to the frame 12 , merely a clutch disc 14 with clutch toothing 16 is illustrated. A covering hood 18 is fastened to the frame 12 , which hood 18 is illustrated partially in section. The vehicle-sensitive sensor 20 is provided to activate the blocking mechanism in the case of intense accelerations or decelerations of the vehicle. The sensor 20 has a metal ball 22 acting as inert mass and has a coupling pawl 24 , which can be directed by a displacement of the ball 22 into the clutch toothing 16 of the clutch disc 14 . The coupling pawl 24 forms here a first arm of a two-armed lever 26 , on the second arm of which the ball 22 engages in the case of a displacement. The two-armed lever 26 is mounted on a sensor housing 28 which in turn is fastened to the covering hood 18 . In order to achieve a low-friction mounting of the lever 26 , the latter has two bearing edges 30 which rest each on the sensor housing 28 in a V-shaped depression. In the housing 28 in addition a ball support 32 is formed, on which the ball 22 lies. The second arm of the lever 26 has at its end facing the ball 22 a ring 34 which surrounds a segment of the ball 22 and is arranged concentrically to the ball support 32 . The coupling pawl 24 is provided with a nose 36 which on a displacement of the ball 22 engages into the clutch toothing 16 . Furthermore, the coupling pawl 24 has a weight 37 , which ensures that the ring 34 lies against the ball 22 .
In the side view of FIG. 2, the sensor housing 28 , the two-armed lever 26 and the covering hood 18 are illustrated in section. The sensor housing 28 has at its end facing away from the coupling pawl 24 an adjusting cylinder 38 , which is arranged in a bore in the covering hood 18 . The sensor housing 28 is thereby arranged on the covering hood 18 so as to be rotatable about an adjustment axis 40 . As can be readily seen in FIG. 2, which shows the state of rest of the vehicle-sensitive sensor 20 , the foremost point of the nose 36 of the coupling pawl 24 , the edge of the bearing edges 30 indicated in dashed lines, i.e. the rotation axis of the lever 26 , the center of gravity S of the ball 22 and the longitudinal axis of the adjusting cylinder 38 lie on the adjustment axis 40 . The sensor 20 can thereby be rotated about the adjustment axis 40 and hence can be aligned to the direction of the acceleration due to gravity, without its release characteristics changing. As can be further seen from FIG. 2, a rotation of the sensor 20 about the adjustment axis 40 also does not alter the distance of the nose 36 from the clutch toothing 16 on the clutch disc 14 , because the point of the nose 36 lies on the adjustment axis 40 and, as can be seen in FIG. 1, the point 36 is rounded in a circular shape. Also with the sensor 20 rotated about the adjustment axis 40 , the point of the nose 36 has substantially always the same distance from the toothing 16 of the clutch disc 14 .
In FIG. 2 also the second arm 42 of the lever 26 can be seen, which has at its end facing the ball 22 the ring 34 . The ring 34 surrounds a ball segment of the ball 22 and lies with its contact face 46 against the ball 22 . The contact face 46 has the form of a circular frustum surface. A generatrix of this circular frustum surface is inclined here by approximately 40° to the central axis 48 of the ring 34 , which also runs through the center of gravity S of the ball 22 .
The ball 22 rests on the ball support 32 , which is formed by a circular cylinder integral with the housing 28 , which cylinder has a conical depression 50 in its end face facing the ball 22 . The ball 22 thereby lies on an annular support surface.
FIG. 3 shows a view corresponding to FIG. 2, in which, however the ball 22 owing to an intense vehicle acceleration, for example by a rear impact of a further vehicle, is displaced to the right. In so doing, the ball 22 only then moves in the manner illustrated in FIG. 3, when it is raised partially from the annular support surface of the ball support 32 through the action of the acceleration. With such a movement, the center of gravity S of the ball 22 also shifts upwards. In order to achieve a displacement of the ball 22 , an acceleration is therefore necessary, which exceeds a particular threshold. This threshold can be set by the weight of the ball 22 , the diameter of the ball 22 and also by the diameter of the annular support surface of the ball support 32 . The displacement of the ball 22 illustrated in FIG. 3 leads to the ring 34 being pressed downwards Consequently also the second arm 42 of the lever 26 is pressed downwards, so that the first arm or the coupling pawl 24 moves upwards. Consequently, the nose 36 of the coupling pawl 24 arrives into the region of the clutch toothing 16 of the clutch disc 14 , and with a rotation of the belt spool and hence of the clutch disc 14 , the blocking mechanism for the belt spool is activated.
FIG. 4 shows the conditions in the case of an intensive deceleration acting on the vehicle, for example with a frontal impact. Under the action of the intensive acceleration then occurring, the ball 22 is displaced to the left, whereby the ring 34 is pressed downwards. Also, with an intensive deceleration of the vehicle, as shown in FIG. 4, the coupling pawl 24 is thereby deflected upwards and the nose 36 arrives into the region of the clutch toothing 16 on the clutch disc 14 , so that with a rotation of the belt spool the blocking mechanism is activated.
The perspective view of FIG. 5 shows, in part from obliquely to the rear, the belt retractor illustrated in FIGS. 1 to 4 and with the sensor according to the invention. It can be seen in FIG. 5 that the adjusting cylinder 38 is accessible from the exterior of the covering hood 18 and has a slit 52 via which, for example with the aid of a screw driver, the sensor 20 can be turned about the adjustment axis 40 . In order to indicate the pivot position of the sensor 20 and of the sensor housing 28 , respectively, in relation to the frame 12 which serves as a reference, and in relation to the clutch disc 14 , the covering hood 18 is provided on the periphery of the bore receiving the adjusting cylinder 38 with a scale 54 . The adjusting cylinder 38 in turn has an arrow 56 which points to the scale 54 .
A vehicle-sensitive sensor 60 of a second embodiment is illustrated in FIG. 6 . This sensor 60 is also provided with a ball 62 which lies on a ball support 64 of a sensor housing 66 , which housing is further provided with an adjusting cylinder 68 and a bearing support 70 . Resting on the bearing support 70 is a two-armed lever 72 , which as first arm has a coupling pawl 74 and has a second arm 76 . The lever 72 is mounted on the bearing support 70 by means of two bearing edges 78 , of which only one is to be seen in FIG. 6 . In order to hold the two-armed lever 72 reliably on the bearing support 70 and at the same time to ensure a low-friction mounting, the bearing support 70 is cut in a V-shape, the opening angle of the V-shaped cut of the bearing support 70 being greater than the angle of the bearing edges 78 . The sensor housing 66 has a stop 80 on which the coupling pawl 74 rests. In the state of rest of the sensor 60 , the coupling pawl 74 always lies here against the stop 80 , because the center of gravity SP of the two-armed lever 72 in relation to the rotation axis of the lever 72 , which is established by the contact line between bearing support 70 and bearing edges 78 , lies on the side of the coupling pawl 74 . Through the abutment of the coupling pawl 74 against the stop 80 , consequently in the state of rest of the sensor 60 also the position of a ring 82 is established, which is arranged on the second arm 76 and surrounds the ball 62 and the ball support 64 in parts.
The sensor 60 illustrated in FIG. 6 is illustrated partially in section in FIG. 7 . In this sectional view, it can be seen that the ring 82 in the state of rest of the sensor is arranged at a predetermined distance from the ball 62 . This is achieved in that, as explained with regard to FIG. 6, the coupling pawl 74 resting on the stop 80 . A displacement of the ball 62 taking place owing to an acceleration acting on the ball 62 thereby takes place unaffected by any possible friction between the contact surface of the ring 82 and the surface of the ball 62 . The structurally given acceleration threshold, as of which a displacement of the ball 62 takes place, is thereby insensitive to an increase in the friction between the ring 82 and the ball 62 , as can take place for example by the aging of the materials or contamination.
|
A vehicle-sensitive sensor for a belt retractor for vehicle safety belt systems, comprises an inertia body displaceable in case of decelerations and accelerations of the sensor, and a two-armed lever. A first arm of the two-armed lever forms a coupling pawl, and a second arm of the two-armed lever is able to be engaged by the inertia body such that, in case of a displacement of the inertia body, the lever is pivoted so that the coupling pawl is directed into a clutch toothing.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of copending International Application PCT/DE98/01155, filed Apr. 24, 1998, which designated the United States.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a method of driving at least one capacitive actuator by means of a charge voltage.
A method of driving capacitive actuators is disclosed in U.S. Pat. No. 4,688,536, entitled "drive circuit for an electrostrictive actuator in a fuel injection valve. As suggested by the title, the patent relates in particular to a method of driving piezoelectrically operated fuel injection valves of an internal combustion engine. The actuators of the prior patent are charged with constant voltage.
A piezoelectric actuator comprises many piezoceramic layers and forms a so-called "stack", which when a voltage is applied changes its dimensions, and especially its length. In the reverse, the stack generates an electrical voltage in response to mechanical pressure or tensions.
The electrical properties of that kind of piezostack vary with the temperature to which it is exposed. As the temperature rises, its capacitance increases, but its stroke also lengthens. At the temperatures to be taken into account for automotive applications, ranging from about -40 C. to +150 C., changes in capacitance of up to a factor of 2 are observed.
If for instance a piezoelectric actuator is charged at all its operating points with a constant voltage, which at low temperatures brings about the required stroke, then at high temperatures the resultant stroke is markedly longer than necessary. In the context of fuel injection valves with a constant fuel pressure, of course, this means an excessive fuel injection quantity. Since at high temperatures the capacitance of the piezostack is also greater, much more charge and energy are needed than may be otherwise necessary.
Hence the method known from the afore-mentioned U.S. Pat. No. 4,688,536 does not work precisely enough unless the ambient conditions do not change at all (no tolerances in the components used, no changes in the electrical properties, constant temperature).
From U.S. Pat. No. 5,387,834 there is known a drive circuit for a capacitive actuator that is triggered with a constant charge voltage and with a charging time that is determined as a function of the actuator temperature. The temperature is measured with a sensor.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a method of driving a capacitive actuator, which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which operates to a sufficient degree of precision, without using a temperature sensor, even if the ambient conditions change.
With the foregoing and other objects in view there is provided, in accordance with the invention, a method of driving a capacitive actuator, which comprises:
charging a capacitive actuator with a charge voltage;
calculating, from a charge quantity ΔQ supplied to the actuator and from an actuator voltage U p applied to the actuator after the charging operation is terminated, an actuator capacitance by the equation C p =ΔQ/U p ;
calculating, from the actuator capacitance C p and the actuator voltage U p , an energy E actual supplied to the actuator during the charging step by the equation E actual =0.5*C p *U p 2 =0.5*ΔQ*U p ;
comparing the energy E actual with a desired energy E setpoint ; and
if the energy E actual is less than the desired energy E setpoint , increasing the charge voltage U L =U C1 +U C2 by a predetermined amount for a next charging operation; or
if the energy E actual is greater than the desired energy E setpoint , increasing the charge voltage U L =U C1 +U C2 by the predetermined amount for the next charging operation.
In accordance with an added feature of the invention, the charge quantity ΔQ supplied to the actuator is determined by integrating the current I p flowing through the actuator during a charging operation according to the integration ΔQ=∫I p dt.
In accordance with an alternative embodiment of the invention, where the capacitive element is charged with a charging capacitor and a discharging capacitor that are connected in series, and a regulatable voltage is applied to the charging capacitor, the charge quantity ΔQ supplied to the actuator is determined by way of a difference ΔU=U before -U after in voltages U before and U after present at the discharging capacitor before and after the charging operation, respectively, and ascertaining a capacitance C2 of the discharging capacitor by the equation ΔQ=C2*ΔU=C2*(U before -U after )
In accordance with a concomitant feature of the invention, the calculated actuator capacitance C p is used to determine an actuator temperature T p .
Tests have shown that the energy supplied to a capacitive actuator is a much more precise measure for the stroke ds than the voltage supplied, and that charging at constant energy over the pertinent temperature range produces a substantially more constant stroke. At a constant temperature, the stroke varies approximately linearly with the voltage applied. If the temperature changes, then the stroke also changes, if the voltage is constant. Conversely, the stroke varies in proportion to the square of the applied energy, but independently of the temperature.
To that end, from the charge quantity ΔQ supplied to the actuator and from the voltage U p measured at the actuator (e.g. actuator P1), after the charging operation is terminated, the capacitance C p =ΔQ/U p of the actuator is calculated, and then from ΔQ and C p , the energy E actual =0.5*C p *U p 2 =0.5*ΔQ*U p supplied to the actuator is ascertained. The value E actual is compared with a specified desired value E setpoint , and depending on the outcome of the comparison, the charge voltage U L is re-regulated for the next triggering operation (that is, U L is increased if E actual<E setpoint , and U L is decreased if E actual >E setpoint .
In a method that can be used for arbitrary drive circuits, charge quantity ΔQ applied is ascertained by integrating the current I p flowing through the actuator. Then
ΔQ=∫I.sub.p dt→C.sub.p =∫I.sub.p dt/U.sub.p →E.sub.actual =0.5*∫I.sub.p dt*U.sub.p
For circuits with a charging and discharging capacitor connected in series, as shown in the drawing, a simpler method for ascertaining the charge quantity ΔQ supplied to the actuator is disclosed according to the invention, in which no integration is necessary. In this method, the voltage present at the discharging capacitor C2 is measured both before the charging operation and then again after the charging operation is terminated, and the difference ΔU=U before -U after is formed and from that the charge quantity ΔQ=C2*ΔU=C2*(U before -U after ) is calculated; with the voltage U p present at the actuator after the end of the charging operation, the actuator capacitance C p and the energy E actual supplied to the actuator are calculated analogously to the method described above:
ΔQ=C2*(U.sub.before -U.sub.after)→C.sub.p =C2*(U.sub.before -U.sub.after)/U.sub.p →E.sub.actual =0.5*C2(U.sub.before -U.sub.after)*U.sub.p
This value is compared, as already described above, with a specified desired value E setpoint , and depending on the outcome of the comparison, the charge voltage U L is re-regulated for the next triggering operation.
Since the actuator capacitance C p is approximately proportional to the actuator temperature T p , the calculated actuator capacitance C p can be used for determining the actuator temperature T p according to the formula C p =ΔQ/U p ≈T p . As a result, a temperature sensor can optionally be dispensed with.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a method of driving at least one capacitive actuator, 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 drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
The sole FIGURE of the drawing is a circuit schematic of a drive circuit according to the invention for driving one or more actuators that actuate fuel injection valve(s).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the FIGURE of the drawing in detail the method of the invention will be explained in terms of the illustrated circuit for driving at least one capacitive actuator (final control element) P1 to Pn for actuating at least one fuel injection valve by means of a control circuit ST. The control circuit ST is a part of a microprocessor-controlled engine control unit. The latter is not illustrated in any detail for reasons of clarity.
Between a positive pole +U SNT and a negative pole GND of a regulated voltage source SNT, preferably a switched mode power supply, a charging capacitor C1 is connected via a diode D1. A series circuit comprising a charging switch Ta, two further diodes D2 and D3, and a discharging switch Tb connected to the negative pole GND, is connected in parallel with the charging capacitor C1.
Between the node point of the two diodes D2 and D3 and the ground terminal GND, there is connected a series circuit comprising a charge reversal capacitor C2, a polarity reversing coil L, a first actuator P1, and a first, controlled selector switch T1.
For every further actuator P2-Pn, one series circuit comprising that actuator and a further selector switch T2-Tn is connected in parallel with the series circuit comprising the first actuator P1 and the first selector switch T1. In the exemplary embodiment, the selector switches, the discharge switches Tb and the bypass switches Tc, described below, are all N-type power MOSFET switches, which typically include inverse diodes. The charge switch Ta in this exemplary embodiment is embodied as a p-type power MOSFET switch.
A bypass switch Tc is also provided, as already mentioned; its drain terminal is connected to the node between the oscillating coil L and the actuators P1-Pn, and its source terminal is connected to the source terminal of at least the selector switch T1. All the switches are controlled via their gate terminals by the output signals of the control circuit ST.
The bypass switch Tc, connected in parallel with the actuators P1-Pn, is triggered by the control circuit ST, if the actuator voltage exceeds a predetermined limit value or if an error occurring in the engine as far as the power end stages of the injection valves is detected, and it discharges the capacitive actuators P1-Pn in short-circuited fashion via the inverse diodes of the selector switches T1-Tn. The bypass switch Tc is also needed for charging the discharging capacitor C2 before the first actuation of the actuator, or for recharging it between two chronologically widely spaced actuations of the actuator. Instead of the bypass switch Tc, a diode or Zener diode with the same polarity as the inverse diode of the bypass switch may be provided; in that case, however, the charging of the discharging capacitor C2 must be done via a actuator actuation for a fuel injection valve preferably without fuel pressure.
The switches T1, Tb, Tc and T1-Tn are controlled by the control circuit ST as a function of control signals st of an engine control unit. The engine control unit is not shown for purposes of clarity in the FIGURE. The charging capacitor C1 can be considered as an output capacitor of the switched mode power supply SNT.
The driving method for the circuit will now be described: During circuit operation, the charging capacitor C1 is charged to an output voltage +U SNT of the switched mode power supply SNT that is determined by the control circuit ST. The determining of this voltage +U SNT will be described later herein.
At the onset of operation, the charging capacitor C1 is charged to +U SNT , and the discharging capacitor C2 is discharged; the polarity reversal coil L is without current. To charge the capacitor C2 as well before the first actuation of the actuator, the bypass switch Tc is first made conducting. As a result, C1 discharges via C2, L and Tc. Tc is then made nonconducting, and the discharge switch Tb is now made conducting. As a result, a current flows in the opposite direction through L, C2, Tb and the inverse diode of the bypass switch Tc, as a result of which C2 is charged and is polarized such that after one or more charging and discharging cycles, the charge voltage U L =U C1 +U C2 is present at the series circuit of C1 and C2.
The voltage U C2 at the capacitor C2 is imparted to the control circuit ST via a measuring circuit, in this exemplary embodiment in the form of a sample-and-hold circuit S&H, and the control circuit sets the output voltage +U SNT ≈U C1 of the switched mode power supply SNT such that a specific initial voltage is present at the series circuit of C1 and C2.
Since the voltage U C2 at the capacitor C2 slowly drops upon nonactuation, such recharging operations of the discharging capacitor C2 are also performed during operation, for instance during the charging operation at low rpm (that is, when actuator actuations are chronologically far apart), or in overrunning mode.
If a actuator actuation is to take place, then by the first method, the current I p flowing in the charging circuit is measured by means of a measuring circuit M, which in the simplest case can comprise a shunt resistor, and integrated in an integrator located in the control circuit. Since the measuring circuit M is needed only for this method, it is outlined by dashed lines in the drawing, and the reference symbol for the current I p is placed in parentheses. The rest of this method is performed as in the second method, described below.
In this second, simpler method, before the actuator is charged the voltage U C2 =U before is measured at the discharging capacitor C2 and is imparted to the control circuit ST. Next, the charge switch Ta and the selector switch T1, assigned to the corresponding actuator, such as P1, is made conducting. Current flows from SNT and C1 via Ta, C2, L, P1 and T1 to GND, until the actuator is charged. Then Ta and T1 are made nonconducting, and the actuator continues to be charged. Now the voltage U C2 =U after at the discharging capacitor C2 and the voltage U p at the actuator P1 are measured and imparted to the control circuit ST. Using the above-explained formulas, this circuit calculates the energy E actual supplied to the actuator and compares the value with a specified desired value E setpoint . The requisite charge voltage U L for the next triggering operation is ascertained accordingly. If E actual <E setpoint , then the charge voltage U L is raised, for instance incrementally by one increment, compared to the value that was previously valid; if E actual >E setpoint , then it is decreased by one increment. The charge voltage U L is regulated to E actual =E setpoint .
The charge status of the actuator P1 is maintained until, after the control signal st vanishes, the discharge switch Tb is made conducting. With the discharge switch Tb conducting, all the actuators P1-Pn are discharged via the coil L to the discharging capacitor C2.
The voltage U C2 present at the discharging capacitor C2 after the actuator has been discharged is imparted, via the sample-and-hold circuit S&H, to the control circuit ST, which re-controls the output voltage +U SNT of the switched mode power supply SNT such that the previously ascertained charge voltage U L =U C1 +U C2 is reached in the next triggering operation. With this charge voltage, the next charging operation of the actuator P1, of the charging operation of the next actuator P2, can be effected, and so forth.
|
A method of driving at least one capacitive actuator with a charge voltage. From a charge quantity ΔQ supplied to the actuator and from the actuator voltage U p applied to the actuator after the charging operation is terminated, the actuator capacitance is calculated by the equation C p =ΔQ/U p . From these values, the energy E actual =0.5*C p *U p 2 =0.5*ΔQ*U p is calculated. The charge voltage is regulated such that the energy actually supplied is equivalent to a specified desired value.
| 5
|
BACKGROUND OF THE INVENTION
The present invention generally relates to a door latch device. In particular, the invention relates to structures and methods for a door latch device used with a panic device for doors wherein the locking as well as the unlocking of the door can be controlled by the door latch device.
Panic devices for doors have been in use in buildings for approximately 100 years and provide a useful means for allowing unrestricted escape from the building in situations such as an emergency, while providing a reasonable amount of security against unauthorized access. Panic devices are generally used on single action outward opening doors and provide retention within the door frame either into the threshold, transom or door frame to hold the door in the closed position when not in use.
There are numerous types and styles of mechanisms used for operating the panic devices where bolts reciprocate vertically in and out of the door frame and extend from the top and bottom of the door. Most of these mechanisms include or are adapted to include a panic bar release arrangement on the inside of the door for rapid and foolproof actuation of the bolts by merely depressing the panic bar to open the door. Many of such mechanisms include an often desirable feature of permitting manipulation of the panic device to latch the bolts in a retracted position during business hours or the like, whereby the door is free to swing open without operating the panic bar or hitting any other release mechanism.
To provide operation of installations of this type, some form of bolt latching mechanism is usually provided which retains the bolts in the retracted position when the interior or exterior actuating device is operated during the time the door is open. This prevents the need to continue pressure on the panic bar or key in order to prevent the bolt from contacting the ground or door frame while the door is swinging during the open and closed cycles.
A problem with these types of mechanisms, however, is that these mechanisms use a keeper plate or trip mounted on the door frame which is an added component to the door assembly. Thus, the added component increases the assembly required to install the door, resulting in higher installation costs. Further, the added component increases the chance for the component to fail, resulting in costly repairs, inefficient use of work space, and unsafe conditions. Further, the bolts in these mechanisms commonly fail to remain in the retracted position when the door has been opened, resulting in damage to the frame or threshold since the bolt strikes the frame or threshold upon closing.
A need, therefore, exists to safely and clearly open a door with a panic device. The solution, however, must be able to retain the bolting mechanism in the retracted position until the door has completely closed. Further, the solution must be capable of sensing that the door has closed to extend the bolt after the door has completely closed.
An example of a current panic device wherein the bolts may be retracted is a key operated lock which also services to lock the bolts in the retracted position. By depressing a panic bar, as described in the United States patent to T. Bejarano, U.S. Pat. No. 3,334,500 the bolts may be retracted. Other examples of such devices wherein the bolts may be retracted by a panic device are described in U.S. Pat. No. 3,993,335 to Schmidt, U.S. Pat. No. 3,940,886 to Ellingson, Jr., and U.S. Pat. No. 4,839,988 to Betts et. al.
Currently, other panic devices use Pullman latches which rotate about a horizontal axis and use a spring loaded mechanism. These panic devices usually consist of a mechanical system concealed within the vertical lock stile of the door connected with a surface mounted actuating push bar or pad mounted horizontally across the inside face of the door. The two parts of the system are normally linked mechanically. The mechanism within the door stile operates a latch or bolt system which retains the door in the closed position. In this system, the latch or bolt is retained in a keeper plate which is mounted on the door frame.
These mechanisms also do not solve the current need since the bolts often do not stay in the retracted position and drag along the ground or across the door frame. Further it is often the case that the door mounted components are installed by the door manufacture in the door assembly and the frame components such as keeper plates are sent to the site separately to be installed after the door frame has been erected. Frequently, the frame mounted components go astray and often the components are installed with less accuracy than can be achieved in the factory. This can lead to potentially dangerous situations should the device fail to open in an emergency.
SUMMARY OF THE INVENTION
The present invention provides an improved latching device that can keep the latch assembly in the disengaged position until after the door has closed. This leads to improved safety and maintenance on the door and door frame. The present invention can also be used without keeper plates and does not require a separate trip device mounted to the frame. This leads to installation cost reductions and improved safety for the occupants of the building.
Thus, there is provided by the invention disclosed herein an improved door latch device which overcomes many of the inadequacies of door latches known to the prior art. The invention provides for the mounting of a novel door latch device on the internal side of the door for providing a latch assembly which, rather than vertically extending from the door to engage the door frame, rotatably engages and disengages the door frame. This door latch device, upon mechanical instructions from the actuation of the panic exit device, or other device such as a key lock, is rotated into a disengaging and engaging position, respectively, to allow the door to be opened and to be closed.
In an embodiment, the door latch device comprises at least one housing fixed within the door stile and at least one fork positioned inward of the housing and slidably engaged to the housing. The door latch device further comprises a latch assembly rotatably mounted to the housing and mechanically connected to the fork. The latch assembly is rotatable from an engaged position in a first rotational direction to a disengaged position to allow the door to open. The latch assembly also is rotatable from the disengaged position to the engaged position in a second rotational direction to engage the door frame after the door has closed.
In an embodiment, the latch assembly comprises a latch rotatably connected to the housing. Additionally, a pair of linkages are positioned below the latch and rotatably connected to the housing. A pair of connecting rods are positioned between the latch and the pair of linkages and are slidably engaged to the pair of linkages. Further, a bias member is fixed to the pair of connecting rods and to the fork. The latch assembly further comprises a rocker element positioned between the housing and the latch wherein the rocker element is rotatably connected to the housing and slidably engaged within the latch.
The pair of linkages have a linkage pin positioned in the middle of the linkages while the connecting rods each have a rod slot for receiving the linkage pin.
The latch has a projection facing the door stile in the engaged position and rotated downward ninety degrees in the disengaged position. The latch further has a latch aperture positioned opposite the projection wherein the latch aperture is rotatably connected to the housing. The rocker element has a rocker pin positioned to mechanically connect to the projection during the second rotational direction. The rocker element further has a bridge positioned within the door stile in the engaged position and positioned outside the door stile in the disengaged position.
The present invention further provides a method of engaging and disengaging a door latch device for a door fitted in a door frame comprised of activating the fork in a downward direction. Thereupon, the latch assembly is rotated from an engaged position in the first rotational direction to a disengaged position to disengage from the door frame. A lost motion arrangement, preferably in the form of slot and pin connections between the housing and the fork permit the latch to be captured in an over center position and held against returning to the latched position while the door remains open. The method also provides for sensing the door frame by the latching mechanism upon the closing of the door. Further, the latch is rotated from the disengaged position to the engaged position in a second rotational direction to engage the door frame after the door frame has been sensed.
An advantage of the present invention is to provide a door latch device that efficiently retains and releases a door.
Another advantage of the present invention is to provide a latch assembly that moves from an engaged position to a disengaged position when the door is opened.
Another advantage provided by the present invention is the automatic sensing of the door frame during a closing movement of the door.
Another advantage of the present invention is to provide a latch assembly that automatically moves from the disengaged position to the engaged position when the door frame is sensed.
Another advantage is to provide a lost motion effect to prevent the latch from returning to the latched position while the door is open.
Another advantage of the present invention is to provide a door latch device eliminating a striker plate and/or a trip mechanism mounted to the door or frame.
Still further advantages will become apparent from a consideration of the following descriptions and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of a door latch device illustrated in an engaged position embodying the principles of the present invention.
FIG. 2 is a cross sectional view of the door latch device of FIG. 1 rotated 90 degrees about a vertical axis.
FIG. 3 is an isolated cross sectional view of a housing portion of the door latch device of FIG. 1 .
FIG. 4 is an isolated cross sectional view of a fork portion of the door latch device of FIG. 1 .
FIG. 5 is an isolated cross sectional view of a rocker portion of the door latch device of FIG. 1 .
FIG. 6 is a partially assembled side elevational view of the door latch device of FIG. 1 .
FIG. 7 is a more complete (than FIG. 6) partially assembled side elevational view of the door latch device of FIG. 1 .
FIG. 8 is an isolated cross sectional view of a latch portion of the door latch device of FIG. 1 .
FIG. 9 is an isolated cross sectional view of a link portion of the door latch device of FIG. 1 .
FIG. 10 is a more complete (than FIG. 7) partially assembled side elevational view of the door latch device of FIG. 1 .
FIG. 11 is an isolated cross sectional view of a rod portion of the door latch device of FIG. 1 .
FIG. 12 is an isolated cross sectional view of a biasing member portion of the door latch device of FIG. 1 .
FIG. 13 is a completely assembled side elevational view of the door latch device of FIG. 1 in the latched position.
FIG. 14 is a completely assembled side elevational view of the door latch device of FIG. 1 in the unlatched position.
FIG. 15 is a partially disassembled side elevational view of the door latch device of FIG. 1 in the unlatched position.
FIG. 16 is a completely assembled side elevational view of the door latch device of FIG. 1 in the latched position and including the use of a plate to protect a relatively soft wooden door.
FIG. 17 is a cross sectional view of a second embodiment of a door latch device illustrated in an engaged position embodying the principles of the present invention.
FIG. 18 is a cross sectional view of the door latch device of FIG. 17 rotated 90 degrees about a vertical axis.
FIG. 19 is an isolated cross sectional view of a housing portion of the door latch device of FIG. 17 .
FIG. 20 is an isolated cross sectional view of a fork portion of the door latch device of FIG. 17 .
FIG. 21 is an isolated cross sectional view of a rocker portion of the door latch device of FIG. 17 .
FIG. 22 is a partially assembled side elevational view of the door latch device of FIG. 17 .
FIG. 23 is a more complete (than FIG. 22) partially assembled side elevational view of the door latch device of FIG. 17 .
FIG. 24 is an isolated cross sectional view of a latch portion of the door latch device of FIG. 17 .
FIG. 25 is an isolated cross sectional view of a link portion of the door latch device of FIG. 17 .
FIG. 26 is a more complete (than FIG. 23) partially assembled side elevational view of the door latch device of FIG. 17 .
FIG. 27 is an isolated cross sectional view of a rod portion of the door latch device of FIG. 17 .
FIG. 28 is an isolated cross sectional view of a biasing member portion of the door latch device of FIG. 17 .
FIG. 29 is a completely assembled side elevational view of the door latch device of FIG. 17 in the latched position.
FIG. 30 is a completely assembled side elevational view of the door latch device of FIG. 17 in the unlatched position.
FIG. 31 is a partially disassembled side elevational view of the door latch device of FIG. 17 in the unlatched position.
FIG. 32 is a plan view of the plate shown in FIG. 16, here shown in isolation.
FIG. 33 is a fragmentary perspective view of a door latch device with a push bar actuator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the present invention may be embodied in many different forms, there is shown in the drawings and discussed herein one or more specific embodiments of a door latch device 20 embodying the principles of the present invention with the understanding that the present disclosure is to be considered only as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments illustrated.
As discussed above, the present invention provides a structure and method to maintain a door latch 22 in a disengaged position until a door 24 which it is mounted on has completely closed. The door latch device 20 of the present invention efficiently and safely retracts and extends the door latch 22 during the opening and closing of the door 24 relative to a door frame 26 .
The door latch device 20 of the present invention is to be mounted on the door 24 which has an active style 28 and an inactive style (not shown), it being understood that the term “active style” merely refers to the edge of the door which opens and closes and the inactive style refers generally to the hinged edge of the door. Although the active style 26 as depicted is of a design suitable for specific types of doors, it is within the scope of the invention to mount the door latch device 20 on any type of door having an active style as hereinafter described.
FIGS. 1 and 2 illustrate, in cross sectional views, an exemplary door latch device 20 which is used to engage and disengage the door 24 relative to the frame 26 . FIGS. 1 and 2 illustrate the door latch device in a condition where the latch 22 is extended and in FIG. 1 is illustrated as being engaged with the frame 26 .
The door latch device 20 is comprised of a plurality of individual components, each of which are shown in detail in isolated views in FIGS. 3-9.
FIG. 3 illustrates a housing 30 which is secured to the door style 28 , for example, by threaded fasteners extending into apertures 32 formed in an end wall 34 of the housing 30 . The housing preferably is formed in a U-shape with two side legs 36 and with the wall 34 forming the bight of the U. The two side legs are mirror images of each other and therefore only one of the side legs is shown in FIG. 3 .
The side legs are provided with four apertures for receiving pins. A first aperture 38 is in the form of a vertical slot and is located near a lower edge 40 and a free edge 42 of the housing 30 . A second aperture 44 is located above the first aperture and toward the bight wall 34 . The third aperture 46 is above the second aperture and is located adjacent to the free edge 42 . The fourth aperture 48 is located near a top edge 50 of the housing 30 and toward the bight side 34 .
FIG. 4 illustrates a fork 52 which also may be formed in a U-shape with two mirror image legs 54 and a lower bight wall 56 of the U. An adapter 58 , in the form of an internally threaded nut is captured on the bight wall 56 by an appropriate crimping operation. The fork 52 is received within the housing 30 and, as seen best in FIG. 2, a lower portion of the fork legs 60 is provided with sliding clearance within the side legs 36 of the housing. This portion of the fork legs includes an aperture 62 for receiving a pin that also extends through the slot 38 of the housing as described below.
Fork side leg 54 has an inward jog section 64 and a vertical upper section 66 spaced slightly inwardly of the side legs 36 of the housing as seen in FIG. 2 . In the upper section 66 of the leg 54 , there is provided a vertical slot 68 which receives a pin (described below) that also extends through aperture 44 in the housing. Near a top end 70 of the upper section 66 is a horizontal slot 72 to receive a pin to be described below.
FIG. 5 illustrates a rocker member 74 which has two legs 76 which are mirror shaped and may be connected by a bridge 78 extending between an upper end 80 of the two legs 76 . Alternatively, two separate rockers may be provided which have an inturned portion corresponding to the bridge 78 , which, however, do not extend across the full distance between the two separate rockers. An aperture 82 is provided near a lower end 83 of the rocker leg 76 for receiving a pin (described below) that also extends through aperture 44 in the housing and slot 68 in the fork. Near the upper end 80 of the rocker leg 76 is provided a generally horizontal slot 84 to receive a pin also extending through aperture 48 in the housing. Positioned below the slot is an aperture 86 to receive a rocker pin as described below.
FIG. 6 is a cross section illustrating the arrangement of the rocker 74 relative to the housing 30 and illustrating a pin 90 extending through the aperture 82 in the rocker and aperture 44 in the housing, as well as a pin 92 extending through the slot 84 in the rocker 74 and the aperture 48 in the housing. The rocker 74 is arranged to pivot about the pin 90 through a range constrained by the length of the slot 84 which receives the pin 92 . As illustrated, the rocker 74 is pivoted counter clockwise so that the pin 92 rests against a right hand edge 93 of the slot 84 .
FIG. 7 illustrates the placement of the fork 52 into assembly with the housing 30 and the rocker 74 . Here it is seen that the pin 90 is further received in the slot 68 of the fork 52 and that a pin 94 is received in the aperture 62 in the fork and also in the slot 38 of the housing 30 . The fork 52 can slide vertically within the housing, constrained by the dimension of the slot 68 and the slot 38 . As illustrated in FIG. 7, the fork 52 is slid upwardly to the greatest extent possible within the housing 30 such that the pin 90 rests on a bottom 95 of the slot 68 and the pin 94 engages a top 96 of the slot 38 of the housing.
FIG. 8 illustrates the latch 22 which has a first aperture 98 for pivotally receiving the pin 92 which extends through the housing 30 and the rocker 74 . A second aperture 100 is provided for receiving a pin described below. The latch 22 has a curved top portion 102 which extends the full width of the latch 22 . At an end of the leg 97 opposite the aperture 98 is a projection 104 which protrudes slightly beyond the curved portion 102 .
FIG. 9 illustrates one of two link members 106 . Each link member has a first aperture 108 near one end to receive a pin (described below) extending through the housing aperture 46 , a second aperture 110 near an opposite end to receive a pin (described below) extending through the slot 72 in the fork 52 and a third, central aperture 111 to receive a link pin as described below.
FIG. 10 illustrates the placement of the latch 22 and the link 106 onto the assembly of the housing 30 , the rocker 74 and the fork 52 . Here it is seen that the latch 22 is pivotally mounted on the pin 92 and is free to rotate about that pin. The link 106 is pivotally received on a pin 112 which is received in the aperture 46 of the housing 30 . The aperture 110 receives a pin 114 which is received in the slot 72 of the fork 52 . The link 106 is free to pivot about the pin 112 and is constrained only due to the connection of the link 106 to the fork 52 through the pin 114 , with the fork 52 being limited in its vertical motion by the pins 90 and 94 received in the slots 68 and 38 as described above. As illustrated, the link 106 is rotated about the pin 112 to its counter clockwisemost position since the fork 52 is in its uppermost position relative to the housing 30 .
The latch 22 is free to pivot about the pin 92 through an arc where at the clockwisemost position, the projection 104 will engage an inturned tab 116 on the housing 30 and, in a counter clockwisemost position, an edge 118 of the latch 22 will engage a pin 120 carried in the aperture 86 of the rocker 74 . As illustrated in FIG. 10, the latch 22 is in its clockwisemost (engaged) position.
FIG. 11 illustrates one of two identical rod members 126 . The rod member 126 has a first aperture 128 near a top end 130 which receives a latch pin (described below) carried in the latch aperture 100 . The rod member 126 has a vertical slot 132 positioned toward, but spaced above a bottom end 134 for receiving a pin (described below) carried in the aperture 111 of the link 106 as described below. The rod member 126 further has an aperture 136 near the bottom end 134 .
FIG. 12 illustrates a biasing member 140 which may be in the form of a coil spring. The coil spring has a first eye 142 for receiving the pin 94 which extends through the housing 30 and the fork 52 . An eye 144 is located at the opposite end of the biasing member 140 and is received in the aperture 136 in the rod member 126 .
FIG. 13 illustrates the further assembly of the rod member 126 and the biasing member 140 on to the assembly illustrated in FIG. 10 . Here it is seen that the biasing member 140 is captured at the lower end eye 142 by the pin 94 and at its upper end eye 144 by the aperture 136 in the rod 126 . The rod 126 is pivotally captured on a latch pin 150 which is received in the latch aperture 100 . A link pin 152 is received in the slot 132 of the rod member 126 and also extends into the aperture 111 of the link 106 . Thus, FIG. 13 illustrates the door latch mechanism 20 , and each of its component parts, in the latched position in which the latch 22 would be engaged with the door frame 26 .
The door latch mechanism 20 is moved to an unlatched position by operation of a panic bar or push bar 155 shown in FIG. 33 and described in U.S. Pat. No. 3,993,335 incorporated herein by reference which causes a threaded rod 156 (FIGS. 1 and 2) to move downwardly, the threaded rod 156 being threadingly engaged in the adapter 58 , thereby causing the fork 52 to move downwardly relative to the housing 30 . This downward movement of the fork 52 carries the pin 94 downwardly, as well as the pin 114 , thereby pulling the biasing member 140 downwardly and rotating the link 106 in a clockwise direction about the pin 112 . This pivotal movement of the link 106 and the downward force provided by the biasing member 140 moves the rod member 126 downwardly, thereby causing the latch 22 to pivot about the pin 92 in a counter clockwise direction until the edge 118 of the latch engages the rocker pin 120 . The engagement of the edge 118 with the rocker pin 120 will cause the rocker 74 to pivot about the pin 90 in a clockwise direction, thus resulting in the bridge 78 protruding beyond an inner face 160 of the door 28 . This resulting condition of the latch mechanism is illustrated in FIG. 14 .
When the pressure on the panic bar is released, there no longer is a downward force being exerted by the threaded rod 156 , and therefore the biasing member 140 exerts an upward force on the pin 94 to move the fork 52 upwardly relative to the housing 30 . However, the projection 104 of the latch 22 engages the links 106 in an over center condition preventing clockwise rotation of the latch 22 and thereby stopping the upward movement of the fork 52 due to the rod member 126 and its connection to the latch at pin 150 and the link 106 connection at the pin 114 to the fork 52 . The slots 68 in the fork 52 and 38 in the housing 30 allow for lost motion to occur, permitting a slight upward movement of the fork 52 relative to the housing 30 before the projection 104 engages the links 106 .
FIG. 15 illustrates the engagement of the latch 22 with the links 106 , with visibility blocking components removed. In this manner, the latch 22 will be retained in its unlatched position while the door remains open, even though pressure has been released on the panic bar.
When the door 24 returns to its closed position relative to the door frame 26 , the bridge 78 , which is now projecting beyond the face 160 of the door, will engage the door frame 26 and will cause the rocker 74 to pivot about the pin 90 , causing the rocker pin 120 to press against the edge 116 of the latch 22 until the projection 104 moves past “dead center” on the links 106 , which will then release the restraint preventing the biasing member 140 from pulling upwardly on the pin 94 . With this restraint released, pin 94 will be drawn upwardly, thereby carrying the fork 52 upwardly and pivoting the links 106 about the pin 112 , the upward movement of the pin 114 thereby carrying the rod member 126 upwardly, causing the latch 22 to pivot about the pin 92 through the connection of the rod member 126 at the pin 150 to the latch member 22 . The end result of this movement will be a return to the latched condition as illustrated in FIG. 1 . Therefore, it is seen that the door latch mechanism of the present invention utilizes a lost motion arrangement in order to trap the latch 22 against returning to the latched position upon a release of the panic push bar. Also, the present invention utilizes the concept of rotating the latch 22 beyond a top dead center relative to the links 106 to trap the latch 22 against returning to the latched position upon release of the panic exit bar.
The present invention utilizes a frame sensor, in the form of the rocker 74 with its rocker pin 120 , to reactivate the latch 22 and move it back to the latched position by pushing the latch 22 over the top dead center position relative to the link 106 .
The present invention does not require a separate striker plate or trip mechanism mounted on the door frame in order to reactivate the latch mechanism.
Although the invention is illustrated in FIGS. 1 and 2 as being located within a metal door, it can also be utilized in other doors, for example, wood doors. In such an arrangement it may be necessary to utilize an additional plate 161 mounted at the top of the door to protect the relatively soft material of the door frame. The plate 161 is shown in place in FIG. 16 and in an isolated view in FIG. 32, where it is seen that it has a large central aperture 162 to allow the latch 22 to extend through the plate into the latching position and its also includes several apertures 164 for receiving fasteners to secure the plate 161 to the door 24 . A tab 166 may be provided to prevent damage to the door frame 26 when the bridge 78 of the rocker 74 engages the door frame 26 . The tabs 166 is positioned a set distance from aperture 162 in order that free play is minimized between the door and frame when the latch is engaged.
An alternative embodiment of the present invention is shown in FIGS. 17-34 which includes a door latch device 220 embodying the principles of the present invention.
As discussed above, the present invention provides a structure and method to maintain a door latch 222 in a disengaged position until a door 224 which it is mounted on has completely closed. The door latch device 220 of the present invention efficiently and safely retracts and extends the door latch 222 during the opening and closing of the door 224 relative to a door frame 226 .
The door latch device 220 of this embodiment is to be mounted on the door 224 which has an active style 228 and an inactive style (not shown), it being understood that the term “active style” merely refers to the edge of the door which opens and closes and the inactive style refers generally to the hinged edge of the door. Although the active style 226 as depicted is of a design suitable for specific types of doors, it is within the scope of the invention to mount the door latch device 220 on any type of door having an active style as hereinafter described.
FIGS. 17 and 18 illustrate, in cross sectional views, an exemplary door latch device 220 which is used to engage and disengage the door 224 relative to the frame 226 . FIGS. 17 and 18 illustrate the door latch device 220 in a condition where the latch 222 is extended and in FIG. 17 is illustrated as being engaged with the frame 226 .
The door latch device 220 is comprised of a plurality of individual components, each of which are shown in detail in isolated views in FIGS. 19-28.
FIG. 19 illustrates a housing 230 which is secured to the door style 228 , for example, by threaded fasteners extending into apertures 232 formed in an end wall 234 of the housing 230 . The housing preferably is formed in a U-shape with two side legs 236 and with the wall 234 forming the bight of the U. The two side legs are mirror images of each other and therefore only one of the side legs is shown in FIG. 19 .
The side legs 236 are provided with four apertures for receiving pins. A first aperture 238 is in the form of a vertical slot and is located near a lower edge 240 and a free edge 242 of the housing 230 . A second aperture 244 is located above the first aperture and toward the bight wall 234 and is also in the form of a vertical slot. The third aperture 246 is above the second aperture and is located adjacent to the bight wall 234 . The fourth aperture 248 is located near a top edge 250 of the housing 230 and toward the bight wall 234 .
FIG. 20 illustrates a fork 252 which also may be formed in a U-shape with two mirror image legs 254 and a lower bight wall 256 of the U. An adapter 258 , in the form of an internally threaded nut is captured on the bight wall 256 by an appropriate crimping operation. The fork 252 is received within the housing 230 and, as seen best in FIG. 18, the fork legs 254 are provided with sliding clearance within the side legs 236 of the housing 230 . The fork legs 254 include an aperture 262 for receiving a pin that also extends through the slot 238 of the housing 230 as described below.
In an upper section of the legs 254 , there is provided an aperture 268 which receives a pin (described below) that also extends through aperture 244 in the housing. Near a top end 270 of the legs 254 is a horizontal slot 272 to receive a pin to be described below.
FIG. 21 illustrates a rocker member 274 which has two legs 276 which are mirror shaped and may be connected by a bridge 278 extending between an upper end 280 of the two legs 276 . Alternatively, two separate rockers may be provided which have an inturned portion corresponding to the bridge 278 , which, however, do not extend across the full distance between the two separate rockers. An aperture 282 is provided near a lower end 283 of the rocker leg 276 for receiving a pin (described below) that also extends through hole 246 in the housing 230 . Near the upper end 280 of the rocker leg 276 is provided a generally horizontal slot 284 to receive a pin also extending through aperture 248 in the housing. Positioned below the slot is an aperture 286 to receive a rocker pin as described below.
FIG. 22 is a cross section illustrating the arrangement of the rocker 274 relative to the housing 230 and illustrating a pin 290 extending through the aperture 282 in the rocker and aperture 246 in the housing, as well as a pin 292 extending through the slot 284 in the rocker 274 and the aperture 248 in the housing. The rocker 274 is arranged to pivot about the pin 290 through a range constrained by the length of the slot 284 which receives the pin 292 . As illustrated, the rocker 274 is pivoted counter clockwise so that the pin 292 rests against a right hand edge 293 of the slot 284 .
FIG. 23 illustrates the placement of the fork 252 into assembly with the housing 230 and the rocker 274 . Here it is seen that a pin 293 is received in the aperture 268 of the fork 52 and also in the slot 244 of the housing 230 . A pin 294 is received in the aperture 262 in the fork and also in the slot 238 of the housing 230 . The fork 252 can slide vertically within the housing, constrained by the dimension of the slot 244 and the slot 238 . As illustrated in FIG. 23, the fork 252 is slid upwardly to the greatest extent possible within the housing 230 such that the pin 293 rests on a top of the slot 244 and the pin 294 engages a top of the slot 238 of the housing.
FIG. 24 illustrates the latch 222 which has a first aperture 298 for pivotally receiving the pin 292 which extends through the housing 230 and the rocker 274 . A second aperture 300 is provided for receiving a pin described below. The latch 222 has a curved top portion 302 which extends the full width of the latch 222 . At an end of a leg 303 opposite the aperture 298 is a projection 304 which protrudes slightly beyond the curved portion 302 .
FIG. 25 illustrates one of two link members 306 . Each link member has a first aperture 308 near one end to receive a pin (described below) extending through the housing aperture 246 , a second aperture 310 near an opposite end to receive a pin (described below) extending through the slot 272 in the fork 252 and a third, central aperture 311 to receive a link pin as described below. The link members 306 also include a projection 313 formed on one edge between the apertures 308 and 310 .
FIG. 26 illustrates the placement of the latch 222 and the link 306 onto the assembly of the housing 230 , the rocker 274 and the fork 252 . Here it is seen that the latch 222 is pivotally mounted on the pin 292 and is free to rotate about that pin. The link 306 , via aperture 308 , is pivotally received on the pin 290 about which the rocker pivots. The aperture 310 receives a pin 312 which is received in the slot 272 of the fork 252 . The link 306 is free to pivot about the pin 290 and is constrained only due to the connection of the link 306 to the fork 252 through the pin 312 , with the fork 252 being limited in its vertical motion by the pins 293 and 294 received in the slots 244 and 238 as described above. As illustrated, the link 306 is rotated about the pin 290 to its clockwisemost position since the fork 252 is in its uppermost position relative to the housing 230 .
The latch 222 is free to pivot about the pin 292 through an arc where at the clockwisemost position, the projection 304 will engage an inturned tab 316 on the housing 230 and, in a counter clockwisemost position, an edge 318 of the latch 222 will engage a pin 320 carried in the aperture 286 of the rocker 274 . As illustrated in FIG. 26, the latch 222 is in its clockwisemost position.
FIG. 27 illustrates one of two identical rod members 326 . The rod member 326 has a first aperture 328 near a top end 330 which receives a latch pin (described below) carried in the latch aperture 300 . The rod member 326 has a vertical slot 332 positioned toward, but spaced above a bottom end 334 for receiving a pin (described below) carried in the aperture 311 of the link 306 as described below. The rod member 326 further has an aperture 336 near the bottom end 334 .
FIG. 28 illustrates a biasing member 340 which may be in the form of a coil spring. The coil spring has a first eye 342 for receiving the pin 294 which extends through the housing 230 and the fork 252 . An eye 344 is located at the opposite end of the biasing member 340 and is received in the aperture 336 in the rod member 326 .
FIG. 29 illustrates the further assembly of the rod member 326 and the biasing member 340 onto the assembly illustrated in FIG. 26 . Here it is seen that the biasing member 340 is captured at the lower end eye 342 by the pin 294 and at its upper end eye 344 by the aperture 336 in the rod 326 . The rod 326 is pivotally captured on a latch pin 350 which is received in the latch aperture 300 . A link pin 352 is received in the slot 332 of the rod member 326 and also extends into the aperture 311 of the link 306 . Thus, FIG. 29 illustrates the door latch mechanism 220 , and each of its component parts, in the latched position in which the latch 222 would be engaged with the door frame 226 .
The door latch mechanism 220 is moved to an unlatched position by operation of a panic bar or push bar (not illustrated, but which is shown and described in U.S. Pat. No. 3,993,335 incorporated herein by reference) which causes a threaded rod 356 (FIGS. 17 and 18) to move downwardly, the threaded rod 356 being threadingly engaged in the adapter 258 , thereby causing the fork 252 to move downwardly relative to the housing 230 . This downward movement of the fork 252 carries the pin 294 downwardly, as well as the pin 312 , thereby pulling the biasing member 340 downwardly and rotating the link 306 in a counterclockwise direction about the pin 290 . This pivotal movement of the link 306 and the downward force provided by the biasing member 340 moves the rod member 326 downwardly, thereby causing the latch 222 to pivot about the pin 292 in a counter clockwise direction until the edge 318 of the latch engages the rocker pin 320 . The engagement of the edge 318 with the rocker pin 320 will cause the rocker 274 to pivot about the pin 290 in a clockwise direction, thus resulting in the bridge 278 protruding beyond an inner face 360 of the door 228 . This resulting condition of the latch mechanism is illustrated in FIG. 30 .
When the pressure on the panic bar is released, there no longer is a downward force being exerted by the threaded rod 356 , and therefore the biasing member 340 exerts an upward force on the pin 294 to move the fork 252 upwardly relative to the housing 230 . However, the projection 304 of the latch 222 engages the projections 313 on the links 306 in an over center condition preventing clockwise rotation of the latch 222 and thereby stopping the upward movement of the fork 252 due to the rod member 326 and its connection to the latch at pin 350 and the link 306 connection at the pin 312 to the fork 252 . The slots 244 and 238 in the housing 230 allow for lost motion to occur, permitting a slight upward movement of the fork 252 relative to the housing 230 before the projection 304 engages the links 306 .
FIG. 31 illustrates the engagement of the latch 222 with the links 306 , with visibility blocking components removed. In this manner, the latch 222 will be retained in its unlatched position while the door remains open, even though pressure has been released on the panic bar.
When the door 224 returns to its closed position relative to the door frame 226 , the bridge 278 , which is now projecting beyond the face 360 of the door, will engage the door frame 226 and will cause the rocker 274 to pivot about the pin 290 , causing the rocker pin 320 to press against the edge 316 of the latch 222 until the latch projection 304 moves past “dead center” on the links 306 and out of engagement with the projections 313 on the links 306 , which will then release the restraint preventing the biasing member 340 from pulling upwardly on the pin 294 . With this restraint released, pin 294 will be drawn upwardly, thereby carrying the fork 252 upwardly and pivoting the links 306 about the pin 290 , the upward movement of the pin 352 thereby carrying the rod member 326 upwardly, causing the latch 222 to pivot about the pin 292 through the connection of the rod member 326 at the pin 350 to the latch member 222 . The end result of this movement will be a return to the latched condition as illustrated in FIG. 17 . Therefore, it is seen that the door latch mechanism of the present invention utilizes a lost motion arrangement in order to trap the latch 222 against returning to the latched position upon a release of the panic push bar. Also, the present invention utilizes the concept of rotating the latch 222 beyond a top dead center relative to the links 306 to trap the latch 222 against returning to the latched position upon release of the panic exit bar.
In this embodiment, the present invention utilizes a frame sensor, in the form of the rocker 274 with its rocker pin 320 , to reactivate the latch 222 and move it back to the latched position by pushing the latch 222 over the top dead center position relative to the link 306 .
The present invention does not require a separate striker plate or trip mechanism mounted on the door frame in order to reactivate the latch mechanism.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
|
A latch mechanism is provided for a door which includes a rotatable latch which is rotated into and held in an open position to allow the door to open, and is released from the open position only when a sensing mechanism provided as a part of the latch mechanism, held in the door, senses the door frame upon a closing of the door. The latch is held in an over center engaged position which it is moved into due to a lost motion connection among some, but not all, elements of the latch mechanism.
| 8
|
TECHNICAL FIELD
The invention concerns knitted products like trousers, slips, panties, mainly tights.
BACKGROUND ART
According to the know state of the art, knitted products of relevant type—in concrete terms the tights—are manufactured in such a way that the two legs are knitted separately and these are consequently straight-cut in their upper part and then they are sewn together and so the body part is created. This technology of manufacture is well developed and very sophisticated machines—usually automatic or semi-automatic textile machines—were developed for the technology performance. The main disadvantage of tights manufactured in this way is the fact that at point of inter-connection of the two legs and the tight part, the three hoses are practically connected in one point, which is extremely loaded during wearing and seam damage often occurs. Another important disadvantage is also the fact that the seam in the panties section—mainly in case of ladies tights—is significantly unaesthetic.
So as to eliminate the main disadvantage of classic manufacture of tights, there was developed the technology of gore sewing in the point of connection of legs and the body. By sewing in the gore, there was practically fully eliminated the main disadvantage. But this is a technology that has not been automated to acceptable level yet, so it brings undesirable manual operations to the production cycle, delaying the manufacturing process. The question of poor aesthetics of the seam also remained unsolved.
In the course of time, there were developed the small-diameter knitting machines, adjusted to manufacture of tights from one piece, without necessity of sewing the panty section together. There exist several categories of the knitting machines and consequently even products.
As a basic category of these products it is possible to consider tights—their manufacture in knitting industry jargon is called “knitting from toe to toe”. In case of this group of products, manufacture has been started by knitting the toe of one of the legs, it continued by knitting the body part with simultaneous creation of the waist hole and it was finished by knitting the other leg. There also known the solutions when the body part was knitted by reverse run with the purpose of obtaining bigger panties section. But this category of products showed one significant disadvantage that was not successfully eliminated and that was a cause for the products to gradually leave the markets. While in case of classic tights, the knitted fabric lines of the body section are parallel to the leg section, the number of columns of the knitted fabric in the body is twice the number of columns in the leg section. The height of the panties is practically unlimited, while in case of products in the category “knitting from toe to toe” the lines of the knitted fabric in the body section are practically perpendicular to the lines of the knitted fabric of the leg. The number of columns of the knitted fabric—that is in this case decisive for the height of the panties—is even lower than the number of columns in the leg and that causes insufficient height of the body section. That is the main cause why this category of products has not found its permanent position in the market.
Tights manufactured on small-diameter knitting machines equipped with two needle-rolls represented another category of the products. One product of this category was manufactured in such a way that knitting started by knitting the upper section by applying the reverse run simultaneously on both of the needle-rolls. After knitting the body part, there were simultaneously knitted both of the legs by rotation run, while the leg knitted on the upper roll was drafted in to the hollow of the leg knitted in the bottom needle-roll. The main disadvantages of the tights were the facts that the point of connection of both of the legs with the body part was strongly prone to the knitted fabric ripping, while the proper concept of the knitting machine did not allow required fineness of the knitted fabric to be reached, it did not allow development of patterns with exuviated face thread and strengthened patterns. There is also known a variant solution, when the body part was knitted by rotation run of the needle-rolls, while on a part of the circumference of both of the needle-rolls, the hoses were knitted together and then cut up. But the quality of such a seam was poor and it did not find any possible application in the course of time.
There is also known the category of products manufactured on single-roll knitting machines, using special exuviation jacks, respectively using a device plate. In case of this category of products there was usually knitted one of the legs at first, then approximately half of the needle-roll circumference was transferred to jacks to non-operation position and then knitting of the second leg followed. After finishing the second leg knitting, there were dropped down the links from that part of the circumference, where there were placed the links of the first leg transferred to jacks. Then, the knitting of the body part followed, using full number of knitting needles as used for knitting of both of the legs. There is also known a technical solution when—while using the device plate—there was closed the space created by putting off the knitted fabric from a part of the circumference. The main disadvantages of this category of products include insufficient number of columns of the knitted fabric in the body part of the product and mainly low aesthetic value of the products.
Seamless textile product—for example tights—could be theoretically as well as practically manufactured on popular double-bedded knitting machines. But the machines were not applied in practical manufacture mainly due to low productivity of flat knitting machines compared to small-diameter knitting machines and poor quality of product performance in case of tights.
Textile of the underwear type like boxers, panties, slips and so on are practically manufactured in two ways. The first—in fact classic—way includes manufacture of a semi-product for example on large-diameter knitting machines, cutting the semi-product to relevant shape and consequent sewing of the final product. But the classic way of manufacture has some disadvantages, including high share of manual work with small level of automation as well as the fact that the seams—mainly in the buttock area—have significantly different volume and elasticity than the remaining part of the product and they are visible under the outwear, which is frequently undesirable. The efforts aimed at reaching increased elasticity of underwear caused introduction of production technology, when the semi-product is manufactured on medium-diameter knitting machine. Then, the semi-product is cut off the main knitted fabric and the edges are sewn. But even the underwear manufactured in this way shows the above-specified disadvantageous features and more, it causes quite significant technologic waste of the expensive input material.
DISCLOSURE OF THE INVENTION
That is why it is the aim of the invention to create such a seamless knitted product of underwear type and to find the relevant method of its manufacture so as to maximally eliminate the faults of the current technical solution.
Then, it is the aim for the product to be knitted on flat double-bedded knitting machines as well as on double-roll knitting machines. This can be significantly reached by seamless knitted products according to this invention that is based mainly on the fact that the crotch area is closed by at least one pair of knitted-on elements that are placed opposite to each other.
The main advantage of seamless knitted products according to the invention is the fact that the three hoses are not inter-connected in one point, but along the circumference of the area consisting of knitted-on parts, being an integral part of both legs and the body part. That means that there can be reached anatomic shape of the product with simultaneous arrangement of equal and balanced tension of the knitted fabric, which means that it is not breached at the inter-connection spot. Other advantages include the fact that it is very easy to use a mix of materials with different characteristics for manufacture of individual parts of the product—for example massive cotton in the knitted-on part, fine cotton in combination with elastomere for the body part and synthetic material for the legs. The product manufactured in compliance with the invention does not cause well-known and undesirable deformation of buttocks, as it is seamless. That means that it is practically invisible under the outwear. Other advantages of the product according to the invention include easy making on a sole type of textile machine, for example on a special double-roll small-diameter knitting machine with the possibility of high level of production automation, practically negligible technologic waste, high aesthetic value and relatively low production costs.
For simple knitting of products like slips it seems favourable when the pair of knitted-on elements is on opposite sides of the body part, with their tops oriented one against the other.
If it is desirable for the legs to be more apart from each other at the crotch section, it is purposeful for the pair of knitted-on parts to be placed in mirror layout on enclosed parts of the leg circumferences.
From the point of view of knitted product shape performance in the crotch it is favourable for the knitted-on parts to narrow in the direction of their tops.
It is favourable if the border lines of the knitted-on part in the body part are connected with the adjacent border lines of the knitted-on parts for legs, as it eliminates sewing of the body part together with the legs and simultaneously the deformation of the product with seams. That improves the product appearance for wear.
In case of a requirement for enlarged surface of the knitted-on part and higher covering ability it is favourable for at least one of the knitted-on parts of the body part to continue the additional knitted-on part to the body part.
So as to improve the comfort of wear it is favourable—mainly in case of tights—for the knitted-on parts to be made of different material than the body part and legs.
From the point of view of the product aesthetic level it is favourable for the knitted product to be patterned.
Then, from the production point of view it is favourable for the tights when the legs follow the shape of stockings with closed toes, as there are eliminated all and any other finishing operations.
The base of the simple way of knitted products manufacture according to the invention states that the knitting starts from the body part border, it continues by knitting at least one pair of knitted-on parts and consequent knitting of legs. This is favourable even thanks to the fact that it is possible to reach high-quality double border with non-unsewable beginning.
But for knitting of tights it is favourable to knit the legs at first and then there is knitted at least one pair of knitted-on parts and the knitting process is finished by the border in the body part, as in such a case it is possible to close the toes directly on the machine.
For knitting on flat double-bedded knitting machine it is favourable for the body part, the legs as well as the knitted-on parts to be knitted by reverse run while using the double-bedded flat knitting machine.
The favourable method of knitted product manufacture according to the invention on double-bedded knitting machine is based on the fact that the legs are knitted by rotation run of both of the needle rolls, at least the pair of opposite knitted-on parts is knitted by reverse run of both of the needle rolls and the knitting procedure based on reverse run of needle rolls for the body part.
Taking into consideration the unsewing of the product, it is favourable that the knitted-on part in the body part is gradually connected by its border lines with the adjacent border lines of the pair of knitted-on parts of the legs.
One of the advantages of the seamless knitted products according to the invention is characterised by the fact that it can be produced on the basis of manual knitting or on double-bedded flat knitting machine as well as on double-roll small-diameter knitting machine.
If the seamless knitted product according to the invention is to be manufactured on a double-roll small-diameter knitting machine, it will be favourable mainly thanks to the fact that the legs may be knitted by classic rotation run of both of the needle rolls without any minor traces of longitudinal stripes. The production costs are fully comparable with the classic production technology and simultaneously, the seamless knitted product according to this invention shows new and better characteristics compared to well-known products manufactured in compliance with hitherto known technical status.
BRIEF DESCRIPTION OF DRAWINGS
The invention will be explained in detail while using the drawings, schematically showing—in FIG. 1 —the view of the knitted product in sample version as ladies' or children tights, in FIG. 2 the knitted product in the form of panties, in FIG. 3 the knitted product in the form of slips, in FIG. 4 the trousers with additional knitted-on part, in FIG. 5 closing of the crotch with knitted-on parts, in FIG. 6 the detail of knitting connection of the knitted-on parts, being an integral part of both of the legs, in FIG. 7 the detail of the knitting connection of gores, being an integral part of the panties part, in FIG. 8 the detail of knitting connection in the crotch area of the knitted product established on the basis of mutual connection of the two knitted-on parts being an integral part of both legs with two knitted-on parts being an integral part of the panties part, in FIG. 9 the knitted product in decomposed status in case of knitting on double-bedded knitting machine, in FIG. 10 , 11 and 12 the steps of manufacture of a knitted product on double-roll knitting machine.
DESCRIPTION OF PREFERRED EMBODIMENT
In the present application, the term Knitted panty hose garment is to be understood as including slips, trousers and tights.
Knitted product in sample version according to FIG. 1 —the panties type—includes the body part 1 finished with a flexible border 5 and a pair of parts 2 , 3 for legs finished with toes 6 , 7 , favourably closed directly on the machine, without additional sewing. In the crotch section K, the body part 1 and the legs 2 , 3 are interconnected in this version by four knitted-on parts 1 A, 1 B, 2 A, 3 A, that close the crotch area K in this way, see FIG. 5 . In this case, the knitted-on parts 1 A, 1 B are two and they make an integral part of the body part 1 and they extend it. The knitted-on parts 1 A, 1 B are located on opposite halves of the circumference of the body part 1 in such a way that one knitted-on part 1 A is located in the front of the body part 1 and the other one in the rear part of the body part 1 . In this case, the knitted-on parts 1 A, 1 B are wedge shaped and they can be—as specified below—even of some other shape, but they are always shaped in such a way so as they become narrower in the direction of the V top. The legs 2 , 3 also contain a pair of knitted-on parts 2 A, 3 A—one part on each of the legs 2 , 3 , while they are placed on adjacent parts of circumferences in mirror position and—in relation to the position of knitted-on parts 1 A, 1 B—they are partially turned in 90°. The shape of knitted-on parts 2 A, 3 A is similar to the shape of knitted-on parts 1 A, 1 B i.e. they become narrower in the direction of the V top, but they do not have to be symmetrical, which means that their part adjacent to the knitted-on part 1 A may differ from the part adjacent to the knitted-on part 1 B.
The knitted-on parts 1 A, 1 B, 2 A, 3 A close the crotch area K by being interconnected on their edge, while they simultaneously increase the distance L in the crotch areas K between the legs 2 , 3 compared to the distance without knitted-on parts 1 A, 1 B, 2 A, 3 A. The increase of the distance L between the legs 2 , 3 can be affected mainly by knitted-on parts 2 A, 3 A.
As it was stressed out in the previous section of the file, the invention may be advantageously applied to the group of knitted products that is collectively called underwear, consisting of body part 1 and possibly also legs 2 , 3 . The basic description will be performed on one of the group of products—the tights.
FIG. 6 shows a sample version of knitting connection of the knitted-on parts 2 A, 3 A to the legs 2 , 3 , that are made of smooth structure with decrease of the number of lines O. The shape of knitted-on parts 2 A, 3 A during machine production is in fact limited only by the characteristics of the pattern-setting mechanism of the textile machine, which means that the border lines H 2 A, H 3 A may be placed on the straight line as in the sample, but also on any curve. The shape of knitted-on parts 2 A, 3 A does not have to by symmetrical in all the cases and it depends only on concrete requirements regarding the given product.
The sample version of the knitting connection of knitted-on parts 1 A, 1 B of the body part 1 is shown in FIG. 7 again from smooth structure with elimination of lines O in such a way, that there is created in fact a knitted-on part in the gore shape. As far as it concerns the border lines H 1 A, H 1 B and the shape of knitted-on parts 1 A, 1 B, it is possible to say the same as in case of knitted-on parts 2 A, 3 A of legs 2 , 3 . The knitting structure of mutual connection of the sample version of knitted-on parts 1 A, 1 B, 2 A, 3 A according to the invention is shown in detail in FIG. 8 , mainly showing that the connection can not be unsewn without any seam.
As it is clearly schematically shown in FIG. 2 , 3 , 4 , the invention can be easily applicable even to other types of products, not only the tights. In such a case, the number of lines in legs 2 , 3 will be limited to necessary minimum to knit the needles into the unsewable beginning. It can be also favourably applied to classic panties, respectively various shaped slips. If there is required an increased area of the knitted-on parts 1 A, 1 B, 2 A, 3 A, it is possible to complete the above-described knitted-on parts 1 A, 1 B, 2 A, 3 A with an additional knitted-on part 4 , mainly in the front part of the product, above the knitted-on part 1 A in such a way, as shown in FIG. 8 . The number of knitted-on parts 1 A, 1 B, 2 A, 3 A for simpler manufacture—for example slips—may be limited to two knitted-on parts 1 A, 1 B in the body part 1 or three knitted-on parts 1 A, 2 A, 3 A using an additional knitted-on part 4 and so on.
One of great advantages of knitted seamless product according to the invention is the fact that it may be manufactured by using different knitting techniques, for example by manual knitting, knitting on double-bedded knitting machine, respectively by knitting on a special double-roll small-diameter knitting machine.
The procedure of knitted product manufacture according to the invention and using the double-bedded knitting machine, may be explained on the basis of FIG. 9 . The product knitting starts for example by the initial line P 2 of the leg 2 . Knitting of the leg 2 is finished by knitting the knit-on part 2 A, while a half of it is knitted on knitting needles of the front bed and the other half of the knit-on part 2 A is knit on knitting needles of the rear bed. After knitting the leg 3 including the knit-on part 2 A, the knitting of the product will continue by knitting leg 3 including the knit-on part 3 A, while the leg 3 and the knit-on part 3 A are in fact a mirror display of the leg 2 with the knit-on part 2 A. After knitting both of the legs 2 , 3 including knit-on parts 2 A, 3 A knitting continues for example by knitting the knit-on part 1 A of the body part 1 using the knitting needles of the front bed, the border lines H 1 A of the knit-on part 1 A will be gradually connected with the part of the border lines H 2 A of the knit-on part 2 A and border lines H 3 A of the knit-on part 3 A, that were knitted on knitting needles of the front bed, while in this case, the border lines H 1 B of the knit-on part 1 B will be gradually connected with the part of the border lines H 2 A of the knit-on part 2 A and border lines H 3 A of the knit-on part 3 A, that were knitted by using the knitting needles of the rear needle bed. After knitting both of the knit-on parts 1 A and 1 B of the body part 1 and connection of border lines H 1 A and H 1 B with border lines H 2 A and H 3 A the body part 1 is to be knitted.
The procedure of manufacture of the seamless knitted product according to the invention, using the double-roll small-diameter knitting machine is shown in its individual stages in FIG. 10 , 11 and 12 . In this case, there starts simultaneous knitting of legs 2 , 3 from toes, by using rotation run of both of the needle rolls. After knitting the whole length of the legs 2 , 3 , the machine starts simultaneous knitting of both of the knit-on parts 2 A, 3 A by using reverse run of the needle rolls, similarly as in case of knitting the first gore of the heel in case of classic stockings. After finishing the knitting of knit-on parts 2 A, 3 A, the leg 3 is moved to the hollow of the leg 2 , but it remains on the knitting needles of the upper roll. The resulting mutual position of the legs 2 , 3 is shown in FIG. 11 . Then, there starts knitting of the knit-on part 1 B of the body part I by applying reverse run of the needle rolls, while one half of the knit-on part 1 B is knitted on the bottom needle roll and the other half of the knit-on part 1 B is knitted on the upper needle roll. Simultaneously, there are automatically knitted together the border lines H 1 B of the knit-on part 1 B with relevant border lines H 2 A, H 3 A of the knit-on parts 2 A, 3 A. Both created parts of knitted fabric are exhausted by air to the lower needle roll. FIG. 12 shows the body part 1 with appropriate knit-on parts 1 A, LB separated from both legs 2 , 3 , but only for a better idea. After finishing the knitting of the knit-on part 1 B the knit-on part 1 A will be knitted in a similar way, while in this case there will be gradually connected the border lines H 1 A with the remaining border lines H 2 A, H 3 A of the knit-on parts 2 A, 3 A. The last operation will include knitting of the body part 1 by return movement of both of the needle rolls. When knitting the body part 1 similarly as in case of knit-on parts 1 A, 1 B are—for one direction of needle roll turning—put into operation the knitting needles e.g. of the lower needle roll, while during opposite movement of the needle rolls, there are put into operation the knitting needles of the upper needle roll. The knitting yard or yards are periodically switched over between the lower and the upper needle roll.
As it has already been stressed out, the knitted product according to the invention has—in consideration of the hitherto status of technics—many new characteristics and advantages. The most important ones include mainly the fact that the knitted product is free of any seams created by a sewing machine and it has a perfect anatomic shape. Due to the fact of being seamless, the knitted product does not cause deformations of buttocks and it is practically invisible under the outwear. It is perfectly flexible as it is made only of knitted fabrics and it is possible to suitably combine the initial materials of different characteristics. The manufacturing process produces negligible volumes of waste, the production is characterised by high degree of automation, it is economic—mainly in case of using a special double-roll small-diameter knitting machine.
INDUSTRIAL APPLICABILITY
The invention is designed for knitting of such products as panties, slips, trousers and mainly tights.
|
Knitted products like slips, panties, trousers and mainly tights are closed in the crotch area (K) with at least a pair of opposed knitted-on elements ( 1 A, 1 B, 2 A, 3 A) passing to the crotch (K).
The product can be knitted from the border of the body part via at least a pair of knitted-on elements and up to the knitting of the parts for the legs or you can knit from the parts for legs via at least a pair of knitted-on parts and it is finished with a border in the body part.
| 3
|
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of priority from corresponding European Application Serial No. 01305212.1, filed Jun. 15, 2001.
1. Technical Field
The invention relates to a method and an apparatus for transmitting and receiving a plurality of individual tributary signals in multiplex form via a common line.
2. Background of the Invention
A data line can carry a plurality of signals originating from a plurality of individual sources. In practice, a plurality of signals of nominally the same frequency termed “tributary signals” are multiplexed and transmitted via the common line as a “compound signal”. The multiplexed signals are mapped into the compound signal that has a frame structure and is of a higher data rate than the sum of the tributary frequencies. The compound signal is received at the receiver and is demultiplexed. The individual tributary signals so obtained should be identical to the original tributary signals before being multiplexed at the transmitter. This means that the frequency of each demultiplexed tributary signal (“the recovered clock”) should be identical to the frequency of the original signal.
In order to adapt to the common data rate of the compound signal, additional bits are used. This offers the possibility to transmit initial tributary signals of somewhat different frequencies. Some of the additional bits are used to transmit control information needed for the rate adaptation of these tributary signals. Some of the additional bits can also be used to transmit some other additional information. The additional bits are put in a fixed position into the framed compound signal. Rate adaptation is made by a stuffing procedure. To that end, gaps are provided in fixed frame positions, wherein information data can be inserted, or which can be left empty. When the initial tributary frequency is lower than the nominal rate, these gaps remain empty (positive stuffing). When the initial tributary frequency is higher than the nominal rate, some of the bits are inserted in the empty positions (negative stuffing). The tributary signals which are adapted in rate, are multiplexed, that is, the bits or bytes of the signals are interleaved and transmitted to the receiver through the common line. For recovering the tributary signals at the receiver, the signals are demultiplexed. For recovering the frequency or clock, phase information transmitted with the compound signal is used, namely the phase difference between the compound signal and the tributary signal. This phase difference is transmitted in the gaps provided in the fixed frame positions and causes no significant harm. However, the stuffing information results in a rough quantization of the phase, which causes wander and jitter of the recovered frequency or clock.
SUMMARY OF THE INVENTION
Wander and jitter in a compound signal are reduced according to the principles of the invention. According to one illustrative embodiment, the phase difference between the compound signal and the tributary signal is accurately calculated in the transmitter. This calculated phase difference is coded preferably by a binary number and is transmitted in dedicated bytes of the compound line signal. In the receiver, the initial frequency of each tributary signal is recovered using the transmitted phase information. The accurate calculation of the phase difference is obtained by using an auxiliary clock at the transmitter. Furthermore, the mean value of the phase difference is calculated for a fixed time interval where the mean value is obtained by an integrator.
BRIEF DESCRIPTION OF THE DRAWING
A more complete understanding of the invention may be obtained from consideration of the following detailed description of the invention in conjunction with the drawing, with like elements referenced with like reference numerals, in which:
FIG. 1 is a block diagram of a transmitter according to an illustrative embodiment of the invention;
FIG. 2 is a block diagram of a synchronizer according to an illustrative embodiment of the invention;
FIG. 3 is a block diagram of a receiver according to an illustrative embodiment of the invention; and
FIG. 4 is a block diagram of a desynchronizer according to an illustrative embodiment of the invention.
DETAILED DESCRIPTION
FIG. 1 shows a transmitter for inputting four tributary signals 1 , 2 , 3 , 4 and outputting a line compound signal 5 which includes all data of the tributary signals and some control data and may have a frequency of 10 GHz, by way of example. Each tributary signal is delivered to a respective synchronizer 6 which prepares a rate adapted tributary signal 61 that is then interleaved by multiplexer 7 with the remaining rate adapted tributary signals 62 , 63 , and 64 . Multiplexer 7 composes the data of the tributary signals 61 to 64 and delivers such composed signal to a frame constructor 8 which finally outputs the line compound signal via line 5 . The frame constructor is controlled by a frame counter 9 and a system clock 10 having the frequency of the line compound signal. The system clock 10 is also delivered to the frame counter 9 and a phase-locked loop 11 , which outputs an internally generated auxiliary clock. The output of the phase-locked loop 11 and a further auxiliary clock 12 are delivered to a gate 13 so that the auxiliary clock 12 can be made effective for each of synchronizers 6 . The auxiliary clock 12 is an uncorrelated cycle to the writing cycle and the reading cycle and is used to obtain a higher resolution of the phase difference between signals.
Cycle adaptation, which is aimed at, makes it necessary to use a plurality of gate functions. For this reason, cycle adaptation is realized in CMOS technology, which allows a relative low frequency of 78 MHz, by way of example only (in relation to 10 GHz of the compound signal 5 ). Therefore, the serial data are transformed to parallel data and are written with this low frequency into a memory and read out with a similar low frequency from the memory.
FIG. 2 shows particulars of each synchronizer 6 . Input data from one of the tributary signals 1 through 4 is delivered to a FIFO register 14 , which is controlled by a write counter 15 and a read counter 16 . The write counter 15 is operated by a write clock 12 a and receives the numbers of the bits in the tributary signal via line 9 a . The read counter 16 is operated by a read clock 12 b and receives the number of the bits from the compound signal through line 9 b . The register 14 is an elastic store which provides write-in positions (write address) for the data bits of the respective tributary signals 1 to 4 , and read-out positions (read address) for reading out these data bits together with bit gaps as provided by the frame structure of the compound signal. A phase difference unit 17 is provided which, by the operation of the write counter 15 and the read counter 16 , forms or calculates a phase difference between each tributary signal and the compound signal.
In detail, the phase difference is formed between write and read address of register 14 . The resolution obtained with this measurement corresponds to the cycle time of the writing cycle or the reading cycle, that is, phase difference measurement is made synchronously with one of these cycles. However, this resolution is not sufficient to fulfill the requirements as to jitter at the output of the tributary signal. Furthermore, the phase difference between write and read address is changing continuously, and measurement is only a rough quantization of this phase difference, This is the reason why the auxiliary clock 12 is used which is uncorrelated to the writing and reading cycle and allows measurement at fine stepped times. The auxiliary clock 12 drifts slowly so that, in a measuring period, the clock shifts through all possible positions during a cycle time period of the writing or reading cycle. Additionally an average value is formed for a defined measuring period which corresponds to the distance between two stuffing positions, e.g., the measured values are integrated across the measuring time. The average value obtained allows for one of the following decision stuffing positively, stuffing negatively, or no stuffing. Formation of such average value allows for calculating the influence of the gaps which, due to the frame construction, occur regularly.
The phase difference unit 17 makes a binary number from the average phase difference and delivers such coded phase information to a data output gate 18 . The coded phase information is also delivered to a stuff decision unit 19 which has outputs connected to the read counter 16 and the output data gate 18 .
The auxiliary clock 12 , with its portions write clock 12 a and read clock 12 b , allows the accurate calculation of the phase difference between the line signal 5 and the tributary signals 1 , 2 , 3 , and 4 , respectively. The phase difference unit 17 includes the integrator referred to above which, for a fixed time interval, forms the mean or average value of the phase difference that is the basis for calculating the phase difference between line signal and tributary signal.
FIG. 3 shows a receiver for four tributary data outputs 21 , 22 , 23 , 24 . These output lines 21 through 24 belong to respective desynchronizers 26 , which are connected to demultiplexer 27 . Demultiplexer 27 is controlled by a frame alignment circuit 28 , which is interconnected with a frame counter 29 . System clock 30 is connected to frame counter 29 and gate 25 , which is also connected to the frame alignment circuit through a recovered clock line 25 a . Gate 25 generates internally an auxiliary clock which is delivered to a phase-locked loop 31 which outputs to a gate 33 having a second input connected to a further auxiliary clock 32 . The gated auxiliary clock is also connected to each desynchronizer 26 .
Line 5 delivers the compound signal carrying the data of the tributary signals and also additional bits to the frame alignment circuit 28 which firstly outputs the data of the composed signal and secondly the recovered clock 25 a of the compound signal. The recovered clock 25 a is used in the frame counter 29 to decide when a frame begins and ends. Demultiplexer 27 receives the data of the composed signal 28 a and is controlled by the frame counter 29 so as to deliver the appropriate rate adapted data 71 to 74 to the respective desynchronizer 26 in the adapted rate. The auxiliary clock 32 is used to reconstruct the initial frequency or rate of the respective desynchronizer 26 so that each tributary data output 21 , 22 , 23 , or 24 has a frequency that is exactly the same as the initial frequency of the signal.
FIG. 4 shows a desynchronizer circuit 26 according to one illustrative embodiment. Data from demultiplexer 27 on line 27 a is received at FIFO register 34 , to which a write counter 35 and a read counter 36 as well as a phase difference unit 37 are connected. By way of example only, FIFO register 34 is an elastic store having write-in positions (write address) for the compound signal received, and read-out positions (read address) for the data bits of the respective tributary signals. Input line 27 a is also connected to a phase and stuff information unit 39 , which has a second input 29 a from compound signal frame counter 29 . Phase and stuff information unit 39 has a first output 39 a for delivering stuff information to the write counter 35 and a second output 39 b for delivering phase information to a summing member 40 which has a second input from the phase difference unit 37 . The output of summing member 40 is the input of the phase-locked loop 31 which includes a controller 41 , a numeric controlled oscillator 42 , a phase detector 43 , a filter 44 and a voltage-controlled oscillator 45 . The output of the voltage-controlled oscillator is the read clock 32 b and is also used as the tributary clock to an output data gate 38 .
The data of the composed signal reaching demultiplexer 27 from the frame alignment circuit 28 are demultiplexed, so that signals 71 to 74 containing the additional bits in an adapted rate are obtained in succession in the several desynchronizers 26 . Controlled by frame counter 29 , the additional bits in the compound signal are read out from the rate adapted data stream of the tributary signal 27 a into unit 39 , whereas all bits in the compound signal are written into elastic store 34 . The coded phase information taken up from unit 39 is used for an accurate calculation of the phase difference between the write and read address of the elastic store 34 . The whole phase difference is calculated in phase difference unit 37 .
The whole phase difference has several portions, including but not limited to: stuffing information (which is a rough quantization of the phase course, and is only transferred when a stuffing operation is actually made); synchronizer phase difference between write and read addresses (which has been calculated at the synchronizer and is transferred to the desynchronizer with specific bytes—this value is transferred regularly, one time per stuffing position independently from whether there is a stuffing operation, or not); and desynchronizer phase difference between write and read addresses (calculated at the desynchronizer as a mean or average value, in the same manner as at the synchronizer).
In one illustrative embodiment, the phase difference is represented by the addition of these portions and is added to the phase course of the system clock or cycle of the respective channel or tributary signal (when frame gaps removed) so as to yield the original phase course of the respective channel.
In detail, phase information as well as calculated phase difference is further processed for such clock recovery in the phase-locked loop 31 . The loop includes a numeric controlled oscillator 42 so that the output signal thereof takes the initial frequency of the respective tributary signal 1 , 2 , 3 , or 4 . The phase-locked loop 31 is responsive for delivering the clock with the correct phase relation. When recovering the clock on line 32 b , any phase deviation from the phase of an ideal clock of the same frequency is wander and jitter. Wander and jitter are kept low by the procedure described above, since the tributary clock on line 32 b is recovered from the clock of the demultiplexed signal from which the gaps contained in the compound signals have been removed by virtue of the phase-locked loop 31 . The additional bits in the regular gaps of the frame structure of the compound signal produce only low values of phase deviation since the phase-locked loop 31 has a low cut-off frequency. On the other hand, irregular gaps as occurring with stuffing produce irregular phase steps at the input of the phase-locked loop 31 . This will produce big phase changes at the output of the phase-locked loop. However, the transmitted phase difference is used when recovering the clock in the receiver so that the clock produced in the phase-locked loop 31 is a clock with the desired phase for each tributary signal. The phase at the output of summing member 40 contains no more irregular and big phase steps.
|
A method and apparatus are provided for transmitting and receiving a plurality of individual tributary signals in multiplex form via a common line. At the transmitting end, the tributary signals, each of which has a similar initial frequency, are converted into a compound signal having a frame structure with a common data rate. At the receiving end, each individual tributary signal is retrieved from the compound signal with its initial frequency. A phase information signal portion including a respective phase difference between each tributary signal and the compound signal is formed and inserted into the compound signal in the shape of respective coded bits. The initial frequency of each tributary signal is recovered from the phase information signal portion included in the respective coded bits belonging to the respective tributary signals.
| 7
|
FIELD OF THE INVENTION
This invention relates to methods and apparatus for producing hydrocarbon from boreholes drilled into earth formations. More particularly, the invention relates to techniques for well completion and production which employ the concept of reverse water coning in well boreholes to more efficiently produce hydrocarbons, and even more particularly, to such techniques employing in-situ gravity segregation (IGS), and employing only a single fluid conduit to conduct produced well fluids to the surface.
BACKGROUND OF THE INVENTION
Many oil and gas wells in the past have suffered from the physical phenomenon known as "water coning". This phenomenon can seriously affect the rate of hydrocarbon production in a well, even to the point of rendering a perfectly good well non-commercial to produce because of massive water cut or water to oil ratio in the produced well fluid. In water coning, there is a hydrocarbon bearing formation (oil or gas or both) without an impermeable barrier or layer of earth formation between the water and oil bearing layers. That is to say, there is an oil/water contact surface in the well. This situation is common even in the most prolific producing formations wherein an underlying "water drive" can be a main pressure source for hydrocarbon production. When hydrocarbon is withdrawn from the formation by perforations above the oil/water conduct the underlying water is drawn up into the void pore spaces by the viscous forces acting on the fluid. Water thus invades the hydrocarbon bearing portion of the formation, and can do this even up to and beyond level of the production perforations. This can severely impede the rate at which the hydrocarbon can thereafter be withdrawn from the production perforations. The local rise (near the perforations) in the oil/water contact surface has a conical shape, being highest near the borehole and tapering off away from the borehole, thus leading to the name "water coning".
In the prior art, it has been proposed to complete such a well so as to mitigate the effect of water coning by producing into the wellbore, a significant volume of water, drawn thereto by a second set of perforations in the well casing and located below the oil/water contact surface while concurrently producing hydrocarbon through perforations in the well casing above the oil/water contact surface. The water production below the oil/water contact surface has the effect of suppressing the creation of the water cone. This protects the hydrocarbon zone near the casing from being invaded by the underlying water. The downward viscous forces imposed on the formation fluid created by withdrawing water below the oil/water contact surface tend to balance the upward viscous forces created by withdrawing hydrocarbon from the formation above the oil/water contact surface. Hydrocarbons may therefore be withdrawn from the formation through the hydrocarbon production perforations at rates significantly greater than is possible under conditions where a water cone has invaded the hydrocarbon bearing formation. This technique has come to be known in the art as In-Situ Gravity Segregation or IGS.
The present invention, however, provides methods for well completion and production allowing the IGS technique to be practiced using a single string of production tubing and conventional artificial lifting technique. Also, using the techniques to the present invention it is possible to produce and induce different FBHP.sub.(oil) and FBHP.sub.(water) pressures and lift to the surface fluids from two perforated intervals having different bottom hole flowing pressure (BHFP's) while using only a single fluid conduit to the surface. This may be accomplished whether or not the upper set of perforations' BHFP is greater or less than the lower perforations' BHFP.
BRIEF DESCRIPTION OF THE INVENTION
Briefly the present invention comprises methods of well completion and production which employ the IGS technology and artificial lift while employing only a single production tubing string to the surface for both produced fluids. The well is cased and perforated above the oil/water contact and below the oil/water contact surfaces. The hydrocarbon zone is sealed internally in the well bore by packers or seals set above the production perforations and also below the oil/water contact surface. The packers or seals are penetrated by a single production tubing string having its lower end in the water zone and having tubing ports in the oil zone so that produced fluids from both zones may enter it. Artificial lifting apparatus such as ESP's, PCP's or gas lift valves are installed in the tubing string above the upper packer.
In the case where the FBHP requirement to prevent water coning is greater in the water zone, an orifice or choke, is employed in the tubing string penetrating into that zone to restrict water flow into the tubing. This increases the FBHP in the water zone. In the case where the FBHP must be greater in the hydrocarbon zone to prevent water coning, an orifice or choke is employed in the tubing ports entering from the hydrocarbon zone to restrict hydrocarbon flow into the tubing. This causes the FBHP in the hydrocarbon or oil zone to increase. The choke restrictions are chosen to give appropriate fluid flow from either zone to cause the IGS technique. Produced fluid entering the single tubing string in the desired preselected ratio is then conducted to the surface using artificial lifting means such as gas lift, ESP, PCP or rod pumps.
The invention may best be understood by reference to the following detailed description thereof, when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a producing well showing the effect of water coning is a well on gas lift.
FIG. 2 is a schematic diagram of a producing well applying the IGS technique using a rod pump to move water and flowing hydrocarbon into the annulus.
FIG. 3 is a schematic diagram of a producing well on gas lift showing the completion and production technique of the present invention applying the IGS technique where the water zone has a higher FBHP than the hydrocarbon zone.
FIG. 4 is a schematic diagram of a producing well on gas lift showing the completion and production technique of the present invention applying the IGS technique where the hydrocarbon zone has a higher FBHP than the water zone. And,
FIG. 5 is a schematic drawing showing a completion using a submersible electric pump to lift production fluids to the surface.
DETAILED DESCRIPTION OF THE INVENTION
Referring initially to FIG. 1, a schematic drawing of a well lifting produced fluid on gas lift and being affected by the phenomenon of "water coning" is illustrated. A well borehole 10 penetrates earth formations 11 and 12 with formation 12 being a highly permeable formation having a hydrocarbon zone 13 and a water zone 14. The borehole 10 is lined with a steel casing 15 terminated in a plug 17 below the producing zone 12 and having a set of perforations 16 therein which initially was placed above the oil/water contact surface 18 but which, as shown, has been affected by water coning. A production tubing string 19 extends from a packer 20 to the surface and is equipped with a plurality of gas lift valves 21. In gas lift, a source of compressed natural gas (not shown) introduces natural gas under pressure into the casing/tubing annulus 22 as shown. Gas lift valve 21 permits one way flow of the pressurized gas into the tubing string 19 where it interacts with fluids produced from the formation 12 into the borehole 10 via perforations 16. The compressed gas lightens the produced fluids stream reducing the density from that of the produced fluid. The formation pressure, normally not enough to lift the produced fluid to the surface, is able to lift the lighter fluid column to the surface because of its reduced density. At the surface, separators may separate the produced oil and water and recycle the produced gas.
In the well shown in FIG. 1 the hydrocarbon zone 13 has been produced at such a rate that viscous forces have acted on the oil/water contact surface 18, particularly in the volume of the formation 12 near the borehole 10. The oil/water contact surface 18 has been drawn upward by the viscous forces in the formation acting on it. This has formed the inverted cone shaped volume 23 or water cone. The water cone 23 has impinged on the perforations 16 producing an undesired water cut and seriously affecting the rate at which hydrocarbon can be withdrawn from the hydrocarbon zone 13.
To alleviate the problem of water coning the technique of In-Situ Gravity Segregation or IGS is illustrated in FIG. 2. In FIG. 2 the well borehole 30 penetrates earth formations 31 and 32. Formation 32 is a highly permeable formation having a hydrocarbon zone 33 and a water bearing zone 34 therein. A casing 35 is set and terminated it plug 47 and is perforated at 46 in the hydrocarbon zone and at 46A in the water zone.
A sucker rod pump assembly 51 is installed in the lower end of production tubing string 39 which terminates in packer or seal 40 set below the oil/water contact surface 48. A sucker rod string 52 extends to the surface inside tubing 39 where it is driven up and down in a reciprocating manner by conventional surface means (not shown). In the well of FIG. 2 the hydrocarbon zone 33 has sufficient pressure to produce hydrocarbons via perforations 46 into the casing/tubing annulus 52 where they are conducted to the surface. Water is produced at a comparable rate through water zone perforations 46A and pumped to the surface by rod pump assembly 51 in tubing string 39. The concurrent, but separate, production of water and oil leads to the suppression of the water cone 43 in the borehole vicinity. The suppressed water cone 43 does not impinge on the hydrocarbon zone perforations 46 and this leads to an increased rate of hydrocarbon production.
The production/completion technique of FIG. 2 may be used if either the water zone or the oil zone, or both, have sufficient pressure to lift fluids to the surface. If either zone does not, then an artificial lift means as shown in FIG. 2 (rod pump) can be employed in the tubing string while the pressured zone is produced in the casing/tubing annulus. If both zones required artificial lifting means, however, a second tubing string (or dual action pumping system) would have to be employed within the casing 35. This might not be feasible with conventional sized casing.
In the completion/production system of FIG. 3, methods according to the present invention are employed in a well, employing the IGS technique and artificial lifting in both the water and hydrocarbon zones where the FBHP is higher in the water zone than in the hydrocarbon zone, and only one tubing string is required.
The well borehole 130 again penetrates earth formations 131 and 132. Formation 132 is a highly permeable formation having a hydrocarbon zone 133 and a water zone 134. In this well it has been determined that due to formation characteristics that the water zone 134 must be restricted causing a higher pressure in water zone 134 than in the hydrocarbon zone 133 to balance reservoir forces to prevent water coning. However neither zone has a sufficient pressure to lift fluids to the surface. Casing 135 lines borehole 130 and is provided with a set of perforations 146 in the hydrocarbon zone 133 and a second set of perforations 146A in the water zone 134. Casing 135 terminates in plug 147. The water zone 134 and hydrocarbon zone 133 are isolated interior to the casing via packers 140, the lower packer, and 151, the upper packer. A production tubing string 139 extends to the surface and is provided with gas lift valves 121, as an artificial lifting source. Other artificial lifts such as pumps could be used if desired. Tubing string 139 terminates at its lower end penetrating packer 140 with an orifice plate 160. The size of the orifice in orifice plate 160 causes there to be a higher FBHP.sub.(water) pressure in the water zone thus restricting flow of water. Tubing string 139 is also provided with one or more tubing ports 139A in the interval adjacent the lower FBHP pressure hydrocarbon zone 133 which is isolated between packers 140 and 151. Pressurized compressed natural gas is introduced into the casing/tubing annulus 152 from a surface source (not shown). Gas lift valves 121 permit the one way flow of the pressurized gas into the tubing string 139 where it permeates the tubing string and lowers the density of the oil/water mixture entering the tubing via ports 139A and orifice plate 160. The formation pressure inside the tubing string is sufficient to lift the lowered density oil/water/gas fluid to the surface inside the tubing string 139.
The constriction of orifice plate 160 is chosen based on the pressure differential desired to be induced between zones 133 and 134, the formation permeability, and the viscosity of the crude in oil zone 133 to allow water production into perforations 146A at a rate to suppress any excess water cone 143. The oil/water interface 148 is kept below upper perforations 146 during production by this method.
Referring now to FIG. 4, methods of well completion and production according to the concepts of the present invention and employing the IGS technique issued in production from a well requiring a higher pressure (FBHP) in oil zone 233 than in water zone 234 to suppress water coning, while using only one tubing string on artificial lift for both produced hydrocarbon and water.
Well borehole 230 penetrates earth formations 231 and 232. Formation 232 is again a highly permeable formation having a hydrocarbon zone 233 and a water zone 234. In the well of FIG. 4 it has been determined that if hydrocarbon zone 233 must be restricted resulting in a higher pressure than that of water zone 234 (but neither zone have sufficient pressure to lift produced fluids to the surface without artificial lifting being used) then excess water coning into perforations 246 will be avoided. The borehole 230 is lined with a steel casing 235 terminated at its lower end by plug 247. The casing 235 has two sets of perforations therein, an upper set 246 into the oil or hydrocarbon zone 233 of highly permeable formation 232, and a lower set 246A into the water zone 234. The oil zone 233 and the water zone are isolated interior to casing 235 by a lower packer 240 and an upper packer 251. A tubing string 239 penetrates both packers 240 and 251 and terminates at lower packer 240 providing fluid communication from oil zone perforations 246A to production tubing 239. A tubing port 239A provides fluid communication into tubing string 239, via an orifice 260, with perforations 246 in the higher pressure oil zone 233. Pressurized compressed natural gas is introduced from a surface supply (not shown) into the casing/tubing annulus 252 at the surface. The gas lift valves 221 permit one way flow of gas from the annulus 252 into the interior of the tubing string 239 where it can interact with produced fluids from perforations 246A and 246 to form a reduced density oil/water/gas fluid in the tubing 239. This lower density fluid is lifted to the surface by the formation pressure of the oil zone 253 and water zone 234 which is sufficient for this purpose.
The constriction of orifice 260 is chosen based on the desired pressure differential between zones 233 and 234 to suppress water coning the permeability of the formation 232 and the viscosity of the oil in zone 233. The back pressure in the hydrocarbon zone 273 which is induced by orifice 260 allows sufficient water production into perforations 246A at a rate to suppress the water cone 243, hence applying the IGS technique principle. The oil/water interface 248 is kept below upper hydrocarbon producing perforations 246 during production by this method.
Referring now to FIG. 5 a well completion similar to that of FIG. 3 (higher desired FBHP in the water zone) is shown schematically. A well borehole 352 is cased with steel casing 335 and penetrates into a very permeable production interval 332 having an oil zone 333 and a water zone 334. In formation 332 it has been determined that it would be desirable to induce a higher FBHP in water zone 334 than in oil zone 333 to suppress water coning. The zones 333 and 334 are isolated interior to casing 335 by packer 351. The oil zone has perforation 346 and the water zone has perforation 346A. A tubing string 339 goes to the surface and has, near its lower end an electric pump comprising pump body 341 and motor 340. Fluid ports 339B above packer 351 draw in oil while water enters the lower end of tubing string 339 via a variable orifice 360. Variable orifice 360 may be of the type hydraulically or electrically controlled from the surface. The size of orifice 360 is adjusted and selected to provide the desired induced FBHP differential between the oil zone 333 and the water zone 334 to suppress the undesired water coning. Alternatively, a fixed size orifice could be used, if desired.
The foregoing descriptions may make other techniques and configurations apparent to those of skill in the art. For example, in each of the completions shown other artificial lifting techniques rather than gas lift or ESP's could be applied to lift the fluid in the tubing. The aim of the appended claims is to cover all such changes and modifications that fall within the true spirit and scope of the invention.
|
Methods for completing and producing hydrocarbon from a well having a highly permeable production formation having a water zone and a hydrocarbon zone are disclosed. In the disclosed techniques a cased well borehole is cemented in place through the production formation. A packer is set in the casing to isolate the hydrocarbon zone from the water zone. Perforations in the water zone and in the hydrocarbon zone produce a mixture of both fluids into the casing/tubing annulus at different bottom hole pressures (FBHP's) due to the installation of a flow restriction limiting the flow of either hydrocarbon or water into the tubing string. Artificial lift means are used to produce the fluid mixture to the surface.
| 4
|
RELATED APPLICATIONS
The present application claims priority to Japanese Application Number 2014-216252, filed Oct. 23, 2014, the disclosure of which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an injection molding system configured to perform a set of work of inspecting, classifying, and packing the molded item fallen freely from a molding device continuously and in short time.
2. Description of the Related Art
The present invention relates to an injection molding system configured to perform a set of work of inspecting, classifying, and packing the molded item fallen freely from a molding device continuously and in short time.
In molding by an injection molding machine, there is a case in which a molded item is made to fall to a box for reducing cycle time. The molded item in the box is sent to inspection process and inspected whether the item is defective or not by an image processing inspection device. At the inspection, the molded items loaded in bulk need to be set on the image processing inspection device one by one, requiring man hours.
When the molded item is inspected by the image processing inspection device, it is necessary to inspect portions liable to crack or have burring, but there is a case in which the portions can be inspected only at specified angle based on the place of the portions.
A technique disclosed in Japanese Patent Laid-Open No. 2013-24852 performs inspection more simply an less expensively by showing a face of a workpiece to be inspected by an articulated robot. The articulated robot releases the workpiece in non defective item chute when the item is non defective, and releases the item in defective item chute when the item is defective.
In a technique disclosed in Japanese Patent Laid-Open No. 9-123232, a plurality of molded items simultaneously molded by a mold are grasped and taken out by a plurality of grasping units of a take-out hand, arranged at targeted molded item pitch during conveyance, and sent to the next process.
Though effective inspection process is proposed in Japanese Patent Laid-Open No. 9-123232, a processing line includes not only the inspection process but also molding process, packing process, and the like before or after the inspection process. Therefore, it is necessary to reduce the total time throughout the all processes.
In a technique disclosed in Japanese Patent Laid-Open No. 9-123232, since the molded items are taken out by take-out units, time for the take-out unit to move in the mold is required. In addition to that, a large sized hand equipped with a movement mechanism of the molded item is required and time is taken for the taking out of the molded item.
SUMMARY OF THE INVENTION
An injection molding system according to the present invention is one for making a molded item freely fall in demolding process from a mold, the injection molding system including a molded item photographing device for capturing image of the molded item fallen freely, an image analysis device configured to perform image analysis of the image photographed by the molded item photographing device, and a molded item classification device configured to classify the molded item to one of a plurality of predetermined regions based on result of the image analysis, wherein the image analysis device is configured to perform analysis of appearance feature of the molded item, and make the item classification unit classify the molded item based on result of the analysis.
The molded item photographing device may be fixed to the molded item classification unit.
The molded item photographing device may be fixed and configured to photograph free fall region of the molded item falling freely.
The injection molding system according may include, a first molded item photographing device for capturing image of the molded item fallen freely and determining position of the molded item, a second molded item photographing device for photographing the molded item to analyze image of the molded item, and a molded item movement device configured to grasp the molded item at the position of the molded item determined by the first molded item photographing device and move the molded item to photographing position for photographing the molded item by the second molded item photographing device, wherein the image analysis unit is configured to analyze the image photographed by the second molded item photographing device.
The first molded item photographing unit may be fixed to the molded item movement device.
The second molded item photographing unit may photograph free fall region of the molded item.
The appearance feature of the molded item may include at least one of, whether presence of defective part in molding, cavity number transcribed to the molded item, configuration of the molded item, and color of the molded item.
At least one of the plurality of predetermined regions may be a region on a molded item conveyer.
At least one of the plurality of predetermined regions may be a region in a storing box or in a storing vessel for containing the molded item.
The molded item classification device may align the molded item at the predetermined region.
The molded item classification device and the molded item movement device may be the same device.
The injection molding system according may further includes a communication unit configured to output the result of analysis of the image analysis device, wherein result of analysis or result of classification is configured to be input to production management process data of the injection molding system.
The present invention, with the above configuration, can provide an injection molding system with reduced cycle time by performing a set of work of inspecting, classifying, and packing of the molded item fallen freely from the molding device continuously and in short time.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-described object, the other object, and the feature of the invention will be proved from the description of embodiments below with reference to the accompanying drawings. In these drawings:
FIG. 1 is a top view of an injection molding system.
FIG. 2 is a front view of an injection molding system.
FIGS. 3A and 3B are diagrams illustrating classification and alignment of a molded item.
FIG. 4 is a view illustrating a parallel link robot to which an image processing inspection camera is fixed
FIG. 5 is a diagram illustrating production management process data of an injection molding machine of classification and alignment of a molded item shown in FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1, 2 are a schematic diagram of an injection molding system according to the present invention. The injection molding system consists of an injection molding machine 1 , a mold 2 , a conveyer 3 , a position determination camera 4 , a parallel link robot 5 , an image processing inspection camera 6 , a non defective item packing box 7 , a defective item packing box 8 , and a stand 9 .
The parallel link robot 5 works as a molded item movement device, a molded item classification device, and an image analysis device. The image processing inspection camera 6 corresponds to the molded item photographing device in claim 1 , and the second molded item photographing device in claim 4 . The position determination camera 4 corresponds to the first molded item photographing device in claim 4 .
A molded item 10 molded in the mold 2 of the injection molding machine 1 is demolded by ejection by an ejector not shown in the figure, to fall on the conveyer 3 installed below the mold 2 , after the stationary mold 2 a and a movable mold 2 b are opened. At the falling, position and direction of the molded item are random. After the position determination camera 4 detects the molded item 10 conveyed by the conveyer 3 , the parallel link robot 5 grasps the molded item. The parallel link robot 5 shows the grasped molded item 10 to the image processing inspection camera 6 , and packs the molded item 10 in the non defective item packing box 7 when the molded item is a non defective item, and releases the molded item 10 in the defective item packing box 8 when the molded item is a defective item, as shown in FIG. 3 . The parallel link robot 5 turns the molded item 10 such that the molded item 10 can be contained in a partitioned space in the non defective packing box 7 , before the parallel link robot 5 packs the molded item 10 in the non defective packing box 7 .
Cavity number is usually stamped on the molded item, and the molded item is usually managed according to a cavity, since it can be determined to which molded item is defective when the defective items are generated by a specific mold core which is damaged. Therefore, the cavity number of the molded item 10 is determined when the position determination unit 4 photographs the molded item 10 , and the parallel link robot 5 packs the molded item 10 in each region corresponding to each cavity number. In FIG. 3 , rows corresponding to each cavity number are provided in the non defective item packing box 7 , and the molded item in the first cavity is packed in a row of the first cavity. Similarly, the molded item in the second cavity is packed in a row of the second cavity, the molded item in the third cavity is packed in a row of the third cavity, and the molded item in the fourth cavity is packed in a row of the fourth cavity.
As mentioned above, in the present embodiment, a set of work of inspecting, classifying, and packing the molded item fallen freely from the molding device can be performed continuously and in short time.
In the present embodiment, the molded item is classified based on the presence of a defective part in molding and the cavity number transcribed to the molded item 10 , but molded item identification number, configuration of the molded item, color of the molded item may be used for the classification.
In the present embodiment, the molded item is packed in the packing box, but the molded item may be aligned on a palette or a conveyer.
The conveyer 3 may be moved in constant speed or by pitch feeding. When the conveyer 3 is moved in constant speed, movement distance of the molded item during time from when the position determination camera 4 photographs to when the parallel link robot 5 grasps the molded item is corrected using an encoder or calculation based on speed of the conveyer. When the conveyer 3 is moved by pitch feeding, the conveyer 3 is moved for a fixed distance after all molded items 10 in a range photographed by the position determination camera 4 .
A plurality of parallel link robots may be used as a molded item movement device. A plurality of parallel link robots may be used for each of the molded item movement device and the molded item classification device.
The molded item movement device may be a parallel link robot or an articulated robot. The image processing inspection camera 6 may be fixed such that the image processing inspection camera 6 can photograph the free fall region where the molded item freely falls. More specifically, the molded item may be fallen to, for example, a saucer instead of the conveyer 3 , and the robot may grasp the itemed item on the saucer.
The image processing inspection camera 6 may be fixed to the parallel link robot 5 as shown in FIG. 4 . Operation of the parallel link robot 5 to grasp the molded item 10 and show the molded item 10 to the image processing inspection camera 6 can be omitted, thus the cycle time can be reduced.
When the image processing inspection camera 6 determines that the molded item 10 is defective, the image processing inspection camera 6 transmits the information to the injection molding device 1 . As shown in FIG. 5 , the injection molding machine 1 stores data of shot number at which the molded item is defective as production management process data. The operator can easily grasp in what molding condition the defective item generates.
A bucket may be set on the conveyer 3 for precisely determining the shot number of the molded item the image analysis device analyzing the image thereof, and the conveyer may be fed at each shot time for a pitch of the bucket. The molded items for a shot fall from the mold to one bucket, thus the molded items of the first shot, those of the second shot, those of the third shot, and so on are conveyed to the image processing inspection camera 6 .
|
An injection molding system for making a molded item freely fall in demolding process from a mold, the injection molding system comprising:
a molded item photographing device, an image analysis device, and a molded item classification device, wherein the image analysis device is configured to perform analysis of appearance feature of the molded item, and make the item classification unit classify the molded item based on result of the analysis.
| 1
|
FIELD OF THE INVENTION
The present invention is directed to a method and apparatus for separating fluids having different specific gravities, and is more specifically directed to fluid separators employing axial flow-type pumps.
BACKGROUND OF THE INVENTION
Millions of gallons of diesel fuel and jet fuel are transported by ships to various parts of the world for refueling of planes at sea and for delivery to ports. These transport ships contain many compartments for holding the diesel and jet fuel. While the fuels are in these compartments, they may become contaminated with water. However, fuel contaminated with water is unsuitable for use. Thus, at the point of delivery, any fuel contaminated with water will be rejected, and must be returned to the point from which it was shipped for refinement. The retransportation and refinement of the fuel is both costly and time consuming.
It is a purpose of my invention to provide a method and apparatus for separating fluids having different specific gravities, and more specifically, for separating water from an oil such as jet or diesel fuel, and which is adaptable for use in the removal of the contaminating water at the point of delivery.
Tubular centrifugal separators for the separation of immiscible fluids of different specific gravities are well know. These centrifugal separators employ a rotor carrying blades for rotating the mixture of fluids, causing the fluid having the lighter specific gravity to migrate to the center of the rotating mass, and the fluid having the heavier specific gravity to migrate to the perimeter, where it can be extracted. Examples of such centrifugal separators are disclosed in U.S. Pat. No. 4,478,712 to Arnaudeau, U.S. Pat. No. 3,517,821 to Monson et al., German patent No. 1,186,412 to Groppel, and Swiss patent No. 563,186 to Reynolds. Flow pumps and blowers built on the same general principle are disclosed in U.S. Pat. No. 1,071,042 to Fuller and U.S. Pat. No. 3,083,893 to Dean, respectively, and in my U.S. Pat. Nos. 3,276,382, 3,786,996, and 3,810,635.
However, none of these devices provides a sufficiently great G-force to create a well-defined boundary between the fluids as they separate under centrifugal force, e.g. by compressing the fluid having the lighter specific gravity to a tight core in the center of a tube of the fluid having the heavier specific gravity, whereby the fluid having the heavier specific gravity can be drawn off in a single pass without the need for additional treatment of the fluid having the lighter specific gravity. Further, none of these devices provides an adjustable mechanism for drawing off the fluid having the heavier specific gravity. It is the solution of these problems to which the present invention is directed.
SUMMARY OF THE INVENTION
Therefore, it is the primary object of this invention to provide a method and apparatus for separating immiscible fluids having different specific gravities which greatly increases the gravitational force acting on the fluids by accelerating the swirl velocity of the fluids and maintaining a high volume flow.
It is another object of this invention to provide a method and apparatus for separating immiscible fluids having different specific gravities at the point of delivery of the fluids.
It is still another object of this invention to provide a method and apparatus capable of separating immiscible fluids having different specific gravities with only one treatment stage.
The foregoing and other objects of the invention are achieved by provision of an axial flow-type pump for separating immiscible fluids having different specific gravities and a discharge manifold fluid connected to the fluid pump for drawing of the fluid having the heavier specific gravity. The fluid pump employs a rotatable impeller mechanism having a hollow core and a decreasing axial pitch in the direction of fluid flow. The fluid interface between the pump and the discharge manifold is adjustable, so that the discharge of the fluid having the heavier specific gravity can be adjusted.
The method according to the invention comprises introducing the fluids into the inlet end of a rotatable impeller in accordance with the invention, to produce a high velocity swirling action in the fluids and a low pressure area along the longitudinal axis of the flow line, to generate a high centrifugal force as the fluids move axially, thereby throwing the fluid having the heavier specific gravity to the perimeter, and using a discharge manifold in accordance with the invention to draw off the fluid having a heavier specific gravity.
A better understanding of the disclosed embodiments of the invention will be achieved when the accompanying detailed description is considered in conjunction with the appended drawings in which like reference numerals are used for the same parts as illustrated in the different figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a fluid axial flow type pump and discharge manifold in accordance with the present invention;
FIG. 2 is a rear elevational view of the pump of FIG. 1;
FIG. 3 is a right side elevational view of the pump of FIG. 1;
FIG. 4 is a top plan view of the pump of FIG. 1; and
FIG. 5 is a partial cross-sectional view of the pump and discharge manifold of FIG. 1, showing the fluid vortex created by the pump and the manner in which the fluid having a heavier specific gravity is drawn off at the discharge manifold.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1-5, there is illustrated an embodiment of apparatus for separating immiscible fluids having specific gravities in accordance with the invention, generally designated by the reference numeral 10.
Separator 10 comprises a fluid flow device 100 of the axial pump type, a discharge manifold 200, and an upstream discharge conduit 300 fluid connecting fluid flow device 100 and discharge manifold 200. Discharge manifold 200 can be fluid connected to a downstream discharge conduit 400 for carrying the fluid having the lighter specific gravity. As illustrated in FIG. 1, axial pump 100 comprises fluid passage means such as a rotatable cylindrical drum or conduit 110 mounted for rotation in a housing 120 and having an inlet 122 and an outlet 124. Drum 110 provides a passage-way for the fluids.
Drum 110 is provided with an impeller or rotor 130 comprising a pair of helical blades 140 formed integrally with drum 110 to rotate with drum 110. The use of two blades, rather than three or more, is preferred, two blades produce less turbulence and less surface resistance than three or more blades, yet can supply the same amount of volume as three or more blades, but with added swirl velocity.
Blades 140 extend radially inwardly short of the longitudinal axis of drum 110 to provide or define an axial hollow core or opening 150. As blades 140 rotate, core 150 will initiate a low pressure area in the center of the flow line, with the high velocity, higher specific gravity fluid on the outer perimeter, as shown with respect to water W in FIG. 5, to provide an inherent separation of the fluids. Where the lower specific gravity fluid comprises the primary fluid, and the higher specific gravity fluid comprises a small amount of fluid contaminant, for example in the case of fuel contaminated by water, the lower specific gravity fluid will occupy the whole flow line, as does fuel F in FIG. 5. However, where the higher specific gravity fluid comprises the primary fluid, the lower specific gravity fluid will migrate to the center by the low pressure generated by hollow core 150, as shown in dotted lines designated L, again providing an inherent separation of the fluids.
Blades 140 have a higher axial pitch at their inlet ends 152 which is gradually reduced to a smaller axial pitch at their outlet ends 154. Preferably, blades 140 have an axial pitch of approximately ten inches at their inlet ends 152 and an axial pitch of approximately five inches at their outlet ends 154. Although these axial pitches will provide the desired volume and swirl velocity, they can be varied without departing from the spirit of the invention.
Blades 140 will supply a flow volume of ten inch axial pitch, and as the helical pitch reduces to five inches, the swirl velocity increases greatly to provide a tight swirling axial movement of the fluids. With the reduction in pitch of blades 140, the swirl velocity and the centrifugal force are both doubled in comparison to blades of uniform pitch. Blades 140 produce approximately 672 G's, in comparison with three blades of uniform pitch, which produce approximately 336 G's.
Because of their configuration, each of blades 140 is in contact with the fluids for a complete revolution. Continuous contact with the fluids for one complete revolution is necessary to change the swirl velocity and provide a smooth transition from low to high centrifugal action. Blades 140 also create less turbulence than, for example, three or more short impeller blades would. This is a great advantage when one of the fluids is oil or another liquid which is easily emulsified, as the reduced turbulence will prevent emulsification.
Axial pumps such as pump 100 are normally powered and require a suitable power source such as a motor (not shown) for rotating an input shaft 160 drivingly connected to gearing 170. Suitable bearing means 180 must be employed for axially positioning and rotatably supporting drum 110 within housing 120. A detailed description of the structure associated with the drive mechanism for pump 100 can be found in my U.S. Pat. Nos. 3,786,996 and 3,810,635, which are specifically incorporated herein by reference, and made a part hereof as though reproduced herein, with respect to their descriptions of the structure associated with the drive mechanism for a pump.
Upstream discharge conduit 300 has an inlet end 310 and an outlet end 312. Inlet end 310 can be fluid connected by conventional means to the tank or other container holding the fluids to be separated, at the point of delivery of the fluids. Drum 110 is conventionally fluid connected at its outlet end 154 to the inlet end 310 of upstream discharge conduit 300. Outlet end 312 tapers outwardly, that is, its outer edge 314 tapers outwardly in the downstream direction from the inner surface 320 to the outer surface 322 of upstream discharge conduit 300, for a purpose to be described hereinafter. The angle of the taper, that is, the angle between edge 314 and outer surface 322 preferably is approximately 12°, to obtain optimum results.
Discharge manifold 200 comprises an axially movable conduit section 210 having substantially the same inner diameter as drum 110, and having an inlet end 212 and an outlet end 214. An upstream sealing ring 220 is affixed to conduit section 210 for sealingly connecting conduit section 210 at its inlet end 212 to the outlet end 312 of upstream discharge conduit 300, and permitting relative axial movement of conduit section 210 and upstream discharge conduit 300.
Inlet end 212 tapers outwardly, i.e., its outer edge 230 tapers outwardly in a downstream direction from the inner surface 232 to the outer surface 234 of conduit section 210 for mating engagement with tapered outer edge 314 of upstream discharge conduit 300. For this purpose, the angle formed between outer edge 230 and inner surface 232 of conduit section 210 is substantially the same as the angle formed between outer edge 314 and outer surface 322 of upstream discharge conduit 300.
An adjustment assembly 240 is provided for moving conduit section 210 into and out of engagement with outlet end 312 of upstream discharge conduit 300 for respectively closing and opening discharge manifold 200.
Adjustment assembly 240 comprises a platform 250 extending over upstream sealing ring 220 and fixed to discharge manifold 200 upstream of outlet end 312 of upstream sealing ring 220. An operating handle 252 is provided for operating discharge manifold 200. Handle 252 has a distal end 254 extending outwardly from platform 250 and a proximal end 256 by which it is pivotally mounted to platform 250. A link 260 is pivotally mounted at one end to moveable conduit section 210 and pivotally mounted at the other end to proximal end 256 of handle 250 through a slot (not shown) in platform 250. As handle 252 is pivoted, its motion is transmitted to movable conduit section 210 through link 260. Thus, when handle 252 is pivoted towards upstream discharge conduit 300, movable conduit section 210 moves away from upstream discharge conduit 300 to open discharge manifold 200; and when handle 252 is rotated away from upstream discharge conduit 300, movable conduit section 210 moves away from upstream discharge conduit 300 to close discharge manifold 200, and upstream discharge conduit 300 Movable conduit section 210 can be fully engaged, fully disengaged, or any position in between, depending upon the amount handle 252 is rotated. A gauge (not shown) can be provided on platform 250 (e.g. at the slot) to indicate by the position of handle 252 what percentage discharge manifold 200 is open.
Platform 250 has an upstream end 262 and a downstream end 264. A first block 270 joins upstream end 262 to upstream discharge conduit 300 and also acts as a stop for discharge manifold 200 in it full closed position. A second block 272 extends downwardly from downstream end 264 of platform 250 and acts as a stop for discharge manifold 200 in the full open position.
Upstream sealing ring 220 has an upstream end 274 and a downstream end 276. Upstream end 274 slidably engages outlet end 312 of upstream discharge conduit 300. Downstream end 276 is fixed to inlet end 212 of moveable 10 conduit section 210 upstream of link 260, e.g., by a weld 278.
A pair of O-ring seals 280 is provided in a pair of circumferential channels 282 formed in upstream sealing ring 220 adjacent its upstream end 274 to provide a fluid seal between upstream sealing ring 220 and upstream discharge conduit 300 as upstream end 274 of upstream sealing ring 220 slides relative to outlet end 312 of upstream discharge conduit 300. A circumferential discharge channel 290 is provided in upstream sealing ring 220 at its downstream end 276 immediately adjacent the termination of the taper in edge 314 of upstream discharge conduit 300 to receive the fluid of lighter specific gravity circulating adjacent inner surface 320 of upstream discharge conduit 300 when discharge manifold 200 is open. A discharge port 292 opens into discharge channel 290 for receiving and discharging water from discharge channel 290.
Movable conduit section 210 is sealingly connected at its outlet end 214 to downstream discharge conduit 400 by a downstream sealing ring 500. Downstream sealing ring 500 has an upstream end 510 which slidingly engages outlet end 214 of movable conduit section 210, and a downstream end 520 which is fixed to inlet end 410 of downstream discharge conduit 400, e.g., by a weld 522.
A pair of O-ring seals 530 is provided in a pair of circumferential channels 540 formed in upstream end 510 of downstream sealing ring 500 to provide a fluid seal between downstream sealing ring 500 and movable conduit section 210 as upstream end 510 of downstream sealing ring 500 slides relative to outlet end 214 of movable conduit section 210.
Referring now to FIGS. 1 and 5, the operation of the invention will now be described with reference of the delivery of diesel or jet fuel from a transport ship, which fuel has been contaminated by sea water. However, it should be understood that application of the invention is not limited to the separation of water and fuel or to use in the context of fuel transport ships, but can be used for the separation of any two fluids having different specific gravities, e.g. oil and water where water is the primary fluid, sludge and treated water in a water purification system, or in reverse osmosis.
In operation, the fluids in their unseparated state are fed into inlet 122 of drum 110 using conventional means. As blades 140 rotate, the water W (which has a heavier specific gravity) swirls in a vortex adjacent the inner surface 320 of upstream discharge conduit 300. The fuel F, as the primary fluid, occupies the entire flow line. It is noted that, if the water W were the primary fluid, the water W would still migrate to the perimeter, but the low pressure initiated by hollow core 150 would cause the fuel F (which has a lighter specific gravity) to be compressed into a tight core around the axis of upstream discharge conduit 300, as shown in dotted lines in FIG. 5. However, if the water W were the primary fluid, then discharge manifold 200 would be replaced by a different discharge manifold, which does not constitute a part of this invention.
With discharge manifold 200 in the full open position as shown in FIG. 5, the water W will flow between edge 314 of upstream discharge conduit 300 and edge 216 of movable conduit section 210 into discharge channel 290, and out through discharge port 292. The fuel F, separated from the water W, will continue to flow through discharge manifold 200 and out through downstream discharge conduit 400 to its destination.
Thus, it will be seen that the present invention provides a unique method for separating immiscible fluids having different specific gravities. While a preferred embodiment of the invention has been disclosed, it should be understood that the spirit and scope of the invention are to be limited solely by the appended claims, since numerous modifications of the disclosed embodiment will undoubtedly occur to those of skill in the art.
|
An axial flow-type pump for separating immiscible fluids having different specific gravities and a discharge manifold fluid connected to the fluid pump for drawing of the fluid having the heavier specific gravity. The fluid pump employs a rotatable impeller mechanism having a hollow core and a decreasing axial pitch in the direction of fluid flow. The fluid interface between the pump and the discharge manifold is adjustable, so that the discharge of the fluid having the heavier specific gravity can be adjusted. The fluids are introduced into the inlet end of the rotatable impeller to produce a high velocity swirling action in the fluids and a low pressure area along the longitudinal axis of the flow line, to generate a high centrifugal force as the fluids move axially and cause the fluid having the heavier specific gravity to migrate to the perimeter. The discharge manifold is then used to draw off the fluid having a heavier specific gravity.
| 8
|
RELATED APPLICATIONS
[0001] This application claims priority from co-pending U.S. Provisional Application No. 60/688,184, filed Jun. 7, 2005, the full disclosure of which is hereby incorporated by reference herein
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to wellbore completion operations. More specifically, the present invention relates to an apparatus and method for isolating wellbore pressure during tool removal.
[0004] 2. Description of Related Art
[0005] Certain devices known as downhole tools 12 are inserted into a wellbore 5 for various reasons relating to exploration, completion, and production of a wellbore 5 . These tools include imaging devices, retrieval tools, and perforating guns, to name but a few. As is known, these tools are often inserted into the wellbore 5 under pressure. That is the pressure within the wellbore 5 might far exceed the ambient pressure at the surface. Thus, for safety concerns, the differential between the wellbore pressure and the surface pressure must be maintained when inserting or removing downhole tools 12 from the wellbore 5 . In order to maintain this pressure differential between pressurized wellbores and the surface, devices known as “lubricators” are often employed to seal around the inserted tool and prevent pressure leakage from the wellbore.
[0006] A lubricator is typically comprised of one or more tubular members that form a sealed chamber around a downhole tool. The lubricator is usually attached to a pressure containment spool, such as a valve or blowout preventer at the top of the wellhead. At an upper end of the lubricator, sealing equipment such as a grease injector and/or a stuffing box seals the top of the lubricator, while permitting the downhole tool to be suspended by a downhole tool insertion string, a wireline for example, that extends through the sealing equipment. Thus, a sealed chamber is provided within the lubricator above a closure mechanism of the pressure containment spool e.g. blow out preventer (BOP) or a Christmas Tree. The sealed chamber houses the downhole tool and contains well pressure while the downhole tool is inserted into the wellbore. Pressure between the wellbore and the lubricator is equalized using an equalizer valve or other means by which the pressure above the pressure barrier (e.g. the BOP or Christmas Tree) can be equalized to that below. The closure mechanism of the pressure containment spool is then opened, allowing access to the wellbore. The downhole tool 12 is lowered into the wellbore by manipulating the downhole tool insertion string.
[0007] In many instances however, the length of the downhole tool 12 far exceeds that of currently available lubricators. Optionally a valve can be situated within the wellbore 5 to act as a means by which the surface can be isolated from the pressure in the wellbore below the valve. Once the valve is shut, the region above the isolation is bled to atmosphere and the tool 12 is removed from within the wellbore 5 . If the isolation valve is not operating properly, this can expose the surface personnel to the possible dangers of full wellbore pressure. Therefore, there exists a need for a method and device capable of safely isolating wellbore pressure from surface pressure that can perform this function during deployment and retrieval of downhole tools.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention includes an isolation system comprising a wellbore tubular, a containment zone disposed within the tubular, an upper isolation valve adjacent the containment zone, a lower isolation valve adjacent the containment zone, a pressure source in communication with said containment zone, and a pressure monitor in communication with the containment zone. The isolation system can further comprise remotely controlled actuators in mechanical cooperation with the upper and lower isolation valves. The upper and lower isolation valves of the isolation system can be ball valves, globe valves, gate valves, slide valves, and butterfly valves.
[0009] The isolation system can also include a downhole tool trap. The downhole tool trap can be positioned above the upper isolation valve and comprise a hinged flap. The hinged flap can be selectively placed in a stopping position and in a resting position.
[0010] Disclosed herein is also a method of forming a pressure differential within a wellbore comprising, forming a containment zone within the wellbore, creating a pressure seal along the containment zone, venting the region of the wellbore above the containment zone, and verifying the integrity of the pressure seal along the containment zone.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0011] FIG. 1 depicts a side cross sectional view of prior art manner of isolating wellbore pressure.
[0012] FIG. 2 illustrates a side view of an embodiment of an isolation device.
[0013] FIG. 3 portrays a side view of an embodiment of an isolation device within a wellbore.
[0014] FIG. 4 illustrates a cutaway view of an embodiment of a tool catcher.
[0015] FIG. 5 illustrates a cutaway view of an embodiment of a tool catcher restraining a tool.
[0016] FIG. 6 a demonstrates an overhead view of an embodiment of catcher flap of a tool catcher.
[0017] FIG. 6 b depicts a cutaway view of an embodiment of catcher flap of a tool catcher.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The device and method of the present disclosure provides an isolation system capable of isolating the upper portion of a wellbore 5 from the portion below the isolation system 20 . With reference now to FIG. 2 , one embodiment of the pressure isolation system 20 is shown in a side view. The isolation system 20 comprises a tubular, such as tubing 18 , an upper isolation valve 22 with actuator 23 , a lower isolation valve 24 with actuator 25 , a fluid supply port 30 , and pressure probe 32 . It should be pointed out that the tubular can comprise production tubing as shown, but can also be casing or a portion of a production string.
[0019] The valves ( 22 , 24 ) are integral with the tubular as shown and vertically spaced apart along the length of the tubular. The distance between these valves ( 22 , 24 ) is not important; the valves can be integrated into a single assembly or separated as far apart as required for the particular application. As will be described in more detail below, some advantages exist in maintaining a smaller displacement between the upper and lower isolation valves ( 22 , 24 ). The valves can be opened or closed by the actuators ( 23 , 25 ), the operation of the valve actuators ( 23 , 25 ) can hydraulic, pneumatic, or via telemetry. When fluids are utilized in operating the actuators ( 23 , 25 ) operation is provided via the respective actuation control lines ( 34 , 36 ). The control lines are shown to illustrate their function other systems may be employed to operate the actuators ( 23 , 25 ). For example, sequencing valves and other systems may be used thereby allowing the number of control lines ( 34 , 36 ) to be reduced.
[0020] The placement of the valves ( 22 , 24 ) on the tubular provides a containment zone 28 within a portion of the tubular. The valves ( 22 , 24 ) should be of a design suitable for integral placement within a tubular as well as being capable of sealing against wellbore pressures such that a seal is formed along the containment zone 28 . Examples of suitable valves include ball valves, gate valves, globe valves, slide valves, butterfly valves and the like. Accordingly when one or both of these valves is in the closed position, the pressure within the portion of the tubular located above the containment zone 28 is isolated from the portion of the tubular below the containment zone 28 . Thus in operation, when it is desired to remove a downhole tool 12 from within the wellbore 5 , these valves ( 22 , 24 ) can be put into their closed position once the tool 12 is raised above the elevation of the upper isolation valve 22 .
[0021] The operation of the isolation system 20 of the present device involves filling the containment zone 28 with fluid from the fluid supply line 31 via the supply port 30 once the lower isolation valve 24 is shut. The fluid is pumped into the containment zone 28 until the fluid level is above the upper valve 22 . The upper valve is then closed and the containment zone 28 is pressurized by pumping additional fluid through the fluid supply line 31 and port 30 . The pressure within the containment zone 28 can be measured with the pressure probe 32 or a gauge at surface (not shown) and monitored to ensure the pressure seal is maintained within the zone 28 . The pressure test time is not limited by this design but instead can be determined by those skilled in the art without undue experimentation. Once operations personnel are satisfied the isolation system 20 maintains a pressure seal between the upper and lower tubular sections ( 19 , 21 ), the pressure in the upper tubular 19 can be bled to the surface and the tool 12 removed from within the wellbore 5 . Thus by creating a test pressure zone, the integrity of the pressure seal created within the tubular by the containment zone 28 can be verified, which imparts an added measure of safety and assurance that the operations personnel at the surface will not be exposed to an overpressure condition from a high pressure wellbore.
[0022] Optionally a downhole tool trap 38 can be added within the tubular above the isolation system 20 . The downhole tool trap 38 can be useful for stopping tools that may have fallen within the wellbore before reaching and damaging the hardware within the isolation system 20 . The downhole tool trap 38 includes a piston 40 , spring 42 , housing 44 , flow restrictor 45 , catcher flap 48 , and a groove 50 . With reference now to FIG. 4 , the catcher flap 48 is shown in a horizontal arrangement perpendicular to the axis of the tubing 18 . An actuator (not shown) in communication with the valves actuators ( 23 or 25 ) can be used to horizontally position the flap 48 when either of these valves ( 22 , 24 ) is in the closed position. Item 48 a shows the flap 48 in the open position when the valves ( 22 and 24 ) are open.
[0023] With reference now to FIG. 5 , a tool 12 is shown resting on the flap 48 after having fallen due to some unforeseen mishap. The piston 40 has moved downward (from its original resting position of FIG. 4 ) thereby compressing the spring 42 . Additional shock absorption is realized with the present device by the addition of the flow restrictor 46 that meters fluid from within the housing 44 to the exterior of the tubing 18 . Alternatively, the flow restrictor port can be plugged and the volume beneath the piston filled with a compressible gas, such as nitrogen, which is compressed by the piston. The addition of the compressible gas provides a function similar to a gas filled shock absorber. As seen, the presence of the downhole tool trap 38 can successfully stop the free fall of a tool 12 within the tubing 18 and prevent damage to the isolation system 20 from such an occurrence. A groove 50 is provided on the inner circumference of the housing 44 formed to fit with the outer diameter of the piston 40 . The groove 50 can maintain the piston in its rest position ( FIG. 4 ) until sufficient force from a falling tool 12 removes the piston 40 from the groove 50 . Also included within the housing 44 is a collar stop 52 and a profile 51 for reseating the piston 40 into the groove 50 after use of the tool catcher 38 . A pulling tool (not shown) can be inserted within the wellbore 5 for grasping the profile 51 and pulling the piston 40 upward until the piston 40 hits the collar stop 52 thereby reseating the piston 40 within the groove 50 .
[0024] FIG. 6 a is an overhead view of the catcher flap 48 , fluid bypass apertures 54 are provided through the flap 48 for allowing drilling fluid to pass therethrough when the flap 48 is closed. The flap 48 can have a high tensile abrasion resistant composite cover material, such as KEVLAR®, to help withstand the harsh downhole conditions. This covers a preformed spring material 56 , which partially absorbs the first impact as the downhole tool or other items hits the flap 48 . The downhole tool trap 38 can be run in conjunction with the two valves 22 and 24 or on it's own as additional protection for other designs of sub surface safety valves or impact sensitive devices installed on down hole completions.
[0025] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. For example, prior to inserting a downhole tool 12 within a pressurized wellbore, the valves ( 22 , 24 ) could be actuated into the closed position and the upper section 19 could be vented to atmosphere. Also, use of the downhole tool trap 38 is not limited to configurations as disclosed herein, but instead can be used in any downhole application. Moreover, the isolation system 20 of the present disclosure can be utilized with any design of tool catcher and is not limited to use with the embodiment of the downhole tool trap described herein. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.
|
An isolation system employing a containment zone within the casing or tubing of a wellbore. The containment zone can be isolated from the wellbore pressure and leak tested to ensure no leakage is occurring across the zone. The isolation system prevents wellbore pressure below the system from communicating with the surface, thereby allowing for safe egress of tools from within the wellbore.
| 4
|
CROSS-REFERENCES TO RELATED APPLICATIONS
Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a device including a container adapter that allows a dip tube to be attached to a fluid container rather than the fluid sprayer. When the sprayer is removed from the fluid container, the dip tube stays in the fluid container. When the sprayer is attached to the fluid container, the container adapter seals against a sprayer connector allowing fluid to be pumped from the fluid container by the sprayer.
2. Description of the Related Art
A variety of devices are known for delivering liquid from a container. Some devices rely on a manual trigger pump sprayer. See, for example, U.S. Pat. No. 4,747,523. Still other devices use a motorized pumping system such as that shown in U.S. Patent Application Publication No. 2005/0133626. The disclosure of this patent and publication, and all other patents and publications referred to herein, are incorporated by reference as if fully set forth herein.
Often these devices use a dip tube (also referred to as a down tube) that extends from the sprayer unit down into the container holding the liquid to be dispensed. The upper end of the dip tube is typically connected to a sprayer inlet port, and the lower end of the dip tube is positioned near the bottom of the interior space of the container. In such devices, the pump will suck liquid from the container through the dip tube and then pump the liquid out of a sprayer nozzle.
It can be important to prevent the use of a liquid not intended for use with a particular sprayer. For example, one may not want to mistakenly use an outdoor insecticide in a sprayer intended to dispense a cleaner for an indoor food contact surface. Therefore, under these circumstances, it is preferred that the sprayer and/or refill container include keying structures that prevent use of a refill containing an inappropriate liquid with the sprayer. These keying structures ensure that only refill containers containing a liquid appropriate for a particular purpose are used with the sprayer. These keying structures may also provide for easy alignment of the sprayer and the fluid container, both during high speed automated assembly of the sprayer to a container at a manufacturing site and when a consumer assembles a refill container to a sprayer.
Thus, there is a need for a device that places a fluid container in fluid communication with a sprayer and that provides a keying structure such that only refill containers having a liquid appropriate for a particular purpose are used with the sprayer.
SUMMARY OF THE INVENTION
The foregoing needs can be met with a device according to the invention which includes a container adapter that allows the dip tube to be attached to the fluid container rather than the sprayer. When the sprayer is removed from the fluid container, the dip tube stays in the fluid container. Refill fluid containers may come with the adapter and dip tube installed. When the sprayer is attached to the fluid container, the adapter seals against a sprayer connector allowing fluid to be pumped from the fluid container by the sprayer.
In one form, a feature with geometry that matches the inner or outer shape of the container adapter is attached to and/or built into the sprayer. The feature is constructed to allow easy alignment of the sprayer to the fluid container. The container adapter also provides a unique attachment geometry to insure only containers with formulae compatible to the sprayer are pumped through the sprayer. Thus, the invention may include two parts, the first is being the container adapter which is fit into or onto the neck of a fluid container. The container adapter includes structure for attaching the dip tube to the adapter. The second part of the invention may be a mating sprayer connector which is attached to the sprayer inlet port such as by a friction fit. Alternatively, the sprayer connector can be integral with the sprayer to incorporate the necessary geometry. When the sprayer is placed onto the fluid container, the mating sprayer connector is pressed into or over the container adapter thereby sealing the mating sprayer connector against a surface of the container adapter.
In one aspect, the invention provides a device for placing an inlet port of a sprayer in fluid communication with an interior space of a container. The device includes a container adapter with (i) an outer wall that terminates at an open end of the adapter wherein the outer wall is dimensioned to engage an inner surface of the neck of the container, (ii) a hollow inlet port that terminates at an upstream open end and that terminates at a downstream open end, and (iii) a hollow inner wall connecting the outer wall and the upstream open end of the inlet port wherein at least part of the inner wall slopes inward from the outer wall toward the upstream open end of the inlet port. Together the inner wall and the inlet port of the adapter may be funnel shaped. The device also includes a sprayer connector having a flow conduit suitable for being placed in fluid communication with the inlet port of the sprayer and the adapter wherein the sprayer connector is dimensioned to matingly engage the inner wall of the adapter to create a flow path from the container to the sprayer. The sprayer connector may be integral with the inlet port of the sprayer.
The device may further include a dip tube, and the downstream open end of the inlet port of the adapter may be dimensioned to sealingly engage the dip tube. The inner wall of the adapter may include venting holes for transferring air into the container. The outer surface of the sprayer connector or inner surface of the adapter may include at least one sealing rib for an air-tight fit. Optionally, the open end of the adapter includes an outwardly projecting lateral flange for engaging a top surface of the neck of the container or a gasket on the top surface of the neck of the container. The adapter may further include a skirt that extends longitudinally from the lateral flange, and an inner surface of the skirt may include a sealing protrusion for engaging an outer surface of the neck of the container. The outer surface of the skirt may also include threads for engaging inner threads on a sprayer attachment cap. The sprayer connector may include an outwardly extending exit port in fluid communication with the flow conduit, and the exit port may be dimensioned to sealingly engage the inlet port of the sprayer.
In another aspect, the invention provides a fluid container for attaching to a sprayer having an inlet port. The container may be sold as a separate refill container with a dip tube and without the sprayer. The container includes a bottom wall, side wall structure, and a neck having an opening. The bottom wall, the side wall structure, and the neck define an interior space of the container for holding liquid. The container also includes a container adapter having (i) an outer wall that terminates at an open end of the adapter wherein the outer wall is dimensioned to engage an inner surface of the neck of the container, (ii) a hollow inlet port that terminates at an upstream open end and that terminates at a downstream open end, and (iii) a hollow inner wall connecting the outer wall and the upstream open end of the inlet port wherein at least part of the inner wall slopes inward from the outer wall toward the upstream open end of the inlet port.
The refill container may have other features. The inlet port of the adapter may further comprise a dip tube that is separable from the inlet port of the adapter, and the downstream open end of the inlet port of the adapter may be dimensioned to sealingly engage the dip tube. The inner wall of the adapter may include venting holes for transferring air into the container. The open end of the adapter may include an outwardly projecting lateral flange for engaging a top surface of the neck of the container or a gasket on the top surface of the neck of the container. The adapter may further include a skirt that extends longitudinally from the lateral flange, and an inner surface of the skirt may include a sealing protrusion for engaging a groove in an outer surface of the neck of the container. The outer surface of the skirt may also include threads for engaging threads on a sprayer attachment cap.
In yet another aspect, the invention provides a device for placing an inlet port of a sprayer in fluid communication with an interior space of a container. The device has a container adapter including (i) a hollow inlet port that terminates at an downstream open end and that terminates at an upstream end, and (ii) an outer wall that terminates at an open end of the adapter opposite the upstream end of the inlet port of the adapter wherein the outer wall is connected to the inlet port and an inner surface of the outer wall is dimensioned to engage an outer surface of the neck of the container. The device also includes a sprayer connector having a flow conduit suitable for being placed in fluid communication with the inlet port of the sprayer wherein an inner surface of the sprayer connector is dimensioned to matingly engage an outer surface of the outer wall of the adapter to create a flow path from the container to the sprayer. The inlet port of the adapter may further comprise a dip tube that is separable from the inlet port of the adapter, and the downstream open end of the inlet port of the adapter may be dimensioned to sealingly engage the dip tube. The outer surface of the outer wall of the adapter may include a sealing protrusion, and the inner surface of the sprayer connector may include a recess for matingly engaging the sealing protrusion. The upstream end of the inlet port may be a projection having flow holes. Optionally, the sprayer connector is integral with the inlet port of the sprayer.
In still another aspect, the invention provides a fluid container for attaching to a sprayer having an inlet port. The container may be sold as a separate refill container with a dip tube and without the sprayer. The container includes a bottom wall, side wall structure, and a neck having an opening. The bottom wall, the side wall structure, and the neck define an interior space of the container for holding liquid. The container also includes a container adapter having (i) a hollow inlet port that terminates at an downstream open end and that terminates at an upstream end, and (ii) an outer wall that terminates at an open end of the adapter opposite the upstream end of the inlet port of the adapter wherein the outer wall is connected to the inlet port, and an inner surface of the outer wall sealingly engages an outer surface of the neck of the container. The inlet port of the adapter may further comprise a dip tube that is separable from the inlet port of the adapter, and the downstream open end of the inlet port of the adapter may be dimensioned to sealingly engage the dip tube. The outer surface of the outer wall of the adapter may include a sealing protrusion, and the inner surface of the sprayer connector may include a recess for matingly engaging the sealing protrusion. The upstream end of the inlet port may be a projection having flow holes. Optionally, the sprayer connector is integral with the inlet port of the sprayer.
These and other features, aspects, and advantages of the present invention will become better understood upon consideration of the following detailed description, drawings, and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a device according to a first embodiment of the invention with a trigger sprayer head removed.
FIG. 2 is an exploded perspective view of the device of FIG. 1 .
FIG. 3 is a cross-sectional view taken along line 3 - 3 of FIG. 1 .
FIG. 3A is a cross-sectional view similar to FIG. 3 with a sprayer head shown on the device.
FIG. 4 is a top view of a sprayer connector of the device of the first embodiment of the invention taken along line 4 - 4 of FIG. 2 .
FIG. 5 is a top view of a container adapter of the device of the first embodiment of the invention taken along line 5 - 5 of FIG. 2 .
FIG. 6 is an exploded perspective view of a device according to a second embodiment of the invention.
FIG. 7 is a cross-sectional view similar to that of FIG. 3 of the device of FIG. 6 .
FIG. 8 is a top view of a sprayer connector of the device of the second embodiment of the invention taken along line 8 - 8 of FIG. 6 .
FIG. 9 is a top view of a container adapter of the device of the second embodiment of the invention taken along line 9 - 9 of FIG. 6 .
FIG. 10 is an exploded perspective view of a device according to a third embodiment of the invention.
FIG. 11 is a cross-sectional view similar to that of FIG. 3 of the device of FIG. 10 .
FIG. 12 is an exploded cross-sectional view of a device according to a fourth embodiment of the invention.
Like reference numerals will be used to refer to like parts from Figure to Figure in the following description of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
Turning first to FIGS. 1 to 5 , there is shown an embodiment of a device 10 according to the invention. The device 10 may be used with a container 12 having a bottom wall 13 that is integral with a side wall 14 . The bottom wall 13 and the side wall 14 define an interior space 15 of the container 12 . The side wall 14 of the container 12 terminates at its upper end in a neck 17 having an inner surface 18 and a top surface 19 that define a container opening 20 . The outer surface 21 of the container 12 has threads 22 for engaging a sprayer attachment cap as described below. A dip tube 25 with a downstream end 26 is provided for suctioning fluid from the interior space 15 of the container 12 . An annular flat container gasket 28 is provided for sealing the top surface 19 of the neck 17 as described below. The container 12 , the dip tube 25 and the container gasket 28 may be formed from plastic materials.
The device 10 is suitable for use with a sprayer. In FIGS. 1 to 5 , there is shown a generally circular sprayer base 30 for a sprayer such as that described in U.S. Patent Application Publication No. 2005/0133626. The specific sprayer selected for use with the invention is not critical and therefore, some sprayer parts other than the sprayer base 30 have been omitted for ease of illustration. The sprayer base 30 has an inlet port 31 including a downstream tubular end 32 and an upstream tubular end 33 . The inlet port 31 provides an inlet fluid path that provides fluid to the pump of the sprayer such that the pump can spray the fluid out of the sprayer nozzle as is well known in the art. The sprayer base 30 also includes an outer wall 36 with an annular recess 37 for mounting a sprayer cap as described below, and a lower surface 38 . The sprayer base 30 also has a venting valve assembly 41 that provides a vent path such that air may pass downward through the sprayer base 30 . The venting valve assembly 41 is constructed by placing a duckbill valve 42 in vent passageway 43 of the sprayer base 30 . A valve cover 44 secures the duckbill valve 42 in the vent passageway 43 as shown in FIG. 3 . A disc-like sprayer gasket 46 is also included for sealing the lower surface 38 of the sprayer base 30 . The sprayer gasket 46 has a vent hole 47 for surrounding the valve cover 44 and a sprayer port hole 48 for surrounding the inlet port 31 of the sprayer base 30 . The sprayer base 30 , duckbill valve 42 , valve cover 44 and sprayer gasket 46 may be formed from plastic materials.
Referring still to FIGS. 1 to 5 , the device 10 according to the invention includes a sprayer connector 50 that connects to the upstream tubular end 33 of the inlet port 31 of the sprayer base 30 . The sprayer connector 50 has a tubular outer wall 51 that terminates at one end in a bottom wall 52 and that terminates at an opposite end in an open top end 53 . The outer wall 51 and the bottom wall 52 define an interior 54 of the sprayer connector 50 . The outer wall 51 of the sprayer connector 50 has an outwardly projecting circumferential rib 56 near the bottom wall 52 of the sprayer connector 50 . The sprayer connector 50 includes an upper inner tubular section 59 that terminates in a fluid exit port 60 of the sprayer connector 50 . The outer wall 51 of the sprayer connector 50 has an outer wall cutaway section 61 that provides a fluid path out of the interior 54 of the sprayer connector 50 around the outside of the upper inner tubular section 59 . The sprayer connector 50 includes a lower inner tubular section 63 that terminates in a fluid entry port 64 of the sprayer connector 50 . The upper inner tubular section 59 , the fluid exit port 60 , the lower inner tubular section 63 and the fluid entry port 64 define an end to end flow conduit 66 in the sprayer connector 50 . The sprayer connector 50 may be formed from a plastic material such as acrylonitrile butadiene styrene (ABS) or like material.
Still looking at FIGS. 1 to 5 , the device 10 according to the invention includes a container adapter 70 that connects to the neck 17 of the container 12 . The container adapter 70 has a cylindrical outer wall 71 that terminates in a downstream open end 72 . The outer wall 71 of the container adapter 70 has an outer surface 73 that engages the inner surface 18 of the neck 17 of the container 12 when the container adapter 70 is assembled to the container 12 as shown in FIG. 3 . An annular flange 76 extends outwardly from the outer wall 71 of the container adapter 70 at the downstream open end 72 of the container adapter 70 . The flange 76 engages the flat container gasket 28 on the top surface 19 of the neck 17 of the container 12 when the container adapter 70 is assembled to the container 12 as shown in FIG. 3 . The container adapter 70 also includes a sloping inner wall 81 that is connected to the outer wall 71 and that defines an annular space 82 between the inner wall 81 and the outer wall 71 . Venting holes 83 are provided in the inner wall 81 . The venting holes 83 provide an air path between the downstream open end 72 of the container adapter 70 and the annular space 82 between the inner wall 81 and the outer wall 71 . The container adapter 70 also includes an inlet port 85 that is connected to the inner wall 81 . The inlet port 85 has an upper tubular section 86 that terminates in an upstream open end 87 and that terminates at an opposite end at a bottom wall 88 . A central hole 89 is provided in the bottom wall 88 and leads to a lower tubular section 90 of the inlet port 85 . The lower tubular section 90 terminates in a downstream open end 91 of the inlet port 85 which receives the dip tube 25 in a friction fit. The container adapter 70 can be made of a plastic material such as polyethylene or polypropylene.
A sprayer attachment cap 95 is provided for securing the sprayer base 30 of the sprayer to the neck 17 of the container 12 as shown in FIG. 3 . The cap 95 has an annular top wall 96 and a cylindrical skirt 97 that depends downward from the top wall 96 . The inner surface of the skirt 97 has threads 98 that engage the threads 22 on the outer surface 21 of the container 12 when the sprayer is assembled to the container 12 . The inner edge of the annular top wall 96 of the cap 95 is secured for rotating movement in the annular recess 37 of the outer wall 36 of the sprayer base 30 . FIG. 3A shows a sprayer 99 with the sprayer attachment cap 95 . The sprayer 99 has the usual nozzle 99 n and trigger 99 t . Pumping means for delivering fluid from the inlet port 31 of the sprayer 99 to the nozzle 99 n of the sprayer 99 by way of actuation of the trigger 99 t are known in the art and therefore will not be explained further.
Assembly of a sprayer to the container 12 proceeds as follows. A sprayer is selected with a sprayer base such as the sprayer base 30 and a cap such as cap 95 mounted on the sprayer base 30 . The venting valve assembly 41 is constructed by placing a duckbill valve 42 in vent passageway 43 of the sprayer base 30 and then securing the valve cover 44 over the duckbill valve 42 in the vent passageway 43 as shown in FIG. 3 . The disc-like sprayer gasket 46 is then placed on the lower surface 38 of the sprayer base 30 . The exit port 60 of the sprayer connector 50 is then inserted into the downstream tubular end 32 of the sprayer base 30 as shown in FIG. 3 . The sprayer connector 50 and the sprayer base 30 may be separate parts as shown in FIGS. 1 to 5 or alternatively, the sprayer connector 50 and the sprayer base 30 may be integrally formed as a single piece. In this manner, a sprayer with the sprayer connector 50 is provided for connection to the container 12 .
The container adapter 70 is assembled to the container 12 . The dip tube 25 is inserted into the downstream open end 91 of the inlet port 85 of the container adapter 70 in a friction fit. Alternatively, the container adapter 70 and the dip tube 25 may be integrally formed as a single piece, or may be secured together such as by adhesive or friction welding. The container adapter 70 and the dip tube 25 are then inserted into the opening 20 of the container 12 so that the outer surface 73 of the outer wall 71 of the container adapter 70 engages the inner surface 18 of the neck 17 of the container 12 as shown in FIG. 3 . The annular flange 76 engages the flat container gasket 28 on the top surface 19 of the neck 17 of the container 12 as shown in FIG. 3 . In this manner, a container 12 with a container adapter 70 and attached dip tube 25 is provided for connection to a sprayer with the sprayer connector 50 .
In an example automated assembly of the sprayer with the sprayer connector 50 to the container 12 with the container adapter 70 and attached dip tube 25 , a plurality of the containers 12 with the container adapter 70 and attached dip tube 25 travel on a conveyor. A sprayer 99 with the sprayer connector 50 is then lowered over each container 12 with the container adapter 70 and attached dip tube 25 . The outer wall 51 of the sprayer connector 50 is aligned with the upper tubular section 86 of the inlet port 85 of the container adapter 70 . The sprayer connector 50 is then lowered into the container adapter 70 such that the rib 56 on the outer wall 51 of the sprayer connector 50 seals with the inner surface of the upper tubular section 86 of the inlet port 85 of the container adapter 70 . The cap 95 is then automatically threaded on the threads 22 on the outer surface 21 of the container 12 to secure the sprayer 99 to the container 12 . While the invention has been illustrated herein with a threaded cap 95 , alternative means are suitable for attaching the sprayer to the container. For example, bayonet-type couplings have been used to couple a sprayer and a container. U.S. Pat. No. 6,138,873 shows an example bayonet-type coupling.
The container adapter 70 is dimensioned to provide for easier automated assembly. For example, the sloping inner wall 81 of the container adapter 70 guides the outer wall 51 of the sprayer connector 50 into the upper tubular section 86 of the inlet port 85 of the container adapter 70 . Also, the inside diameter of the upper tubular section 86 of the inlet port 85 of the container adapter 70 may decrease from top to bottom to further guide the outer wall 51 of the sprayer connector 50 into the bottom region of the upper tubular section 86 of the inlet port 85 of the container adapter 70 wherein the rib 56 engages the inner surface of the upper tubular section 86 of the inlet port 85 of the container adapter 70 .
Referring to FIG. 5 , fluid flow in the device 10 is as follows during use of the assembled device. When the sprayer 99 is actuated (for example, by repeatedly pulling a manual trigger that operates a pump or by pulling a trigger switch that activates an electric pump), liquid in the interior space 15 of the container 12 is suctioned up through dip tube 25 . The liquid then enters the lower tubular section 90 of the inlet port 85 , passes through the central hole 89 , and enters the bottom of the upper tubular section 86 of the inlet port 85 . The liquid then enters the fluid entry port 64 of the sprayer connector 50 and flows into the lower inner tubular section 63 of the sprayer connector 50 . Because the rib 56 seals against the inner surface of the upper tubular section 86 of the inlet port 85 of the container adapter 70 , liquid is prevented from flowing above the rib 56 between the inner surface of the upper tubular section 86 of the inlet port 85 of the container adapter 70 and the outer wall 51 of the sprayer connector 50 . From the lower inner tubular section 63 of the sprayer connector 50 , the liquid flows into the upper inner tubular section 59 of the sprayer connector 50 and exits the fluid exit port 60 . The liquid flows into the upstream tubular end 33 of the inlet port 31 of the sprayer base 30 and then into downstream tubular end 32 of the sprayer base 30 . The liquid then enters the pumping system (not shown) of the sprayer 99 for spraying out of the nozzle 99 n of the sprayer 99 .
As the sprayer 99 is actuated and liquid is removed from the interior space 15 of the container 12 , negative pressure may result in the container 12 . The pressure differential is eliminated by way of the venting valve assembly 41 and the venting holes 83 in the container adapter 70 . Because of the negative pressure, the duckbill valve 42 opens and air passes downward through the duckbill valve 42 into the vent passageway 43 of the sprayer base 30 . The air then travels into the downstream open end 72 of the container adapter 70 and then into the annular space 82 between the inner wall 81 and the outer wall 71 of the container adapter 70 by way of the venting holes 83 . The air then enters the interior space 15 of the container 12 equalizing the pressure inside and outside the container 12 .
Because the rib 56 seals against the inner surface of the upper tubular section 86 of the inlet port 85 of the container adapter 70 , air is prevented from flowing below the rib 56 between the inner surface of the upper tubular section 86 of the inlet port 85 of the container adapter 70 and the outer wall 51 of the sprayer connector 50 . Thus, the rib 56 serves to establish and maintain independent liquid and air flow paths when the container adapter 70 and the sprayer connector 50 are assembled together. Alternatively, an inner surface of the adapter 70 may include a sealing rib for engaging the outer surface of the sprayer connector 50 . Also, the rib may take the form of an O-ring.
The mating dimensions of the sprayer connector 50 and the container adapter 70 also provide keying structures that ensure that only refills containing a liquid appropriate for a particular purpose are used with the sprayer. Specifically, a tight fit is required between the sprayer connector 50 and the container adapter 70 so that the sprayer may be primed with liquid by way of the dip tube 25 . If air leakage were to occur between the inner surface of the upper tubular section 86 of the inlet port 85 of the container adapter 70 and the outer wall 51 of the sprayer connector 50 , the sprayer would suck air into the sprayer rather than liquid. Therefore, only refills comprising a container 12 with an attached container adapter 70 that mates with the sprayer connector 50 of the sprayer 99 would be suitable for use with the container.
Turning now to FIGS. 6 to 9 , there is shown a second embodiment of a device 10 a according to the invention. The device 10 a may be used with a container 12 a having a bottom wall that is integral with a side wall as in container 12 of FIG. 1 . The bottom wall and the side wall 14 a define an interior space 15 a of the container 12 a . The side wall 14 a of the container 12 a terminates at its upper end in a neck 17 a having an inner surface 18 a and a top surface 19 a that define a container opening 20 a . The outer surface 21 a of the neck 17 a of the container 12 a has threads 22 a for engaging a sprayer cap as described below. The outer surface 21 a of the neck 17 a of the container 12 a also has an annular groove 23 a for engaging a container adapter 70 a as described below. A dip tube 25 as in FIGS. 1-5 is provided for suctioning fluid from the interior space 15 a of the container 12 a . The container 12 a may be formed from plastic materials.
The device 10 a is suitable for use with a sprayer. In FIGS. 6 to 9 , there is shown a generally circular sprayer base 30 for a sprayer such as that described above with reference to FIGS. 1 to 5 . Therefore, a description of the sprayer base 30 in FIGS. 6-9 is the same as that provided above for FIGS. 1-5 .
Referring still to FIGS. 6 to 9 , the device 10 a according to the invention includes a sprayer connector 50 a that connects to the upstream tubular end 33 of the inlet port 31 of the sprayer base 30 as in the embodiment of FIGS. 1-5 . The sprayer connector 50 a has a tubular outer wall 51 a that terminates at one end in a bottom wall 52 a and that terminates at an opposite end in an open top end 53 a . The outer wall 51 a and the bottom wall 52 a define an interior 54 a of the sprayer connector 50 a . The outer wall 51 a of the sprayer connector 50 a has an outwardly projecting rib 56 a near the bottom wall 52 a of the sprayer connector 50 a . The sprayer connector 50 a includes an upper inner tubular section 59 a that terminates in a fluid exit port 60 a of the sprayer connector 50 a . The outer wall 51 a of the sprayer connector 50 a has an outer wall cutaway section 61 a that provides a fluid path out of the interior 54 a of the sprayer connector 50 a . The sprayer connector 50 a includes a lower inner tubular section 63 a that terminates in a fluid entry port 64 a of the sprayer connector 50 a . The upper inner tubular section 59 a , the fluid exit port 60 a , the lower inner tubular section 63 a and the fluid entry port 64 a define a flow conduit 66 a in the sprayer connector 50 a . The sprayer connector 50 a may be formed from a plastic material such as ABS or like material.
Still looking at FIGS. 6 to 9 , the device 10 a according to the invention includes a container adapter 70 a that connects to the neck 17 a of the container 12 a . The container adapter 70 a has a cylindrical outer wall 71 a that terminates in a downstream open end 72 a . The outer wall 71 a of the container adapter 70 has an outer surface 73 a that engages the inner surface 18 a of the neck 17 a of the container 12 a as shown in FIG. 7 . An annular flange 76 a extends outwardly from the outer wall 71 a at the downstream open end 72 a of the container adapter 70 a . The flange 76 a engages the top surface 19 a of the neck 17 a of the container 12 a as shown in FIG. 7 . A skirt 77 a extends longitudinally downward from the outer edge of the flange 76 a . The skirt 77 a terminates at its lower end in an inwardly directed circumferential rib 78 a that engages groove 23 a of the container 12 a as described below.
The container adapter 70 a also includes a sloping inner wall 81 a that is connected to the outer wall 71 a and that defines an annular space 82 a between the inner wall 81 a and the outer wall 71 a . Venting holes 83 a are provided in the inner wall 81 a. The venting holes 83 a provide an air path between the downstream open end 72 a of the container adapter 70 a and the annular space 82 a between the inner wall 81 a and the outer wall 71 a . The container adapter 70 a also includes an inlet port 85 a that is connected to the inner wall 81 a. The inlet port 85 a has an upper tubular section 86 a that terminates in an upstream open end 87 a and that terminates at an opposite end at a bottom wall 88 a . A central hole 89 a is provided in the bottom wall 88 a and leads to a lower tubular section 90 a of the inlet port 85 a . The lower tubular section 90 a terminates in a downstream open end 91 a of the inlet port 85 a which receives the dip tube 25 in a friction fit. The container adapter 70 a can be made of a plastic material such as polyethylene or polypropylene.
A cap 95 a is provided for securing the sprayer base 30 of the sprayer to the neck 17 a of the container 12 a as shown in FIG. 7 . The cap 95 a has an annular top wall 96 a and a cylindrical skirt 97 a that depends downward from the top wall 96 a . The inner surface of the skirt 97 a has threads 98 a that engage the threads 22 a on the outer surface 21 a of the container 12 a when the sprayer is assembled to the container 12 a . The inner edge of the annular top wall 96 a of the cap 95 a is secured for rotating movement in the annular recess 37 of the outer wall 36 of the sprayer base 30 .
Assembly of a sprayer to the container 12 a proceeds as follows. A sprayer is selected with a sprayer base such as the sprayer base 30 and a cap such as cap 95 a mounted on the sprayer base 30 . The venting valve assembly 41 is constructed as in the embodiment of FIGS. 1-5 . The disc-like sprayer gasket 46 is then placed on the lower surface 38 of the sprayer base 30 . The exit port 60 a of the sprayer connector 50 a is then inserted into the downstream tubular end 32 of the sprayer base 30 as shown in FIG. 7 . The sprayer connector 50 a and the sprayer base 30 may be separate parts as shown in FIGS. 6 to 9 or alternatively, the sprayer connector 50 a and the sprayer base 30 may be integrally formed as a single piece. In this manner, a sprayer with the sprayer connector 50 a is provided for connection to the container 12 a.
The container adapter 70 a is assembled to the container 12 a . The dip tube 25 is inserted into the downstream open end 91 a of the inlet port 85 a of the container adapter 70 a in a friction fit. Alternatively, the container adapter 70 a and the dip tube 25 may be integrally formed as a single piece, or may be secured together such as by adhesive or friction welding. The container adapter 70 a and the dip tube 25 are then inserted into the opening 20 a of the container 12 a so that the outer surface 73 a of the outer wall 71 a of the container adapter 70 a engages the inner surface 18 a of the neck 17 a of the container 12 a and so that the circumferential rib 78 a of the skirt 77 a of the container adapter 70 a enters the groove 23 a at the top of the container 12 a as shown in FIG. 7 . The annular flange 76 a engages the top surface 19 a of the neck 17 a of the container 12 a as shown in FIG. 7 . In this manner, a container 12 a with a container adapter 70 a and attached dip tube 25 is provided for connection to a sprayer with the sprayer connector 50 a.
In an example automated assembly of the sprayer with the sprayer connector 50 a to the container 12 a with the container adapter 70 a and attached dip tube 25 , a plurality of the containers 12 a with the container adapter 70 a and attached dip tube 25 travel on a conveyor. A sprayer with the sprayer connector 50 a is then lowered over each container 12 a with the container adapter 70 a and attached dip tube 25 . The outer wall 51 a of the sprayer connector 50 a is aligned with the upper tubular section 86 a of the inlet port 85 a of the container adapter 70 a . The sprayer connector 50 a is then lowered into the container adapter 70 a such that the rib 56 a on the outer wall 51 a of the sprayer connector 50 a seals with the inner surface of the upper tubular section 86 a of the inlet port 85 a of the container adapter 70 a . The cap 95 a is then automatically threaded on the threads 22 a on the outer surface 21 a of the container 12 a to secure the sprayer to the container 12 a.
As with container adapter 70 , the container adapter 70 a is dimensioned to provide for easier automated assembly. The sloping inner wall 81 a of the container adapter 70 a guides the outer wall 51 a of the sprayer connector 50 a into the upper tubular section 86 a of the inlet port 85 a of the container adapter 70 a . Also, the inside diameter of the upper tubular section 86 a of the inlet port 85 a of the container adapter 70 a may decrease from top to bottom to further guide the outer wall 51 a of the sprayer connector 50 a into the bottom region of the upper tubular section 86 a of the inlet port 85 a of the container adapter 70 a wherein the rib 56 a engages the inner surface of the upper tubular section 86 a of the inlet port 85 a of the container adapter 70 a.
Referring to FIG. 7 , fluid flow in the device 10 a is as follows during use of the assembled device. Liquid in the interior space 15 a of the container 12 a is suctioned up through dip tube 25 . The liquid then enters the lower tubular section 90 a of the inlet port 85 a , passes through the central hole 89 a , and enters the bottom of the upper tubular section 86 a of the inlet port 85 a . The liquid then enters the fluid entry port 64 a of the sprayer connector 50 a and flows into the lower inner tubular section 63 a of the sprayer connector 50 a . Because the rib 56 a seals against the inner surface of the upper tubular section 86 a of the inlet port 85 a of the container adapter 70 a , liquid is prevented from flowing above the rib 56 a between the inner surface of the upper tubular section 86 a of the inlet port 85 a of the container adapter 70 a and the outer wall 51 a of the sprayer connector 50 a . From the lower inner tubular section 63 a of the sprayer connector 50 a , the liquid flows into the upper inner tubular section 59 a of the sprayer connector 50 a and exits the fluid exit port 60 a . The liquid flows into the upstream tubular end 33 of the inlet port 31 of the sprayer base 30 and then into downstream tubular end 32 of the sprayer base 30 . The liquid then enters the pumping system (not shown) of the sprayer for spraying out of the nozzle of the sprayer.
As the sprayer is actuated and liquid is removed from the interior space 15 a of the container 12 a , negative pressure may result in the container 12 a . The pressure differential is eliminated by way of the venting valve assembly 41 and the venting holes 83 a in the container adapter 70 a . Because of the negative pressure, the duckbill valve 42 opens and air passes downward through the duckbill valve 42 into the vent passageway 43 of the sprayer base 30 . The air then travels into the downstream open end 72 a of the container adapter 70 a and then into the annular space 82 a between the inner wall 81 a and the outer wall 71 a of the container adapter 70 a by way of the venting holes 83 a . The air then enters the interior space 15 a of the container 12 a equalizing the pressure inside and outside the container 12 a.
Because the rib 56 a seals against the inner surface of the upper tubular section 86 a of the inlet port 85 a of the container adapter 70 a , air is prevented from flowing below the rib 56 a between the inner surface of the upper tubular section 86 a of the inlet port 85 a of the container adapter 70 a and the outer wall 51 a of the sprayer connector 50 a . Thus, the rib 56 a serves to establish and maintain independent liquid and air flow paths when the container adapter 70 a and the sprayer connector 50 a are assembled together.
The mating dimensions of the sprayer connector 50 a and the container adapter 70 a also provide keying structures that ensure that only refills containing a liquid appropriate for a particular purpose are used with the sprayer. Specifically, a tight fit is required between the sprayer connector 50 a and the container adapter 70 a so that the sprayer may be primed with liquid by way of the dip tube 25 . If air leakage were to occur between the inner surface of the upper tubular section 86 a of the inlet port 85 a of the container adapter 70 a and the outer wall 51 a of the sprayer connector 50 a , the sprayer would suck air into the sprayer rather than liquid. Therefore, only refills comprising a container 12 a with an attached container adapter 70 a that mates with the sprayer connector 50 a of the sprayer would be suitable for use with the container 12 a.
Turning now to FIGS. 10 and 11 , there is shown a third embodiment of a device 10 b according to the invention. The device 10 b may be used with a container 12 b having a bottom wall that is integral with a side wall as in container 12 of FIG. 1 . The bottom wall and the side wall 14 b define an interior space 15 b of the container 12 b . The side wall 14 b of the container 12 b terminates at its upper end in a neck 17 b having an inner surface 18 b and a top surface 1 9 b that define a container opening 20 b . The outer surface 21 b of the neck 17 b of the container 12 b also has an annular groove 23 b for engaging a container adapter 70 b as described below. A dip tube 25 as in FIGS. 1-5 is provided for suctioning fluid from the interior space 15 b of the container 12 b . The container 12 b may be formed from plastic materials.
The device 10 b is suitable for use with a sprayer. In FIGS. 10 and 11 , there is shown a generally circular sprayer base 30 for a sprayer such as that described above with reference to FIGS. 1-5 . Therefore, a description of the sprayer base 30 in FIGS. 10 and 11 is identical to that provided above for FIGS. 1 to 5 .
Referring still to FIGS. 10 and 11 , the device 10 b according to the invention includes a sprayer connector 50 a that connects to the upstream tubular end 33 of the inlet port 31 of the sprayer base 30 as in the embodiment of FIGS. 6 to 9 . Therefore, a description of the sprayer connector 50 a in FIGS. 10-11 is identical to that provided above for FIGS. 6-9 .
Still looking at FIGS. 10 and 11 , the device 10 b according to the invention includes a container adapter 70 b that connects to the neck 17 b of the container 12 b . The container adapter 70 b has a cylindrical outer wall 71 b that terminates in a downstream open end 72 b . The outer wall 71 b of the container adapter 70 has an outer surface 73 b that engages the inner surface 18 b of the neck 17 b of the container 12 b as shown in FIG. 7 . An annular flange 76 b extends outwardly from the outer wall 71 b at the downstream open end 72 b of the container adapter 70 b . The flange 76 b engages the neck 17 b of the container 12 b as shown in FIG. 7 . A skirt 77 b extends longitudinally downward from the outer edge of the flange 76 b . The skirt 77 b has at its upper inner end in an inwardly directed circumferential rib 78 b that engages groove 23 b of the container 12 b . The outer surface of the skirt 77 b has threads 79 b for engaging a sprayer cap as described below.
The container adapter 70 b also includes a sloping inner wall 81 b that is connected to the outer wall 71 b and that defines an annular space 82 b between the inner wall 81 b and the outer wall 71 b . Venting holes 83 b are provided in the inner wall 81 b . The venting holes 83 b provide an air path between the downstream open end 72 b of the container adapter 70 b and the annular space 82 b between the inner wall 81 b and the outer wall 71 b . The container adapter 70 b also includes an inlet port 85 b that is connected to the inner wall 81 b . The inlet port 85 b has an upper tubular section 86 b that terminates in an upstream open end 87 b and that terminates at an opposite end at a bottom wall 88 b . A central hole 89 b is provided in the bottom wall 88 b and leads to a lower tubular section 90 b of the inlet port 85 b . The lower tubular section 90 b terminates in a downstream open end 91 b of the inlet port 85 b which receives the dip tube 25 in a friction fit. The container adapter 70 b can be made of a plastic material such as polyethylene or polypropylene.
A cap 95 b is provided for securing the sprayer base 30 of the sprayer to the container adapter 70 b as shown in FIG. 11 . The cap 95 b has an annular top wall 96 b and a cylindrical skirt 97 b that depends downward from the top wall 96 b . The inner surface of the skirt 97 b has threads 98 b that engage the threads 79 b on the outer surface of the skirt 77 b of the container adapter 70 b when the sprayer is assembled to the container 12 b . The inner edge of the annular top wall 96 b of the cap 95 b is secured for rotating movement in the annular recess 37 of the outer wall 36 of the sprayer base 30 .
Assembly of a sprayer to the container 12 b proceeds as follows. A sprayer is selected with a sprayer base such as the sprayer base 30 and a cap such as cap 95 b mounted on the sprayer base 30 . The venting valve assembly 41 is constructed as in the embodiment of FIGS. 1-5 . The disc-like sprayer gasket 46 is then placed on the lower surface 38 of the sprayer base 30 . The exit port 60 a of the sprayer connector 50 a is then inserted into the downstream tubular end 32 of the sprayer base 30 as shown in FIG. 11 . The sprayer connector 50 a and the sprayer base 30 may be separate parts as shown in FIGS. 10 and 11 or alternatively, the sprayer connector 50 a and the sprayer base 30 may be integrally formed as a single piece. In this manner, a sprayer with the sprayer connector 50 a is provided for connection to the container 12 b.
The container adapter 70 b is assembled to the container 12 b . The dip tube 25 is inserted into the downstream open end 91 b of the inlet port 85 b of the container adapter 70 b in a friction fit. Alternatively, the container adapter 70 b and the dip tube 25 may be integrally formed as a single piece, or may be secured together such as by adhesive or friction welding. The container adapter 70 b and the dip tube 25 are then inserted into the opening 20 b of the container 12 b so that the outer surface 73 b of the outer wall 71 b of the container adapter 70 b engages the inner surface 18 b of the neck 17 b of the container 12 b and so that the circumferential rib 78 b of the skirt 77 b of the container adapter 70 b enters the groove 23 b at the top of the container 12 b as shown in FIG. 11 . The annular flange 76 b engages the top surface 19 b of the neck 17 b of the container 12 b as shown in FIG. 11 . The annular flange 76 b could also be attached to the neck 17 b of the container 12 b by alternative means such as welding or adhesives. In this manner, a container 12 b with a container adapter 70 b and attached dip tube 25 is provided for connection to a sprayer with the sprayer connector 50 a.
In an example automated assembly of the sprayer with the sprayer connector 50 a to the container 12 b with the container adapter 70 b and attached dip tube 25 , a plurality of the containers 12 b with the container adapter 70 b and attached dip tube 25 travel on a conveyor. A sprayer with the sprayer connector 50 a is then lowered over each container 12 b with the container adapter 70 b and attached dip tube 25 . The outer wall 51 a of the sprayer connector 50 a is aligned with the upper tubular section 86 b of the inlet port 85 b of the container adapter 70 b . The sprayer connector 50 a is then lowered into the container adapter 70 b such that the rib 56 a on the outer wall 51 a of the sprayer connector 50 a seals with the inner surface of the upper tubular section 86 b of the inlet port 85 b of the container adapter 70 b . The cap 95 b is then automatically threaded on the threads 79 b on the outer surface of the skirt 77 b of the container adapter 70 b to secure the sprayer to the container 12 b.
The container adapter 70 b is dimensioned to provide for easier automated assembly. For example, the sloping inner wall 81 b of the container adapter 70 b guides the outer wall 51 a of the sprayer connector 50 a into the upper tubular section 86 b of the inlet port 85 b of the container adapter 70 b . Also, the inside diameter of the upper tubular section 86 b of the inlet port 85 b of the container adapter 70 b may decrease from top to bottom to further guide the outer wall 51 a of the sprayer connector 50 a into the bottom region of the upper tubular section 86 b of the inlet port 85 b of the container adapter 70 b wherein the rib 56 a engages the inner surface of the upper tubular section 86 b of the inlet port 85 b of the container adapter 70 b.
Referring to FIG. 11 , fluid flow in the device 10 b is as follows. Liquid in the interior space 15 b of the container 12 b is suctioned up through dip tube 25 . The liquid then enters the lower tubular section 90 b of the inlet port 85 b , passes through the central hole 89 b , and enters the bottom of the upper tubular section 86 b of the inlet port 85 b . The liquid then enters the fluid entry port 64 a of the sprayer connector 50 a and flows into the lower inner tubular section 63 a of the sprayer connector 50 a . Because the rib 56 a seals against the inner surface of the upper tubular section 86 b of the inlet port 85 b of the container adapter 70 b , liquid is prevented from flowing above the rib 56 a between the inner surface of the upper tubular section 86 b of the inlet port 85 b of the container adapter 70 b and the outer wall 51 a of the sprayer connector 50 a . From the lower inner tubular section 63 a of the sprayer connector 50 a , the liquid flows into the upper inner tubular section 59 a of the sprayer connector 50 a and exits the fluid exit port 60 a . The liquid flows into the upstream tubular end 33 of the inlet port 31 of the sprayer base 30 and then into downstream tubular end 32 of the sprayer base 30 . The liquid then enters the pumping system of the sprayer (not shown) for spraying out of the nozzle of the sprayer.
As the sprayer is actuated and liquid is removed from the interior space 15 b of the container 12 b , negative pressure may result in the container 12 b . The pressure differential is eliminated by way of the venting valve assembly 41 and the venting holes 83 b in the container adapter 70 b . Because of the negative pressure, the duckbill valve 42 opens and air passes downward through the duckbill valve 42 into the vent passageway 43 of the sprayer base 30 . The air then travels into the downstream open end 72 b of the container adapter 70 b and then into the annular space 82 b between the inner wall 81 b and the outer wall 71 b of the container adapter 70 b by way of the venting holes 83 b . The air then enters the interior space 15 b of the container 12 b equalizing the pressure inside and outside the container 12 b.
Because the rib 56 a seals against the inner surface of the upper tubular section 86 b of the inlet port 85 b of the container adapter 70 b , air is prevented from flowing below the rib 56 a between the inner surface of the upper tubular section 86 b of the inlet port 85 b of the container adapter 70 b and the outer wall 51 a of the sprayer connector 50 a . Thus, the rib 56 a serves to establish and maintain independent liquid and air flow paths when the container adapter 70 b and the sprayer connector 50 a are assembled together.
The mating dimensions of the sprayer connector 50 a and the container adapter 70 b also provide keying structures that ensure that only refills containing a liquid appropriate for a particular purpose are used with the sprayer. Specifically, a tight fit is required between the sprayer connector 50 a and the container adapter 70 b so that the sprayer may be primed with liquid by way of the dip tube 25 . If air leakage were to occur between the inner surface of the upper tubular section 86 b of the inlet port 85 b of the container adapter 70 b and the outer wall 51 a of the sprayer connector 50 a , the sprayer would suck air into the sprayer rather than liquid. Therefore, only refills comprising a container 12 b with an attached container adapter 70 b that mates with the sprayer connector 50 a of the sprayer would be suitable for use with the container.
Turning now to FIG. 12 , there is shown a fourth embodiment of a device 110 according to the invention. The device 110 is suitable for use with a sprayer with a sprayer base having an inlet port similar to that described above with reference to FIGS. 1 to 5 . The device 110 may be used with a container 112 having a bottom wall that is integral with a side wall as in container 12 of FIG. 1 . The bottom wall and the side wall 114 define an interior space 115 of the container 112 . The side wall 114 of the container 112 terminates at its upper end in a circular neck 117 having a wall 118 and a top surface 119 that define a container opening 120 . The outer surface 121 of the neck 117 of the container 112 has threads 122 for engaging a container adapter 170 as described below. A dip tube 125 is provided for suctioning fluid from the interior space 115 of the container 112 . The container 112 and dip tube 125 may be formed from plastic materials.
Referring still to FIG. 12 , the device 110 according to the invention includes a sprayer connector 150 that connects to the inlet port of the sprayer base. The sprayer connector 150 has a circular outer wall 152 with a downstream tubular section 153 that defines an outer wall of an exit port 154 , a shoulder 156 and an upstream tubular section 156 . The sprayer connector 150 also has a circular inner wall 158 including a downstream tubular section 159 that forms an inner wall of the exit port 154 , a central sloping wall 160 having inner surface sealing ribs 161 and an inner surface annular recess 162 , and an upstream tubular section 164 that forms an inner wall of an entry port 165 . The hollow inner wall 158 defines a flow conduit 166 in the sprayer connector 150 . The sprayer connector 150 may be formed from a plastic material such as ABS or like material.
Still looking at FIG. 12 , the device 110 according to the invention includes a container adapter 170 that connects to the neck 117 of the container 112 . The container adapter 170 includes a circular upstream tubular section 171 having inner surface threads 172 , a circular upstream sloping wall 174 , a circular central tubular section 175 , a circular downstream sloping wall 177 having an outer sealing protrusion 178 and an outer sealing strip 179 and an inner recess 180 dimensioned to receive the dip tube 125 in a friction fit, and a fluid exit port 182 . The fluid exit port 182 is a hollow circular projection 183 having a domed outer surface 184 and having circumferentially arranged flow holes 185 . The container adapter 170 can be made of a plastic material such as polyethylene or polypropylene. Preferably, the outer sealing strip 179 is a softer material than the remainder of the container adapter 170 . The outer sealing strip 179 may be produced in an overmolding or two shot forming process.
Assembly of a sprayer to the container 112 proceeds as follows. A sprayer is selected with a sprayer base having a tubular inlet port. The exit port 154 of the sprayer connector 150 is then inserted into the inlet port of the sprayer base. The sprayer connector 150 and the sprayer base may be separate parts or alternatively, the sprayer connector 150 and the sprayer base may be integrally formed as a single piece. In this manner, a sprayer with the sprayer connector 150 is provided for connection to the container 112 .
The container adapter 170 is assembled to the container 112 . The dip tube 125 is inserted into the recess 180 of the container adapter 170 in a friction fit as shown in FIG. 12 . Alternatively, the container adapter 170 and the dip tube 125 may be integrally formed as a single piece, or may be secured together such as by adhesive or friction welding. The dip tube 125 are then inserted into the opening 120 of the container 112 . The container adapter 170 is then lowered onto the neck 117 of the container 112 such that the inner surface threads 172 of the container adapter 170 engage the threads 122 on the outer surface 121 of the neck 117 of the container 112 . Rotation of the container adapter 170 in direction A of FIG. 12 will attach the container adapter 170 to the neck 117 of the container 112 . In this manner, a container 112 with a container adapter 170 and attached dip tube 125 is provided for connection to a sprayer with the sprayer connector 150 .
In an example automated assembly of the sprayer with the sprayer connector 150 to the container 112 with the container adapter 170 and attached dip tube 125 , a plurality of the containers 112 with the container adapter 170 and attached dip tube 125 travel on a conveyor. A sprayer with the sprayer connector 150 is then lowered over each container 112 with the container adapter 170 and attached dip tube 125 . The inner wall 158 of the sprayer connector 150 is aligned with the outer surface of the container adapter 170 . The sprayer connector 150 is then lowered over the container adapter 170 such that the sealing protrusion 178 on the inner surface of container adapter 170 enters the recess 162 of the sprayer connector 150 . Also, the inner surface sealing ribs 161 of the sprayer connector 150 engage the outer sealing strip 179 of the container adapter 170 to provide an air-tight fit. The container adapter 170 is dimensioned to provide for easier automated assembly. For example, the sloping wall 177 of the container adapter 170 guides the sprayer connector 150 over the outer surface of the container adapter 170 .
Referring still to FIG. 12 , fluid flow F in the device 110 is as follows during use of the assembled device. When the sprayer is actuated (for example, by repeatedly pulling a manual trigger that operates a pump or by pulling a trigger switch that activates an electric pump), liquid in the interior space 115 of the container 112 is suctioned up through dip tube 125 . The liquid then enters the hollow circular projection 183 of the fluid exit port 182 of the container adapter 170 and the liquid then exits the flow holes 185 of the fluid exit port 182 . The liquid continues through the flow conduit 166 of the sprayer connector 150 and then enters the sprayer.
The mating dimensions of the sprayer connector 150 and the container adapter 170 also provide keying structures that ensure that only refills containing a liquid appropriate for a particular purpose are used with the sprayer. Specifically, a tight fit is required between the sprayer connector 150 and the container adapter 170 so that the sprayer may be primed with liquid by way of the dip tube 125 . If air leakage were to occur, the sprayer would suck air into the sprayer rather than liquid. Therefore, only refills comprising a container 112 with an attached container adapter 170 that mates with the sprayer connector 150 of the sprayer would be suitable for use with the container 112 .
Thus, the present invention provides a device that that places an interior space of a fluid container in fluid communication with a sprayer and that provides a keying structure such that only refill containers having a liquid appropriate for a particular purpose are used with the sprayer.
Although the present invention has been described in detail with reference to certain embodiments, one skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments, which have been presented for purposes of illustration and not of limitation. Therefore, the scope of the invention should not be limited to the description of the embodiments contained herein.
INDUSTRIAL APPLICABILITY
The present invention provides a container adapter that allows a dip tube to be attached to a fluid container rather than the fluid sprayer and that provides a keying structure such that only refill containers having a liquid appropriate for a particular purpose are used with the sprayer.
|
A device for that places a fluid container in fluid communication with a sprayer is disclosed. The device includes a container adapter that allows a dip tube to be attached to the fluid container rather than the sprayer. When the sprayer is removed from the fluid container, the dip tube stays in the fluid container. Refill fluid containers may come with the container adapter and dip tube installed. When the sprayer is attached to the fluid container, the adapter seals against the sprayer allowing fluid to be pumped from the fluid container by the sprayer. A sprayer connector with geometry that matches an inner or outer shape of the adapter is attached to and/or built into the sprayer. The sprayer connector is constructed to allow easy alignment of the sprayer to the fluid container. The sprayer connector and the container adapter also provide a unique attachment geometry to insure only containers with formulae compatible to the sprayer are pumped through the sprayer.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the previously filed Korean Patent Application No. 10-2007-0011801 that has a filing date of Feb. 5, 2007.
FIELD OF THE INVENTION
[0002] The present invention relates to a connector.
BACKGROUND
[0003] Generally, an electrical connector functions to electrically connect separate parts of a circuit. Electrical connectors often comprise a cap and a plug as a pair. Electrical connectors are widely used to supply electric power to various machines and electronic appliances. Electrical connectors are also used to intermittently connect various electric operation signals with one another.
[0004] However, when connecting the cap to the plug of a conventional connector, an operator has to grip the cap and the plug using both hands and apply a great force to the cap and the plug in opposite directions. Therefore, connection of the cap and the plug is sometimes very laborious, especially when doing so within the confines of a small space.
[0005] To solve such problems, a lever connector has been introduced that forcibly connects a cap and a plug of the lever connector with each other by pivoting a lever that is mounted to the connector. In such a conventional lever connector, however, since the lever is pivotable in one direction, and enough space for the pivoting of the lever is required, a length of the lever is necessarily increased.
SUMMARY
[0006] The present invention relates to, in one embodiment among others, a connector having a first connector portion and a lever movably connected to an outside of the first connector portion. The lever is rotatable with respect to the first connection portion and the lever is translatable with respect to the first connection portion. A guide projection is connected to the lever and the connector further has a second connector portion. The second connector portion has a guide channel having an open upper part, at least a portion of the guide channel having a sloped portion being sloped with respect to a direction in which the first connector portion is connectable to the second connector portion, the guide channel configured to receive the guide projection through the open upper part of the guide channel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0008] FIG. 1 is an oblique view of a connector according to an embodiment of the present invention;
[0009] FIG. 2 is an orthogonal view of the connector of FIG. 1 before assembly;
[0010] FIG. 3 is an orthogonal view of the connector of FIG. 1 during assembly; and
[0011] FIG. 4 is an orthogonal view of the connector of FIG. 1 after assembly.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0012] Hereinafter, an exemplary embodiment of the present invention will be described in detail with reference to the accompanying drawings.
[0013] Referring to FIG. 1 , a connector 1 according to an embodiment of the present invention comprises a first connector portion 10 and a second connector portion 20 that are connected to each other, thereby supplying power or connecting electric signals. The connector 1 further comprises a lever 30 for pivoting that is mounted to an outside of the second connector portion 20 . The connector 1 can be easily assembled with minimal force using the principle of leverage, more specifically, by forcibly connecting the first connector portion 10 with the second connector portion 20 by pivoting operation of the lever 30 .
[0014] The first connector portion 10 comprises a first terminal 11 formed at one end thereof for connection with a circuit board or a cable, and a guide channel 12 formed on an outer surface thereof to be engaged with the lever 30 so that the first connector portion 10 is introduced into the second connector portion 20 by pivoting the lever 30 .
[0015] The second connector portion 20 supplies power or connects electric signals through connection with the first connector portion 10 . The first connector portion 10 is inserted in and engaged with the second connector portion 20 . The second connector portion 20 comprises a second terminal 21 at one end for connection with the circuit board or the cable to be supplied with the power or the electric signals, and first shafts 22 formed at opposite positions on an outer surface of the second connector portion 20 for the lever 30 to be hinged upon.
[0016] The lever 30 is hinged on the outside of the second connector portion 20 to pivot vertically with respect to the second connector portion 20 , thereby forcing the first connector portion 10 into the second connector portion 20 . For this operation, the lever 30 comprises first apertures 32 engaged with the first shafts 22 , and a guide projection 31 formed to be projecting inwardly at a lower part of the first aperture 32 to be engaged with the guide channel 12 of the first connector portion 10 .
[0017] The guide channel 12 is recessed from the outer surface of the first connector portion 10 and open at the upper part thereof in a state where the lever 30 is maximally lifted, such that the guide projection 31 can be conveniently engaged with the guide channel 12 . In addition, the guide channel 12 is sloped downward in a direction opposite to the lever 30 . Therefore, the guide projection 31 is slid into the guide channel 12 by leverage with respect to the first shafts 22 .
[0018] The lever 30 further comprises second apertures 33 formed on lateral sides of the lever 30 in a longitudinal direction corresponding to a pivoting motion of the lever 30 . In addition, a second shaft 23 is formed on the outer surface of the second connector portion 20 and inserted in a second aperture 33 . The first aperture 32 is in the form of slot allowing the lever 30 to move horizontally with respect to the second connector portion 20 .
[0019] According to this structure, when the lever 30 pivots vertically relative to the second connector portion 20 , the lever 30 is also able to move horizontally depending on positions thereof. Therefore, a moving distance of the guide projection 31 can be maximized in proportion to a pivoting angle of the lever 30 . Consequently, a length of the lever 30 can minimized, thereby reducing the overall size of the connector 1 .
[0020] The second connector portion 20 further includes upper and lower lock projections 24 formed on the outer surface at positions corresponding to a highest position and a lowest position of the lever 30 , respectively. The lever 30 includes a third aperture 34 for receiving the lock projections 24 therein so as to secure the lever 30 at the highest position and the lowest position, thereby preventing disassembling of the connector 1 by an external impact applied to the lever 30 . Preferably, movement of the lever 30 is prevented to avoid deviation between the guide channel 12 and the guide projection 31 , during assembling of the connector 1 .
[0021] FIGS. 2-4 show the operation of the connector 1 according to the embodiment of the present invention. When connecting the first connector portion 10 and the second connector portion 20 , which are separated, to each other, the lever 30 is lifted to the highest position as shown in FIG. 2 , thereby engaging the upper lock projection 24 with the third aperture 34 . In this state, the lever 30 is prevented from pivoting downward by gravity.
[0022] In this state, since the lever 30 is moved outward relative to the second connector portion 20 by pivoting, the guide projection 31 is maintained at a position corresponding to the open part of the guide channel 12 . When the first connector portion 10 and the second connector portion 20 are pushed toward each other, the guide projection 31 is inserted in the guide channel 12 , hence completing a primary step of assembling connector 1 .
[0023] Next, when the lever 30 is pivoted as shown in FIG. 3 , the lever 30 moves down, maintaining engagement between the second shaft 23 and the second aperture 33 , thereby moving toward the second connector portion 20 . Simultaneously, as the guide projection 31 moves along the guide channel 12 , the first connector portion 10 is pulled into the second connector portion 20 .
[0024] When being pivoted down to the lowest position, the lever 30 is fully moved toward the second connector portion 20 . Simultaneously, the guide projection 31 is inserted up to an inner end of the guide channel 12 , thereby completely connecting the first connector portion 10 and the second connector portion 20 to each other so that the power supply connection or the signal connection is accomplished.
[0025] After the lever 30 is pivoted down to the lowest position, the third aperture 34 of the lever 30 is fixed by engagement with the lower lock projection 24 of the second connector portion 20 so that the lever 30 is not affected by an external impact or the like. Accordingly, undesired separation of the first connector portion 10 from the second connector portion 20 is prevented.
[0026] As apparent from the above description, the present invention provides a connector 1 capable of forcibly connecting a first connector portion 10 and a second connector portion 20 with each other through a pivoting operation of a lever 30 mounted to the first connector portion 10 . According to the present invention, assembly of the connector 1 can be achieved even with minimal force since the first connector portion 10 and the second connector portion 20 are easily connected by the principle of leverage of the lever 30 even though the connector 1 includes a plurality of first and second terminals 11 and 21 . Furthermore, since a length of the lever 30 can be reduced, the overall size of the connector 1 can be minimized, while maximizing a moving distance of the connector 1 .
[0027] The connector 1 according to the present invention enables both vertical and horizontal movements of the lever 30 relative to the first connector portion 10 , by comprising first apertures 32 and second apertures 33 formed on the lever 30 . As a result, the structure of the connector 1 is simplified, further simplifying the manufacture of the connector 1 . Further, assembly and disassembly of the connector 1 can be performed more precisely.
[0028] Moreover, since the lever 30 is fixed at highest and lowest positions thereof by third apertures 34 and lock projections 24 , undesired movement of the lever 30 is prevented before assembly of the connector 1 . Consequently, more precise assembly is achieved while preventing failure in connection due to movement of the lever 30 after assembly.
[0029] Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
|
A connector having a first connector portion and a lever movably connected to an outside of the first connector portion is disclosed. The lever is rotatable with respect to the first connection portion and the lever is translatable with respect to the first connection portion. A guide projection is connected to the lever and the connector further has a second connector portion. The second connector portion has a guide channel having an open upper part, at least a portion of the guide channel having a sloped portion being sloped with respect to a direction in which the first connector portion is connectable to the second connector portion, the guide channel configured to receive the guide projection through the open upper part of the guide channel.
| 7
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2008/054326 filed Apr. 10, 2008, and claims the benefit thereof. The International Application claims the benefits of German Application No. 10 2007 017 518.5 DE filed Apr. 13, 2007; both of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The present invention relates to a coating for containers and pipes made, for example, from metal, glass, plastics or ceramic material, in particular condenser pipes, for reducing or preventing biofilm formation, and a method for manufacturing the coating.
BACKGROUND OF INVENTION
[0003] Due to the fact that there are optimum temperatures for organisms, it is possible that, for example, in condenser pipes of industrial turbines and other heat exchangers, biofilms and algal growth known as ‘biofouling’ can form.
[0004] A biofilm is a permanent protective habitat for microorganisms (e.g. bacteria, algae, fungi, protozoa). Biofilms form mainly in aqueous systems when microorganisms colonize boundary surfaces, for example, the boundary surface to a solid phase. Apart from the microorganisms, the biofilm contains mainly water. Extracellular polymer substances (EPS) excreted by the microorganisms combine with water to form hydrogels, so that a slimy matrix, the glycocalyx is produced, giving the biofilm a stable structure and enabling the microorganisms to hold firmly to all materials and tissues. The glycocalyx consists of biopolymers. A wide spectrum of polysaccharides, proteins, lipids and nucleic acids is involved herein.
[0005] The glycocalyx protects the bacteria against environmental influences such as temperature changes, flow rates, etc. The bacteria are supplied with oxygen and nutrients through water channels of the glycocalyx. The sorption properties of the glycocalyx result in an accumulation of nutrients and this is therefore part of the survival strategy of biofilm organisms in oligotrophic environments.
[0006] At the boundary layer to water, cells or whole sections of the biofilm can be repeatedly released and taken up by the water flowing past. The biofilms themselves filter arriving new cells and bacteria and decide whether a particle arriving from outside is permitted to remain or is repelled. For this intercellular communication necessary for the differentiation of the biofilm, also known as ‘cell-to-cell signaling’, suitable messenger substances or signal molecules are emitted.
[0007] The highest purpose of this information exchange is the regulation of gene expression, which ultimately enables the ordered formation of the biofilm system. This intercellular information exchange is essentially based on the continuous release of messenger substances in low concentrations by the bacterial cells. This principle of cell density-dependent regulation of gene expression is designated ‘quorum sensing’. This involves an intercellular and intracellular communication and regulation system using signal molecules, the ‘autoinducers’. The system enables the cells of a suspension to measure the cell density of the population and to react thereto through autoinduction. Depending on the cell density, the concentration of the signal molecules in the ambient medium rises and, once a critical threshold concentration has been exceeded, induces the transcription of specific gene products in the bacterial cells, leading to targeted changes in the phenotypic functions of the microorganism.
[0008] Industrial process water or processing water systems, for example, open or closed water circuits, water processing systems and service water systems or cooling water systems offer suitable conditions for the multiplication of microorganisms. The biofilm leads to changes in the physicochemical properties of the material in question, e.g. with regard to its frictional resistance, diffusion properties or thermal conductivity. In addition, the excretions from the biofilm organisms can accelerate the corrosion of their substrate, a process known as ‘biocorrosion’. Biocorrosion essentially causes changes in the structure and stability of a material through aesthetically impairing discoloration, the excretion of directly or indirectly corrosive metabolic products, right through to enzymatic decomposition of the materials in question.
[0009] A wide variety of damage can be produced as a consequence of biofouling and biocorrosion, such as increased resistance to thermal conduction and, associated therewith, raised condenser pressure, worsening of water quality, safety problems, e.g. through blocking of valves, increased cleaning costs, breakdown times, loading of plant parts due to cleaning procedures, reduced plant output, shortened service lifetimes, reduced cooling performance with a grater energy consumption and increased use of biocides and cleaning agents, and therefore increased waste water pollution.
[0010] A variety of methods have been developed to prevent or delay the formation of biofilms or to remove them. These include mechanical destruction of the biofilms, measures for disinfection and germ removal from the water and enzymatic methods for removing biofilms.
[0011] In order to prevent or clear away deposits, pipe cleaning systems, such as the Taprogge system, are used, wherein sponge rubber balls are fed through the plant in the circuit together with the cooling water. These systems are very expensive and are seldom used in relatively small condensers such as industrial turbines and subsidiary circuits. Other conventional methods for preventing biofouling are, for example, a pipeline design which leads to a flow rate of 2-3 m/s, a two-part condenser design, a two-stranded pipe cleaning system, condenser back-flushing and thermal treatment.
[0012] The deposition of bacterial slimes can be effectively controlled with biocides, although the biofilm affords a certain degree of protection to the microorganisms. Therefore, very high concentrations of biocides are required to kill off the bacteria, and this is undesirable for reasons of environmental protection. Microorganisms are also particularly difficult to remove from the biofilms. In order to prevent formation of the biofilm, biocides such as sodium hypochlorite and chlorine dioxide are currently used.
[0013] Metals such as copper, aluminum and zinc and possibly also silver are toxic to bacteria. For example, the Cuprion anti-fouling system uses copper and aluminum anodes in an insulated steel frame which serves as a cathode. Herein, soluble biocides in the form of copper ions and aluminum ions are released into the cooling water.
[0014] DE 102 25 324 A1 uses an antimicrobial (acryl) paint with nanoparticles that are smaller than 100 nm, the surfaces of which are enriched with silver or copper, as ions or in elemental form. A biocidal effect has been produced, for example, with Si-coated TiO 2 particles.
[0015] DE 103 37 399 A1 describes a method for producing a silver colloid-containing substance and its inclusion in paints. Silver amine and diamine complexes with components based on epoxysilanes are included. The silver colloid particles have a diameter in the range of 5 nm to 30 nm, so that a controlled Ag release is achieved. The paints show a biocidal or bactericidal effect.
[0016] The bactericidal effect of silver is known, although the mechanism is not yet fully understood. Silver particles are physiologically tolerated. However, silver salts such as silver nitrate show only a slight antibacterial effect on zeolites. In addition, even with controlled release, silver particles leach out over time. Investigations by the inventor have shown that the antibacterial effect of silver-based systems falls off after only two weeks.
[0017] DE 696 23 328 concerns a composition which contains mannanase to prevent and/or remove biofilms on surfaces. DE 696 19 665 discloses an exopolysaccharide-decomposing enzyme which is able to break down colonic acid. However, these enzymatic processes are not preventative, but attack an existing biofilm.
SUMMARY OF INVENTION
[0018] An object of the invention is to find an improved coating which significantly reduces or prevents biofilm formation, particularly in heat exchangers such as condenser tubes (of industrial turbines) and subsidiary cooling circuits, and a method for the manufacturing thereof. The coating is intended to
[0019] disrupt the attachment mechanism of the bacteria and thereby prevent or minimize attachment,
[0020] make it possible to dispense with the use of soluble biocide chemicals or toxic metals and therefore to design, for example, affected power stations to be more ecologically tolerable,
[0021] improve, or not restrict, the thermal conductivity of the coated material,
[0022] adhere well to the coated material and be resistant to hydrolysis,
[0023] enable a much lower maintenance cost for the plant compared with mechanical cleaning processes.
[0024] This object is achieved with a coating and a method as claimed in the independent claims. Advantageous embodiments and applications of the invention emerge from the dependent claims.
[0025] Surprisingly, the object could be achieved according to the invention in that the coating has the following combination of properties:
[0026] prevention, by hydrophobic surfaces, of the formation of a water film,
[0027] reduction of the surface energy by nanoparticles,
[0028] increasing the thermal and electrical conductivity with nano and/or microparticle composites,
[0029] hydrolysis-resistance through the use of hydrolysis-resistant polymers,
[0030] corrosion protection for pipelines.
[0031] The hydrophobic surface of the coating according to the invention prevents the formation of a water film. It is known that the formation of deposits can be suppressed by coating the relevant surfaces with a low-energy coating material. The surface energy determines the wettability (see FIG. 1 ). The contact angle or wetting angle θ of a liquid drop depends on the surface energy of the liquid σ 1 and of the substrate surface σ s and is a measure of the energetic interaction between the solid body and the liquid. The energy of the interface between the liquid and the substrate surface is σ s1 .
[0000]
cos
θ
=
σ
s
-
σ
sl
σ
l
=
σ
c
σ
l
[0032] A permanent water film on the surface would favor the attachment of bacteria. The coatings according to the invention produce superhydrophobic surfaces with surface energies of less than 20 mN/m, so that a permanent water film, and thus the attachment of bacteria, is lessened or avoided. In one embodiment, the surface energy is less than 15 mN/m. In another embodiment, the surface energy is less than 10 mN/m.
[0033] Thermally stable metal alkoxidic materials which are preferably producible with the sol-gel method are suitable as coating materials according to the invention. The sol-gel hybrid polymers are curable thermally and by UV radiation.
[0034] Sol-gel-based anti-adherence coatings have a network structure with organic and inorganic components.
[0035] Metal alkoxides with the following formula (I) are essentially used in the present invention.
[0000] X n -M-(OR) m-n (I)
[0000] where X is a branched or straight-chain C 1 to C 12 alkylsilyl group or a C 1 to C 12 arylsilyl group wherein the alkylsilyl group or the arylsilyl group is also substituted with one or more C 1 to C 12 alkoxy groups and/or C i to C 12 aryloxy groups. Suitable groups for X preferably include methyltrimethoxysilane, methyltriethoxysilane, tetraethoxyorthosilane, propyltrimethoxysilane, propyltriethoxysilane, isobutyltrimethoxysilane, isobutyltriethoxysilane, octyltriethoxysilane, hexadecyltrimethoxysilane, octadecyltrimethoxysilane, phenyltrimethoxysilane and phenyltriethoxysilane.
[0036] M can be an arbitrary metal or element having a plurality of groups X n and (OR) m-n . Preferably, M=Al, Si, Ti or Zr, or more preferably M=Si.
[0037] R is a branched or straight-chain C 1 to C 5 alkyl group or aryl group or a silyl group substituted therewith. R preferably comprises ethyl groups (tetraethyl titanate), isopropyl groups or trimethylsiloxide groups.
[0038] Values for m, n and n′ are given by the valency of the metal or element M and can be selected accordingly. It is a general principle that m and n are natural numbers ≧1 and n′=m−n. For example, m=4 for M=Si, Ti, Zr, m=3 for M=Al, n=1 to 3 for M=Si, Ti, Zr and n=1 to 3 for M=Al.
[0039] Further, according to the invention, coatings which comprise conventional hydrolysis-resistant paints are suitable. Preferably, a paint system is selected from the group including polyurethanes, acrylics and silicones.
[0040] In silicones, silicon atoms are linked via oxygen atoms to molecule chains and/or network structures. The remaining free valency electrons of the silicon are saturated through hydrocarbon groups, for example, by methyl groups as illustrated in formula (A).
[0000]
[0041] As silicones, above all cross-linked polymethylsiloxanes or polymethylphenylsiloxanes and fluorosilicones are suitable. Fluorosilicones are temperature-resistant and oxidation-resistant silicones wherein the methyl groups are replaced by fluoroalkyl groups. For example, one or two-component silicone rubbers such as Powersil 567 or Elastosil® 675 from the firm of Wacker Chemie AG are used. These silicones are heat-resistant, hydrophobic, dielectric and are usually regarded as being physiologically tolerated.
[0042] Coatings according to the present invention can be applied with conventional methods known to persons skilled in the art, such as dipping, flooding, spraying or spreading. The coating according to the invention preferably has a coating depth of more than 10 μm, preferably 30 μm to 150 μm, more preferably 50 μm to 100 μM, so that the surface roughness of the raw material is evened out. Due to the low layer thickness of the hydrophobic coating, the pressure loss in the pipe is not reduced. The layer thickness is in any event selected so that the roughness of the raw material can be evened out.
[0043] In one embodiment, by addition of microparticles and/or nanoparticles, at the same time as the surface functionalization, a defined stochastic microroughness is obtained in the coating with regard to the maximum occurring height difference between elevation and depression in the coating surface, which further improves the anti-hold properties with respect to bacteria. In one embodiment, the coating has a roughness (determined according to DIN 4762, ISO 4287/1) of less than 200 nm, preferably less than 150 nm and/or stochastic topographies with roughnesses of less than 500 nm, preferably less than 300 nm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] In the drawings:
[0045] FIG. 1 shows the contact angle or wetting angle θ of a liquid drop as a measure of the energetic interaction between the solid body and the liquid,
[0046] FIG. 2 shows the surface of a coating according to the invention in an enlargement of 3 μm, comprising a stochastic topography of 500 μm produced by microparticles. The roughness Ra is less than 500 nm,
[0047] FIG. 3 shows the surface of a coating according to the invention in an enlargement of 3 μm, which comprises a stochastic topography of 500 nm produced by microparticles. The roughness Ra is less than 500 nm,
[0048] FIG. 4 shows the smooth surface of a coating according to the invention in an enlargement of 3 μm, which does not contain any microparticles and has a roughness of less than 50 nm.
DETAILED DESCRIPTION OF INVENTION
[0049] Suitable microparticles or nanoparticles which can be contained in the coating are, according to the invention, selected from the group consisting of SiO 2 , Al 2 O 3 , SiC and BN. The particles have a size in the range of 0.5 μm to 5.5 μm, and preferably 0.5 μm to 2.0 μm. If smaller particle sizes are selected, the polymer system becomes viscous even with a content of 10%.
[0050] In one embodiment, the particles are SiO 2 particles, in particular fluorine-functionalized SiO 2 particles. In another embodiment, the particles are BN particles. According to the invention, the coating comprises particles in a quantity in the range of 10% to 35% by volume, preferably 25% to 32% by volume and more preferably 30% by volume. With volume proportions up to approximately 30%, the thermal conductivity of the composite is almost independent of the strengthening phase. The particles are then fully enclosed by the plastics layer. With filling levels of up to 30% by volume, smooth layers are still achieved.
[0051] The resulting contact angle (with respect to water) of commercially available PUR and silicone varnishes are in the range of 95° to 100°. With fluorine-functionalized SiO 2 particles or BN particles, the contact angle can be increased to 140°, so that the surface energy can be reduced to values of less than 15 mN/m.
[0052] By inclusion of heat-conducting particles with anti-adhesion properties, such as boron nitride particles, into the coating, the surface energy can be further reduced to values under 15 mN/m. Due to the very good thermal conductivity of boron nitride, the plate-shaped BN particles result in an improvement in thermal conduction. In addition, electrostatic charging can be prevented by means of anti-static silicone coatings with conducting particles.
[0053] In another embodiment, BN particles are included in the coating. Through the inclusion of electrically insulating BN particles having the above-mentioned dimensions, the coating according to the invention which has a significantly increased contact angle, also has raised thermal conductivity. The thermal conductivity depends on the size and morphology of the included particles. Possible morphologies are, for example, spherical, splintered or layered structures, but a plate-shaped morphology is preferable.
[0054] The cell-to-cell signaling at the surface of the bacteria through messenger substances usually brings about the attachment of further bacteria. By contrast, the cell-to-cell signaling of degraded proteins causes further suppression of the attachment of bacteria. In one embodiment, messenger substances which suppress the cell-to-cell signaling and thus the further attachment of bacteria in the long term are included in the coating. Suitable messenger substances include, for example, homoserine lactones (HSL), AHL and N-acyl-homoserine lactone for gram-negative microorganisms and posttranslationally modified peptides for gram-positive microorganisms. Messenger substances are described, by way of example, in Skiner et al., FEMS Microbiol. Rev. (2005) and include compounds such as 3-oxo-C6-HSL ( Vibrio fisheri ), 2-heptyl-3-hydroxyl-4-quinoline ( Pseudomonas aeruginosa ), Butyrolactone ( Streptomyces griseus ), cyclic thiolactone (type III) ( Staphylococcus aureus ), S-THMF-borate ( V. harveyi ) and R-THMF ( S. typhimurium ).
[0055] Manufacturing Method
[0056] A method for manufacturing the coating according to the invention comprises the following steps:
[0000] Preparation of a Metal-Alkoxide-Sol with an Organically Modified Metal Alkoxide of the General Formula I as the Starting Substance
[0000] X n -M-(OR) m-n (I),
[0000] where X is a branched or straight-chain C 1 to C 12 alkylsilyl group or a C 1 to C 12 arylsilyl group, wherein the alkylsilyl group or the arylsilyl group is also substituted with one or more C 1 to C 12 alkoxy and/or C 1 to C 12 aryloxy groups;
M is a metal or element;
R is a branched or straight-chain C 1 to C 5 alkyl group or aryl group or a silyl group substituted therewith;
m and n are natural numbers where m and n≧1 and n′=m−n;
or alternatively a paint system selected from hydrolysis-resistant paints of the group including polyurethanes, acrylics and silicones;
application of the sol or the paint system to at least one surface to be coated by dipping, flooding, spraying or spreading;
curing the metal alkoxide sol or paint system wherein the curing of the silicone, acrylic or PUR system is carried out at temperatures of between 15° C. and 50° C. and wherein the curing of the metal alkoxide sol is carried out by means of heat or UV radiation by hydrolysis and condensation of the metal alkoxides.
[0057] The groups X preferably comprise methyltrimethoxysilane, methyltriethoxysilane, tetraethoxyorthosilane, propyltrimethoxysilane, propyltriethoxysilane, isobutyltrimethoxysilane, isobutyltriethoxysilane, octyltriethoxysilane, hexadecyltrimethoxysilane, octadecyltrimethoxysilane, phenyltrimethoxysilane and phenyltriethoxysilane. Preferably also, M=Al, Si, Ti or Zr and more preferably M=Si. R preferably comprises ethyl groups (tetraethyl titanate), isopropyl groups or trimethylsiloxide groups.
[0058] The layer thickness of the coating according to the invention is in the range of 10 μm to 150 μm and preferably 50 μm to 130 μm and particularly preferably 50 μm to 100 μm.
[0059] In one embodiment, the at least one surface is a pipe inner surface.
[0060] In another embodiment, silicone which contains in the range of 10% to 30% by volume of boron nitride particles is used as the coating material.
[0061] The surface to be coated can be cleaned and de-greased with an organic solvent before application of the sol or the paint system. The surface to be coated can also be coated with a foundation layer and/or an adhesion promoter before application of the sol or the paint system. The surface to be coated can also be coated with a molecular layer containing silanes or siloxanes before application of the sol or the paint system.
[0062] If spraying is performed to coat the surface, this can be carried out using the Plastocor process wherein a telescopic structure with a spray nozzle is used to coat long cooling pipes having a relatively small pipe diameter.
[0063] The hydrophobic coating according to the invention has been tested for the biocidal effects thereof on stainless steel and titanium substrates. With coating thicknesses of approximately 100 μm on titanium tube substrates, contact angles relative to water in the range of 130° to 145° have been achieved.
[0064] The coating according to the invention has a high hydrolysis-resistance. The surface energies achieved are maintained, even during water storage over many months. For example, with BN-filled silicone coatings and ageing in river water, no colonization with bacteria occurs on the coated substrate even after 40 weeks.
[0065] With BN levels of approximately 30% by volume in the coating, thermal conductivities of greater than 3 W/mK were obtained.
[0066] The use of these biocidal materials in the cooling circuit can make the use of soluble biocides unnecessary. In an ideal case, a tube cleaning system can be dispensed with altogether. Further advantages are the maintenance of plant performance levels, longer plant lifetimes and reduced cleaning effort.
[0067] The invention will now be described in greater detail with the accompanying examples, but without limiting it thereto.
Example 1
[0068] The inside of a steel pipe was treated with a commercially available adhesion promoter from the firm of Wacker Chemie AG and then sprayed with a silicone paint. The silicone paint had previously had 30% by volume of submicrocrystalline platelet-shaped BN particles, BN CTP05, from the firm of Saint-Gobain mixed into it. Following application, the paint was cured at approximately 30° C.
Example 2
[0069] Using the Plastocor method, a polyurethane paint with 20% by volume of fluorine-functionalized SiO 2 particles was applied to the inside of a de-greased titanium pipe. Following application, the paint was cured at 20° C.
|
A coating for containers and pipes of, for example, metal, glass, plastic, or ceramic, particularly for condenser pipes, for reducing or avoiding the formation of a biofilm is provided. Further, a method for producing the coating is provided.
| 2
|
BACKGROUND OF THE INVENTION
The present invention relates to a method and an apparatus for the shaping of plastics material pre-forms into plastics material containers. Apparatus of this type have long been known from the prior art.
In recent years it has also become known in this case for blow moulding machines of this type, and also in particular stretch blow moulding machines, to be provided with air recycling systems. In this case it is possible for plastics material pre-forms to be acted upon with different pressure levels for the expansion thereof, and in this way compressed air can possibly be recovered again. A presently current machine of the Applicants has in this case two pressure ducts which are capable of being recycled. These are a pressure duct which provides available a preliminary blow moulding pressure and a pressure duct which provides an intermediate blow moulding pressure. In particular, the level of the so-called intermediate blow moulding significantly influences the air consumption, in which case, however, an ideal air consumption can be predicted only with difficulty.
DE 10 2004 041 973 B3 describes an air recycling in a blow moulding process. In this case an aeration of the container with respect to an environmental pressure is carried out after a transition phase and a pressure control in the lower compressed air supply is carried out by a variation in the duration of this transition phase.
It has been found, however, that with this method the full potential of a possible saving cannot yet be exploited.
The object of the present invention is therefore to improve the pressure consumption for blow moulding machines of this type still further.
SUMMARY OF THE INVENTION
In the case of a method according to the invention for the shaping of plastics material pre-forms into plastics material containers, plastics material pre-forms are introduced into a blow mould or in each case into blow moulds respectively and are expanded to form the plastic bottles or plastics material containers respectively by being acted upon with a gaseous medium in the blow mould. In this case a preliminary blow moulding is first carried out by acting upon the plastics material pre-forms with a first pressure. After that, an intermediate blow moulding of the plastics material pre-forms is carried out at a second pressure which is higher than the first pressure. Finally a final blow moulding of the plastics material pre-forms is carried out at a third pressure which is higher than the second pressure.
According to the invention at least the second pressure is varied during a working operation. Whereas, as mentioned above, the preliminary blow moulding has a major influence upon the quality of the container, it has been possible to establish that the intermediate blow moulding pressure serves predominantly to reduce the air consumption. It has thus been determined that a variation in the intermediate blow moulding pressure has no such major influence upon the quality of the bottle. The pressure ducts of the preliminary blow moulding and of the intermediate blow moulding are preferably regulated themselves in this case, depending upon the pressure level of the individual annular ducts. Hitherto it was necessary for the marginal conditions or for the pressure level to be set by an operator himself or herself.
The level of the intermediate blow moulding pressure significantly influences the air consumption, in which case a prediction of the optimum is heavily dependent upon the process and until now could not be predicted in a reliable manner.
It is advantageous for at least the second pressure to be regulated at least in a manner dependent upon a further process variable (for example the consumption) during working operation. In contrast to the prior art no setting of the intermediate blow moulding pressure (or only a setting fixed by the user) is carried out, but this intermediate blow moulding pressure, i.e. in this case the second pressure, can be regulated in the scope for example of an optimization operation. According to the prior art, on the other hand, an optimum setting of this type is found difficult for the recycling process and this is not controlled even by numerous operators, so that many stretch blow moulding machines produce with a significantly excessive air consumption.
An essential concept of the invention thus lies in the fact that the intermediate blow moulding pressure is varied automatically according to a process setting found (in this case for example an air recycling can be activated by the operator) in order to settle the recycling in this way. The consumption of the gaseous medium is understood in particular in this case as being that portion of the gaseous medium which can no longer be fed back or recycled respectively. In this case it would be possible for this consumption to be determined for example with a flow meter.
In addition, it is possible for a pre-set characteristic, which is characteristic for example of the air consumption, to be stored. The intermediate blow moulding pressure or the second pressure respectively, by which the lowest air consumption is then generated, can preferably be taken over automatically.
It is advantageous for a measurement of the second pressure to be carried out at least for a time and it is particularly preferred for a continuous measurement of at least this second pressure to be carried out. In addition it would also be possible for the first and/or the third pressure also to be varied.
In the case of a further preferred method the plastics material containers are released after the final blow moulding or air is again released out of the containers. It is preferable for the final blow moulding pressure to be maintained for a pre-set period of time.
It is preferable for the pressure level after the final blow moulding to be reduced again to an intermediate blow moulding pressure at least for a time. It is advantageous for the first pressure or the preliminary blow moulding pressure respectively to be between 2 bar and 15 bar, preferably between 4 bar and 12 bar and in a particularly preferred manner between 4 bar and 10 bar. It is advantageous for the second pressure, i.e. the intermediate blow moulding pressure, to be between 8 bar and 40 bar, preferably between 12 bar and 20 bar. It is advantageous for the third pressure to be between 20 bar and 40 bar, preferably between 20 bar and 35 bar. In the case of a further preferred method the second pressure or the intermediate blow moulding pressure respectively can be varied with a pressure range which is between 3 bar and 20 bar, preferably between 5 bar and 15 bar.
It is advantageous for a correlation to be produced with the air consumption—in particular with reference to a pressure curve—in the blow moulding machine. The higher a pressure before the release of the stretch blow moulding machine or of the container respectively, the higher also the air consumption.
It is therefore preferable for the second pressure to be determined in a manner dependent upon the consumption of the gaseous medium. It is thus preferable for a regulating circuit to be provided which regulates the second pressure in a manner dependent upon a measured consumption.
In the case of a preferred method the level of the second pressure is determined, in which the consumption of the gaseous medium reaches a minimum. This second pressure can be used for the following working operation. A variation during a working operation is understood as being an operation of the machine in which containers are produced at least on a trial basis. In addition, however, a special teach-in or calibration mode of the plant may also be involved. In this way, the working operation also designates those operation situations in which a machine is set, is changed over to new containers or is set up otherwise.
In the case of a further advantageous method the consumption of the gaseous medium required for shaping the plastics material pre-form—in particular in a manner dependent upon the second pressure—is determined. In this case it is possible for the pressure to be varied within the regulation procedure and for the consumption of gaseous medium to be fixed in each case in a manner dependent upon this pressure.
As mentioned, a level of this air consumption is determined in this case. In this way, as mentioned above, the pressure is regulated in a manner dependent upon the consumption.
In the case of a further advantageous method a finished blow moulding of the plastics material containers is initiated when the second pressure exceeds a pre-set threshold value. It would now be possible for the regulation to result in the intermediate blow moulding pressure being estimated very high. In this case a threshold value is set from which the finished blow moulding stage is set in each case. In this way for example, it is possible to determine that the finished blow moulding is automatically activated when 95% of the nominal pressure is achieved during the intermediate blow moulding.
It is advantageous for a threshold value switch-over to be provided for the second pressure. It is thus preferable for a switch-over to take place from the second pressure to the third pressure when a specified threshold value of this intermediate blow moulding pressure is reached.
In the case of a further advantageous method the blow moulds or the containers respectively are conveyed along a pre-set conveying path during the expansion of the plastics material pre-forms and the second pressure is preferably also selected in a manner dependent upon a position of these blow moulds along the conveying path. In this way, it is possible for example for a switch-over to take place from the first pressure level to the second pressure level and/or from the second pressure level to the third pressure level from a specified position of the blow moulds by means of their conveying path in each case.
It is advantageous for the blow moulds or the blow moulding stations respectively, the component part of which is preferably also formed by the blow moulds, to be conveyed along a circular conveying path, for example by means of a blow moulding wheel. A checking of the respective angles, in which the respective method steps are initiated, is preferably carried out in this case. In this way, it is possible for example for the period of time or the angle, during which a recycling takes place, not to be further increased if a pressure equilibrium is already present between the reservoir in question and the residual pressure inside the container. In addition, it would be possible for no further increase to take place if, although a pressure equilibrium is not yet present, there is already approximately an equilibrium, for example the situation differs from an equilibrium by only 0.5 bar or less. Furthermore, it is also preferable for the maximum process angle along which a recycling takes place to be limited.
On account of the method according to the invention it is possible for the intermediate blow moulding also to be completely masked for the user and to be optimized only at the touch of a button in the context of the recycling. In addition, it would be possible for a correction variable to be displayed instead of an air consumption measurement appliance. A touchscreen for example could be used as a display device.
The present invention further relates to an apparatus for the shaping of plastics material pre-forms into plastics material containers. This apparatus has at least one blow mould or a blow moulding station respectively, inside which the plastics material pre-form is capable of being expanded by being acted upon with a gaseous medium. In addition, the apparatus has a stressing device which acts upon the plastics material pre-form with the gaseous medium, as well as a first pressure reservoir which provides the gaseous medium available for the preliminary blow moulding of the plastics material pre-form at a first pressure, and a second pressure reservoir which provides the gaseous medium for the intermediate blow moulding of the plastics material pre-form at a second pressure, the second pressure being higher than the first pressure, and with a third pressure reservoir which provides the gaseous medium for the final blow moulding of the plastics material pre-form at a third pressure, the third pressure being higher than the second pressure.
According to the invention the apparatus has a measuring instrument which determines at least one value which is characteristic of the consumption of the gaseous medium, and a control device which controls or changes respectively at least the second pressure in a manner dependent upon the consumption of the gaseous medium.
It is advantageous for this control device to be a regulating device which carries out a regulation of the second pressure in a manner dependent upon the consumption of the gaseous medium.
It is advantageous for the apparatus to have a carrier on which a plurality of blow moulds of this type are arranged. It is advantageous for this carrier to be designed in the form of a blow moulding wheel and for a plurality of blow moulding stations to be arranged on the latter. The blow moulds in this case are preferably component parts of this blow moulding station. It is advantageous for the individual blow moulding stations also to have stretching rods which extend the containers in the longitudinal direction thereof during the expansion thereof.
In this case it is also possible for a movement of these stretching rods to be altered in a manner dependent upon the pressure level mentioned above and/or in a manner dependent upon the consumption of the gaseous medium or the compressed air respectively. In this case too, a regulation would be possible, so that conversely a movement of the stretching rod is also taken into consideration during the setting of the pressure level.
In the case of a further advantageous design the apparatus has at least one valve device which is arranged between at least one pressure reservoir and the stressing device and which controls the supply of the gaseous medium to the plastics material pre-forms.
The stressing device can be for example a blow moulding nozzle which is preferably applied to an aperture of the plastics material pre-forms before the expansion.
It is advantageous for a plurality of valves to be provided which control the pressure supply, in particular also at different pressure levels. For this purpose each individual blow moulding station of the apparatus can have a valve block which in turn has this plurality of valves.
In the case of a further advantageous design at least part of the gaseous medium is capable of being returned or is fed back respectively from the plastics material containers into, at least into, a pressure reservoir. In this way it would be possible for compressed air to be allowed back again into the second and the first reservoir, which are under a lower pressure, for example after the final blow moulding.
It is advantageous for at least one pressure reservoir to be designed in the form of an annular line which supplies a plurality of blow moulding stations or shaping stations respectively with compressed air.
It is advantageous in this case for these individual shaping stations to have in each case the blow mould indicated here, and in addition, however, also other components, such as for example blow mould holding means, which can be unfolded and folded together respectively during the opening and closing. In addition, these shaping stations preferably also have stretching rod in each case for stretching the plastics material pre-forms.
In the case of a further advantageous design the apparatus also has—in particular per blow moulding station—outlets by way of which compressed air can be released to the environment. In addition, a silencer can also be provided in the region of this outlet in this case.
A measuring instrument is advantageous for measuring the air consumption in the flow connection to one of the aforesaid outlet lines, by way of which compressed air can be released to the environment.
It is advantageous for the apparatus also to have one or more pressure measuring instruments which measures or measure in each case the pressures used for the expansion of the containers. A processor device preferably also controls the pressure levels in a manner dependent upon these measured pressures.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages and designs are evident from the accompanying drawings. In the drawings
FIG. 1 shows a diagrammatic illustration of an apparatus according to the invention for the shaping of plastics material pre-forms into plastics material containers, and
FIG. 2 shows an illustration of a curve pattern for stressing with compressed air.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows in a roughly diagrammatic manner an apparatus 1 according to the invention for the shaping of plastics material pre-forms 10 into plastics material containers 20 . In this case for example, plastics material pre-forms 10 are supplied to the apparatus 1 by way of a supply star wheel (not shown) and they are shaped into plastics material containers 20 , during which the plastics material pre-forms are moved along a conveying path P. The apparatus 1 has in this case a carrier which is designated 6 as a whole and which is rotatable about its axis of rotation D and on which a plurality of blow moulding stations 4 are arranged. These blow moulding stations are arranged equidistantly in this case. Each individual blow moulding station 4 also has in this case a blow mould 2 which can be opened and closed and in the interior of which is formed a cavity inside which the plastics material pre-forms 10 are expanded to form the plastics material containers 20 .
The reference number 22 designates in a roughly diagrammatic manner a stretching rod which stretches for stretching the plastics material pre-forms along their longitudinal direction which extends at a right angle to the plane of the figure in this case.
The reference number 12 designates a first pressure reservoir which is designed in the form of an annular duct in this case. Compressed air can be supplied to this pressure reservoir 12 from the outside for example by way of a compressor (not shown).
This compressed air reservoir 12 is connected to the individual blow moulding stations 4 by way of a connecting line (not shown) and it supplies compressed air to them in this way. In addition, as well as the compressed air reservoir 12 , a second compressed air reservoir 14 and a third compressed air reservoir 16 are further provided, but they are not visible in this case since they are situated below the compressed air reservoir 12 . The second compressed air reservoir 14 and the third compressed air reservoir 16 are supplied at least indirectly by a compressor and are likewise connected in terms of flow to the individual blow moulding stations or shaping stations 4 respectively.
The reference number 8 designates a stressing device which acts upon the plastics material pre-forms with the compressed air for their expansion. It is pointed out that only one stressing device 8 is illustrated in this case solely on grounds of visualization, but each blow moulding station has a stressing device 8 of this type and also a stretching rod 22 as well as also the blow mould 2 .
The references I to IV designate different portions of a blow moulding procedure. In this case a preliminary blow moulding of the plastics material pre-forms is first carried out in a portion I, an intermediate blow moulding in a portion II and a final blow moulding in a portion III. This portion III is the longest portion in terms of time. A release takes place in a portion IV, in which compressed air can again escape from the plastics material containers and the latter can finally be removed from the blow moulds.
The reference number 30 designates in a roughly diagrammatic manner a consumption measuring device which determines the amount of the blow moulding air used. In this case it would be possible for each individual blow moulding station to have a consumption measuring device of this type. It would also be possible, however, for a central consumption measuring device to be provided which measures the total consumption of air with reference to all the blow moulding stations.
The reference number 40 designates a control device or a regulating device respectively which determines the intermediate blow moulding pressure pi in a manner dependent upon the air consumption measured. The reference number 26 designates a valve device which is likewise present at each individual blow moulding station and which preferably has a plurality of valves which control the supply of the gaseous medium or the blow moulding air respectively to the individual stressing devices or the individual plastics material pre-forms 10 . This valve device can be designed in this case in the form of a valve block with a plurality of valves.
FIG. 2 shows a pattern of a pressure curve K. In this case a pressure pv, namely the preliminary blow moulding pressure, is shown, a pressure pi (the intermediate blow moulding pressure, i.e. the second pressure mentioned above), and a pressure pf, i.e. the final blow moulding pressure. The reference letter V designates the air consumption which is given by the distance between pv and pi. The reference letter R designates the air or amount of pressure respectively which can be recycled by the air released again from the respective containers being returned to the respective pressure ducts or reservoirs 12 , 14 at the lower compressed air level.
It will be seen that the amount of the air consumption and also the amount of the recycled air depend essentially upon the magnitude of the pressure pi at the point B. A higher pressure level of the pressure pi is shown at the point C, and this leads in this way to a higher air consumption and a lower amount of compressed air capable of being recycled.
The invention now proposes that this pressure pi should be set automatically whilst taking into consideration the air consumption. In the case of earlier machines this pressure level pi was pre-set by the user of the machines. In this case the corresponding input was masked in an input device, i.e. it cannot be carried out by the user. The point D designates the point from which a start is made again to release air from the containers since the shaping procedure is concluded.
It would also be possible, however, for an initial value pi to be pre-set by the user and for this then to be automatically regulated. In this case, however, it is also preferable to take into consideration the respective angles a 1 to a 4 , which is determined in FIG. 1 by the portions I to IV. In the event that a corresponding recycling angle is too large, i.e. pi is selected to be too low on the other hand, the control device will ensure that the recycling angle or the stopping angle (i.e. the angle at which the recycling is terminated) respectively is not further increased. It is advantageous, as mentioned above, for a threshold-value switch-over to be present which at least when a specified threshold value is achieved activates the pressure level following in each case. In addition, it would be possible to set the time or the angle respectively from which a start is made with the final blow moulding or acting upon the containers with the pressure pf. This is indicated by the curve portion K 1 shown in broken lines.
The control now varies the pi pressure in a purposeful manner and allows recycling to settle, in which case it is determined when air can be recycled for the most part. In other words, the pattern of an air outlet can be checked and if this is minimal, this results in the ideal air consumption. It is advantageous, however, for a plausibility check still to be carried out with reference to the recycling angle occurring in each case.
If, for example, the blow moulding curve pressure drops below the pressure pi in the preliminary blow moulding duct, possibly below this pressure plus a pre-set difference value which is preferably between 0.3 bar and 0.7 bar, or if the blow moulding curve pressure drops below the pressure of the pi annular duct, i.e. of the second reservoir 14 (likewise possibly plus a pre-set value which is between 0.3 bar and 0.7 bar, preferably at approximately 0.5 bar), then the respective recycling angle is not further increased.
It is preferably also possible for a proposed value for the second pressure pi to be issued or even, in a corresponding manner, a proposal for the respective angle, as illustrated in FIG. 1 or the recycling angle of the pressure pi.
In addition it is also possible for the starting point for the recycling, i.e. the time value of the point D in this case, to be set to the value of the maximum recycling R, possibly whilst deducting a specified degree range, such as for example from 1° to 3° and preferably 2°.
In addition, it would be possible for the pressure in the preliminary blow moulding duct, i.e. in the first reservoir 12 , to be compared with the pressure at the point B or for the pressure in the second reservoir or the annular duct respectively, i.e. the second pressure PI, to be compared with the pressure at the point C. If the difference is smaller than 0.5 bar, the corresponding recycling angle is not increased further, since a greatly improved saving can no longer be expected [in] this way.
The point B thus characterizes the optimized intermediate pressure PI at which the maximum recycling is possible. This adaptation of the pressure pi thus takes place, as mentioned above, in the course of the working operation, possibly also a calibration operation. Below the pressure pv (or from the point A respectively) the container is completely released again and can be removed from the individual blow moulding stations 4 . The reference letters Vz designate the delay time of the valves.
The Applicants reserve the right to claim all the features disclosed in the application documents as being essential to the invention, insofar as they are novel either individually or in combination as compared with the prior art.
LIST OF REFERENCES
1 apparatus
2 blow mould
4 blow moulding station
6 carrier
8 stressing device
10 plastics material pre-forms
12 first pressure reservoir
14 second pressure reservoir
16 third pressure reservoir
22 stretching rod
26 valve device
P conveying path
pv first pressure, preliminary blow moulding pressure
pi second pressure, intermediate blow moulding pressure
pf third pressure, final blow moulding pressure
A, B, C, D method points
I, II, III, IV method portions
a 1 , a 2 , a 3 , a 4 angles
D axis of rotation
t time
p pressure
K blow moulding curve
K 1 curve portion
Vz delay time
|
A method for the shaping of plastics material pre-forms into plastics material containers, wherein the plastics material pre-forms are introduced into a blow mould and are expanded to form the plastic bottles by being acted upon with a gaseous medium in the blow mould, includes the steps of:
preliminary blow moulding by acting upon the plastics material pre-forms with a first pressure; intermediate blow moulding of the plastics material pre-forms at a second pressure which is higher than the first pressure; and final blow moulding of the plastics material pre-forms at a third pressure which is higher than the second pressure, wherein
at least the second pressure is varied during a working operation.
| 1
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority based on 35 USC 119 from prior Japanese Patent Application No. P2009-040422 filed on Feb. 24, 2009, entitled “DISPLAY APPARATUS”, the entire content of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a display apparatus including a matrix of semiconductor thin film light emitting elements integrated on a substrate.
[0004] 2. Description of Related Art
[0005] Conventionally, in high-definition LED display apparatus using light emitting diodes (hereinafter, referred to as “LED”), that have very small pixel pitch of 3 mm or less bare chip LEDs are mounted in a two dimensional array (for example, Japanese Patent Application Laid-Open No. 2002-261335).
[0006] Specifically, a matrix of anode common lines and cathode common lines is formed on a substrate. Bare chip LED mounting areas are provided in areas other than the anode common lines and the cathode common lines. In order to electrically connect the bare chip LEDs, an anode electrode pad and a cathode electrode pad are formed extending from each anode common line and each cathode common line to the bare chip LED mounting areas. These electrode pads formed on the substrate are connected to an anode electrode pad and a cathode electrode pad formed on the bare chip LEDs. To connect the electrode pads on the substrate to the electrode pads on the bare chip LED, a gold (Au) bonding wire is applied to connect the electrode pads on the substrate to the electrode pads on the bare chip LED, or the bare chip LED is disposed on the substrate such that the surface having the electrode pads face the substrate and a conductive material connects the electrode pad on the bare chip LED and the electrode pads on the substrate.
SUMMARY OF THE INVENTION
[0007] However, in such a conventional display apparatus, since the bare chip LED mounting areas are provided in areas other than the anode common lines and the cathode common lines, the wire line width is limited by the bare chip LED mounting areas so that the width of the anode common lines and the cathode common lines cannot be widened to reduce the wiring resistance. To achieve reduction of the wire resistance, the area for light emission becomes extremely small.
[0008] On the other hand, if the bare chip LED mounting area is enlarged, the width of the anode common lines and the cathode common lines must be decreased thereby resulting in a higher voltage drop across the wires and uneven brightness over the entire display.
[0009] Further, if increasing the density of bare chip LEDs is desired, the bare chip LED mounting area must be increased making it difficult to maintain the area for the anode common lines and the cathode common lines, thereby requiring the wire width to decrease.
[0010] Therefore, with such a conventional display apparatus, it has been extremely difficult to realize greater density of light emitting elements and a smaller voltage drop across the connecting wires.
[0011] A first aspect of the invention is a display apparatus including: a plurality of parallel electrically conducting first linear electrodes extending on a planer substrate in a first direction; a plurality of parallel electrically conducting second linear electrodes extending in a second direction orthogonal to the first direction and spaced from the first linear electrodes in a third direction orthogonal to the plane of the substrate; a planarizing insulating film provided on the second linear electrodes at the intersections of the first and second linear electrodes to planarize the upper surfaces of the second linear electrodes; a plurality of semiconductor thin film light emitting elements, each one having an upper surface and a lower surface, the upper surface having a first conductive electrode and a second conductive electrode, the first and second electrodes are exposed from the upper surface, and the lower surface being connected to the planarizing insulating film; a first connection wire electrically connecting the first linear electrodes and the second conductive electrodes; and a second connection wire electrically connecting the second linear electrodes and the first conductive electrodes.
[0012] A second aspect of the invention is a display apparatus including: a plurality of parallel electrically conducting first linear electrodes extending on a planer substrate in a first direction; a plurality of parallel electrically conductive second electrodes extending in a second direction orthogonal to the first direction and spaced from the first linear electrodes in a third direction orthogonal to the plane of the substrate; a planarizing insulating film configured to block light, the planarizing insulating film provided on and planarizing the entire upper surface of the substrate including the intersections of the first and second linear electrodes and areas other than the intersections; a plurality of semiconductor thin film light emitting elements, each one having an upper surface and a lower surface, the upper surface having a first conductive electrode and a second conductive electrode, the first and second electrodes are exposed from the upper surface, and the lower surface being connected to the planarizing insulating film; a first connection wire electrically connecting the first linear electrodes the second conductive electrodes; and a second connection wire electrically connecting the second linear electrodes and the first conductive electrodes.
[0013] The display apparatus of the first aspect of the invention has a maximum area for forming the linear electrodes maintaining a high occupancy ratio of the light emitting area. Thus, a high-definition, high-intensity and large-screen display apparatus including semiconductor thin film light emitting elements is achieved.
[0014] In the display apparatus of the second aspect of the invention, since almost all areas around the semiconductor thin film light emitting elements is covered by a light-block planarizing insulating film, a high-contrast display apparatus is achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a sectional view of a pixel of a display apparatus according to the first embodiment of the invention.
[0016] FIG. 2 is a plan view of the surface configuration of the pixel of FIG. 1 .
[0017] FIG. 3 is a plan view of the entire display apparatus according to the first embodiment of the invention.
[0018] FIG. 4 is a sectional view of a pixel of a display apparatus according to the second embodiment of the invention.
[0019] FIG. 5 is a plan view of the surface configuration of the pixel of FIG. 4 .
[0020] FIG. 6 is a plan view of the entire display apparatus of according to the second embodiment of the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
[0021] Next, embodiments of the invention will be described with reference to the drawings. In the respective drawings referenced herein, the same constituents are designated by the same reference numerals and duplicate explanation concerning the same constituents is omitted. All of the drawings are provided to illustrate the respective examples only. No dimensional proportions in the drawings shall impose a restriction on the embodiments. For this reason, specific dimensions and the like should be interpreted with the following descriptions taken into consideration. In addition, the drawings may include parts whose dimensional relationship and ratios are different from one drawing to another.
First Embodiment
Configuration of First Embodiment
[0022] FIG. 1 is a sectional view of a pixel of a display apparatus according to a first embodiment of the invention. FIG. 2 is a plan view of a surface configuration of the pixel of FIG. 1 .
[0023] As shown in FIGS. 1 and 2 , the display apparatus of the first embodiment has substrate 1 . Parallel conducting linear electrodes, hereafter referred to as lower electrode common lines 3 , extending in a first direction, hereafter referred to as the row direction, are formed on interlayer insulation film 2 , which was previously formed on substrate 1 . Substrate 1 is, for example, a metal substrate made of iron (Fe), copper (Cu), stainless steel (SUS), aluminum (Al), or the like, a semiconductor substrate made of silicon (Si), or the like, or an insulating substrate made of glass, plastic, or the like. Note that, in the case where substrate 1 is an insulator, lower electrode common lines 3 may be formed directly on the insulating substrate without interlayer insulation film 2 . Interlayer insulation film 2 is, for example, an inorganic insulating film made of silicon nitride (SiN), silicon oxide (SiO2), aluminum oxide (Al2O3) or the like, or an organic insulation film made of polyimide, acrylic, novolac permanent film or the like. Lower electrode common lines 3 are made of, for example, Au, Al, titanium (Ti), platinum (Pt) or the like. Interlayer insulation film 4 is formed on the whole surface including lower electrode common lines 3 .Interlayer insulation film 4 is made of, for example, the same material as interlayer insulation film 2 . At predetermined positions of interlayer insulation film 4 , contact holes 4 a (see FIG. 3 ) are opened to expose portions of respective lower electrode common lines 3 . Parallel conducting linear electrodes, hereafter referred to as upper electrode common lines 5 that extend in a second direction, hereafter referred to as the column direction, orthogonal to lower electrode common lines 3 are formed on interlayer insulation film 4 . Upper electrode common lines 5 are made of, for example, the same material as lower electrode common lines 3 .
[0024] At the intersections of lower electrode common lines 3 and upper electrode common lines 5 , planarizing insulating films 6 , for planarizing the surface of upper electrode common lines 5 , are formed on upper electrode common lines 5 . On each planarizing insulating film 6 , the lower surface of each of semiconductor thin film light emitting elements (for example, semiconductor thin film LED) 10 is joined using an intermolecular force. Planarizing insulating film 6 is, for example, an inorganic insulating film made of SiN, SiO2, Al2O3 or the like, an organic insulation film made of polyimide, acrylic, novolac permanent film or the like and its typical surface roughness is preferably less than 5 nm. Further, planarizing insulating film 6 is preferably made of a material that transmits light emission wavelength emitted from semiconductor thin film LED 10 joined thereon.
[0025] Semiconductor thin film LED 10 has first conductive electrode (for example, an upper contact layer serving as an anode electrode) 11 whose upper surface is exposed and upper cladding layer 12 formed below upper contact layer 11 . Below upper cladding layer 12 , lower contact layer 15 is formed, such that active layer 13 and lower cladding layer 14 are provided between upper cladding layer 12 and lower contact layer 15 . Second conductive electrode (for example, a lower electrode serving as a cathode electrode) 16 whose upper surface is exposed is formed on lower contact layer 15 .
[0026] Semiconductor thin film LED 10 is, for example, composed of compound semiconductor layers of InP, InxGa1-xP, GaAs, AlxGa1-xAs, GaP, (AlxGa1-x) yIn1-yP, AlxIn1-xP, GaN, InxGa1-xN, AlxGa1-xN and AlN, and the thickness of the film is less than 5 μm for example. Regardless of the mounting area of such LED semiconductor thin films 10 , the width of upper electrode common lines 5 and lower electrode common lines 3 can be increased to an extent until just before interfering with neighboring lines.
[0027] The upper face and side faces of each semiconductor thin film LED 10 are covered with interlayer insulation film 7 . Each interlayer insulation film 7 is made of the same material as other interlayer insulation films 2 and 4 . Interlayer insulation film 7 has openings at portions corresponding to the upper surface of semiconductor thin film LED 10 so that entire upper contact layer 11 , a portion of upper cladding layer 12 , and a portion of lower electrode 16 are exposed. On interlayer insulation film 7 , second connection wire (hereafter referred to as upper electrode connection wire) 8 and first connection wire (hereafter referred to as lower electrode connection wire) 9 are formed for each LED 10 . Each upper electrode connection wire 8 electrically connects upper contact layer 11 and the portion of upper electrode common line 5 that is exposed from planarizing insulating film 6 . Further, each lower electrode connection wire 9 electrically connects lower electrode 16 and the portion of lower electrode common line 3 that is exposed through contact hole 4 a.
[0028] Semiconductor thin film LED 10 is protected by interlayer insulation film 7 formed between upper electrode connection wire 8 and semiconductor thin film LED 10 and between lower electrode connection wire 9 and semiconductor thin film LED 10 . Further, the insulation of semiconductor thin film LED 10 from upper electrode connection wire 8 and lower electrode connection wiring 9 is maintained except for the contacting areas.
[0029] FIG. 3 is a plan view of the entire display apparatus according to the first embodiment.
[0030] Lower electrode common lines 3 and upper electrode common lines 5 are arranged in the row and column directions respectively to form a matrix of wires and are insulated from each other by interlayer insulation film 4 . The matrix wiring is formed on interlayer insulation film 2 on substrate 1 . In the outer portion of the display apparatus, contact pads 21 for lower electrode common lines and contact pads 22 for upper electrode common lines are provided to electrically connect lower and upper electrode common lines 3 and 5 to an external driving circuit (not shown). On contact pads 21 and 22 , neither interlayer insulation film 4 nor planarizing insulating film 6 is formed so that contact pads 21 and 22 are exposed on the upper surface of substrate 1 .
Manufacture of First Embodiment
[0031] Interlayer insulation film 2 , such as an inorganic insulating film or an organic insulation film, is formed on the entire surface of substrate (for example, a metal substrate, a semiconductor substrate or an insulating substrate) 1 by chemical vapor deposition (hereinafter, referred to as “CVD method”) or the like. A wire material made of Au, Al, Ti, Pt or the like is formed on the entire surface of interlayer insulation film 2 by a vapor deposition method, a sputtering method or the like. The wire material is patterned to form lower electrode common lines 3 that are arranged parallel to each other and extend in the row direction by a photolithography technology. At one end of each lower electrode common line 3 , contact pad 21 is formed. Note that when an insulating substrate is used as substrate 1 , interlayer insulation film 2 may be omitted.
[0032] Interlayer insulation film 4 made of an inorganic insulating film, an organic insulation film or the like is formed on the entire surface including lower electrode common lines 3 (but not on contact pads 21 ) by a CVD method or the like. Contact hole 4 a is formed at a portion of interlayer insulation film 4 to expose a portion of lower electrode common lines 3 by a photolithography technology. Wire material made of Au, Al, Ti, Pt or the like is formed on the entire surface of interlayer insulation film 4 by a vapor deposition method, sputtering method or the like. the wire material is patterned and forms upper electrode common lines 5 extending in the column direction by a photolithography technology. At one end of each upper electrode common line 5 , contact pad 22 is formed.
[0033] Planarizing insulating film 6 such as an inorganic insulating film and an organic insulation film that transmits (for example, transparent for) the light emission wavelength emitted from the semiconductor thin film LED is formed on the entire surface including upper electrode common lines 5 by a CVD method or the like. Next, portions of planarizing insulating film 6 that are on areas other than the intersections of lower electrode common lines 3 and upper electrode common lines 5 are removed by a photolithography technology or the like. With this, portions of planarizing insulating film 6 that are on the intersections of lower electrode common lines 3 and upper electrode common lines 5 are left. The typical surface roughness of planarizing insulating film 6 is preferably equal to or less than 5 nm. Lower contact layer 15 comprising the lower surface of each semiconductor thin film LED 10 is joined on planarizing insulating film 6 at each intersection of lower electrode common lines 3 and upper electrode common lines 5 by using an intermolecular force. Note that semiconductor thin film LED 10 , which comprises upper contact layer 11 , upper cladding layer 12 , active layer 13 , lower cladding layer 14 , lower contact layer 15 , and lower electrode 16 , is previously manufactured before the above joint process.
[0034] Semiconductor thin film LED 10 is composed of, for example, a compound semiconductor layer of InP, InxGa1-xP, GaAs, AlxGa1-xAs, GaP, (AlxGa1-x) yIn1-yP, AlxIn1-xP, GaN, InxGa1-xN, AlxGa1-xN and AlN, and the thickness of the entire film is equal to or less than 5 μm for example. The compound semiconductor layer can be created on a substrate by a metal-organic chemical vapor deposition method (MOCVD method), a metal-organic vapour phase epitaxy method (MOVPE method), a molecular beam epitaxy method (MBE method) or the like. Semiconductor thin film LED 10 made of such compound semiconductor layer is separated from the substrate by a chemical lift-off method, a laser lift method, grinding or the like, and then joined to planarizing insulating film 6 .
[0035] After semiconductor thin film LEDs 10 are joined, interlayer insulation film 7 such as an inorganic insulating film, an organic insulation film or the like is formed on the entire surface of semiconductor thin film LED 10 by a CVD method or the like. Interlayer insulation film 7 is patterned by a photolithography technology or the like. In the patterning, portions of interlayer insulation film 7 not on the upper surface of semiconductor thin film LED 10 and a portion of interlayer insulation film 7 at the side of the semiconductor thin film LED 10 are removed. Further, lower interlayer insulation film 4 is also patterned and thereby contact holes 4 a for the lower electrode common line are opened.
[0036] The wire material such as Au, Al, Ti, Pt or the like is formed on the entire surface by a vapor deposition method, a sputtering method or the like, and the wiring material is patterned by a photolithography technology or the like to form upper electrode connection wires 8 and lower electrode connection wires 9 . In this configuration, upper electrode connection wires 8 electrically connect upper contact layer 11 to an area of upper electrode common line 5 that is exposed from planarizing insulating film 6 and, lower electrode connection wires 9 electrically connect lower electrode 16 to an area of lower electrode common line 3 that is exposed through contact hole 4 a . Forming an un-illustrated protective film or the like finishes the process of manufacturing the display apparatus shown FIG. 3 .
Operation of First Embodiment
[0037] To drive the display apparatus shown in FIG. 3 drive current is selectively supplied to contact pads 21 for the lower electrode common lines and to contact pads 22 for the upper electrode common lines from an external driving circuit (not shown). The drive current supplied to contact pads 21 and 22 is sent to upper electrode connection wire 8 and lower electrode connection wire 9 shown in FIGS. 1 and 2 via lower electrode common lines 3 and upper electrode common lines 5 .
[0038] The drive current sent to upper electrode connection wire 8 and lower electrode connection wire 9 is supplied to upper contact layer 11 and lower electrode 16 of semiconductor thin film LED 10 thereby causing active layer 13 in semiconductor thin film LED 10 to emit light upward and downward. The light emitted upward penetrates through upper cladding layer 12 and is radiated upwardly from LED 10 . The light emitted downward penetrates lower cladding layer 14 , lower contact layer 15 and planarizing insulating film 6 and is reflected by upper electrode common line 5 . The reflected light penetrates through planarizing insulating film 6 , lower contact layer 15 , lower cladding layer 14 , active layer 13 and upper cladding layer 12 and is radiated upwardly from LED 10 . With this configuration, a high-intensity display can be obtained.
Effect of First Embodiment
[0039] The typical surface roughness of a thin film wire formed by a vapor deposition method, a sputtering method or the like is generally greater than 5 nm, so it is difficult to mount semiconductor thin film LEDs 10 directly onto the intersection of lower electrode common line 3 and upper electrode common line 5 by using an intermolecular force. In the first embodiment, planarizing insulating film 6 , whose surface has a typical roughness equal or less than 5 nm, is formed on the intersection of lower electrode common line 3 and upper electrode common line 5 to planarize the intersection, and semiconductor thin film LED 10 is three-dimensionally mounted on planarizing insulating film 6 by using an intermolecular force. With this configuration, the following effects (a) to (c) can be obtained.
(a) The width of each lower electrode common line 3 and upper electrode common line 5 can be increased regardless of the size of the area for mounting semiconductor thin film LEDs 10 . (b) Planarizing insulating film 6 is made of a material that transmit (for example, being transparent for) the light emission wavelength emitted from semiconductor thin film LED 10 mounted on planarizing insulating film 6 . Upper electrode common line 5 formed immediately under planarizing insulating film 6 thus functions as a reflection metal. (c) According to effects (a) to (b), while maintaining a high occupancy ratio of LED light emitting areas, areas for forming lower electrode common lines 3 and upper electrode common lines 5 are kept maximum so that the wiring resistance can be reduced. Accordingly, a high-definition, high-intensity and large-screen display apparatus can be created.
Second Embodiment
Configuration of Second Embodiment
[0043] FIG. 4 is a sectional view of a pixel of a display apparatus according to the second embodiment of the invention; FIG. 5 is a plan view of a surface configuration of the display apparatus of FIG. 4 ; and FIG. 6 is a plan view of the entire display apparatus according to the second embodiment. In FIGS. 4 to 6 , the elements that are the same as those in FIGS. 1 to 3 of the first embodiment are designated by the same reference numerals.
[0044] In the display apparatus of the second embodiment, light-block (non-transmissive) planarizing insulating film 36 is substituted for transmissive planarizing insulating film 6 of the display apparatus in the first embodiment. Planarizing insulating film 36 is formed on the substantially entire surface which planarizes the surface of upper electrode common lines 5 immediately under planarizing insulating film 36 , and semiconductor thin film LED 10 is three-dimensionally joined on planarizing insulating film 36 so that the area other than semiconductor thin film LED 10 (the peripheral area of LED 10 ) is darkened. This enhances lightness contrast between semiconductor thin film LED 10 and the peripheral area, thereby improving conspicuous of a display screen of the display apparatus.
[0045] Specifically, similar to the first embodiment, interlayer insulation film 2 on substrate 1 , lower electrode common lines 3 arranged in the row direction, interlayer insulation film 4 , and upper electrode common lines 5 arranged column direction are layered in the display apparatus of the second embodiment. Different from the first embodiment, light-block planarizing insulating film 36 is formed on the substantially entire surface including the intersection of lower electrode common lines 3 and upper electrode common lines 5 and semiconductor thin film LED 10 is joined on planarizing insulating film 36 by an intermolecular force. The material of light-block planarizing insulating film 36 can be, for example, novolac permanent resist to which carbon black is added or polyimide resin to which carbon black is added. Light-block planarizing insulating film 36 has contact holes 36 a for upper electrode common lines, openings at positions corresponding to contact holes 9 a for the lower electrode common lines, openings at positions corresponding to contact pads 21 for lower electrode common lines disposed at the outer portion of the display apparatus, and openings at positions corresponding to contact pads 22 for the upper electrode common lines. Other configurations are the same as those of the first embodiment.
Manufacture of Second Embodiment
[0046] Similar to the first embodiment, interlayer insulation film 2 , lower electrode common lines 3 with contact pads 21 for the lower electrode common lines extending in the row direction, interlayer insulation film 4 , upper electrode common lines 5 with contact pads 22 for upper electrode common lines extending in the column direction are layered on substrate 1 . Light-block planarizing insulating film 36 is formed on the substantially entire surface including the intersection of lower electrode common lines 3 and upper electrode common lines 5 by a CVD method or the like. After forming planarizing insulating film 36 , planarizing insulating film 36 is patterned by a photolithography technology or the like, such that contact holes 36 a for upper electrode common lines, contact holes 4 a for the lower electrode common lines, openings corresponding to contact pads 21 for lower electrode common lines disposed at the outer portion of the display apparatus, and openings corresponding to contact pads 22 for upper electrode common lines are opened. Previously formed semiconductor thin film LEDs 10 are joined on planarizing insulating film 36 by an intermolecular force.
[0047] After that, similar to the first embodiment, interlayer insulation film 7 such as an inorganic insulating film and an organic insulation film is formed on the entire surface including semiconductor thin film LED 10 by a CVD method or the like. Interlayer insulation film 7 is patterned by a photolithography technology or the like so that portions of interlayer insulation film 7 on the above and the side of semiconductor thin film LEDs 10 are left and the other portions are removed. Further, lower interlayer insulation film 4 is patterned so that contact holes 4 a for the lower electrode common lines are opened.
[0048] A wire material is formed on the entire surface by a vapor deposition method, a sputtering method or the like. The wire material is patterned by a photolithography technology so that upper electrode connection wires 8 and lower electrode connection wires 9 are formed. In this configuration, each upper electrode connection wire 8 electrically connects corresponding upper contact layer 11 and the portion of upper electrode common line 5 exposed through corresponding contact hole 36 a for the upper electrode common line. Further, each lower electrode connection wire 9 electrically connects corresponding lower electrode 16 and a portion of lower electrode common line 3 exposed through corresponding contact hole 4 a . When an un-illustrated protective film or the like is formed, the process of manufacturing the display apparatus of FIG. 6 is finished.
Operation of Second Embodiment
[0049] To drive the display apparatus of FIG. 6 , drive current is selectively supplied from an external driving circuit (not shown) to contact pads 21 for the lower electrode common line and to contact pads 22 for the upper electrode common line. The drive current supplied to contact pads 21 and 22 flows through corresponding upper electrode connection wire 8 and lower electrode connection wire 9 shown in FIGS. 4 and 5 via corresponding lower electrode common line 3 and upper electrode common line 5 . The drive current flowing through upper electrode connection wiring 8 and lower electrode connection wiring 9 is supplied to upper contact layer 11 and lower electrode 16 of corresponding semiconductor thin film LED 10 , and active layer 13 of the corresponding semiconductor thin film LED 10 thus emits light. The emitted light is radiated upward via upper cladding layer 12 .
[0050] According to the second embodiment, light-block planarizing insulating film 36 covers areas other than contact holes 4 a for the lower electrode common lines, contact holes 36 a for the upper electrode common lines, contact pads 21 for the lower electrode common lines, and contact pads 22 for the upper electrode common lines. That is, light-block planarizing insulating film 36 covers upper electrode common lines 5 and lower electrode common lines 3 . Thus, light reflected toward substrate 1 is blocked and darkened substrate 1 itself can be visually recognized. In other words, since the contrast between the lightened area of semiconductor thin film LEDs 10 and non-illuminated area of semiconductor thin film LEDs 10 is enhanced, a high-contrast display apparatus is obtained.
Effect of Second Embodiment
[0051] According to the second embodiment, it is possible to manufacture a display apparatus that maximizes the area for forming lower electrode common lines 3 and upper electrode common lines 5 while maintaining a high occupancy ratio of the LED light emitting area. Thus, it is possible to manufacture a high-definition, high-intensity and large-screen display apparatus using semiconductor thin film LEDs 10 . Further, since substantially the entire area around semiconductor thin film LED 10 is covered by light-block planarizing insulating film 36 , a high-contrast display apparatus can be obtained.
Modification Examples
[0052] The invention is not limited to the first and second embodiments described above and various applications and modifications can be made. The following (a) to (c) are examples of the applications and modifications.
[0053] (a) Although column-direction lines 5 are provided above row-direction lines 3 in the first and second embodiment, positions of column-direction lines 5 and row-direction line 3 in the stacking direction may be changed with each other such that row-direction lines 3 are provided above column-direction lines 5 and planarizing insulating film 6 or 36 is formed on above-located row-direction line 3 . Modification (a) results in substantially the same effects as those of the first and second embodiments.
[0054] (b) The configuration and shape of the display apparatus may be different from those shown in the drawings.
[0055] (c) The materials of each element of the display apparatus and the manufacturing method of the display apparatus may be different from those of the first and second embodiments.
[0056] The invention includes other embodiments in addition to the above-described embodiments without departing from the spirit of the invention. The embodiments are to be considered in all respects as illustrative, and not restrictive. The scope of the invention is indicated by the appended claims rather than by the foregoing description. Hence, all configurations including the meaning and range within equivalent arrangements of the claims are intended to be embraced in the invention.
|
A high-definition, high-intensity display apparatus having a plurality of semiconductor thin film light emitting elements and a plurality of linear electrodes connecting a power source to the light emitting elements, the linear electrodes being disposed so as to minimize the voltage drop across the linear electrodes.
| 7
|
BACKGROUND OF THE INVENTION
The present invention relates to a voltage controlled oscillator (VCO) for producing an output signal of a frequency corresponding to an input voltage applied thereto.
In a PLL (phase locked loop) frequency synthesizer, for example, it is required that the frequency of the output signal always be equal to a preset frequency. To this end, a voltage controlled oscillator (VCO) is usually employed.
A typical example of such a VCO is found in FIG. 1 and 3 in Japanese Patent Disclosure (KOKAI) No. 59-62215.
The output frequency of this prior art tends to vary when process parameters are varied during manufacturing. For example, the thickness of the oxide film can vary and capacitances of the capacitors in the oscillator can change. Variation of the gate lengths of transistors results in variation of the current values for charging the capacitors of the manufactured oscillators. Consequently, the process parameters inevitably vary when the circuit is IC fabricated. This would suggest that the oscillating frequencies of the fabricated oscillators are not invariable for the chips containing them, and that the production yield is reduced.
To solve this problem, Japanese Patent Disclosure (KOKAI) No. 59-28209 discloses an improved voltage controlled oscillator. A block diagram of the VCO shown in FIG. 2b of the KOKAI is shown in FIG. 1 of this specification.
In FIG. 1, first and second oscillators 21 and 22 have equal circuit arrangements and circuit patterns. These oscillators 21 and 22 each oscillate at a frequency corresponding to a: the sum of the voltages applied to voltage input terminals CONT and OFFSET. A reference voltage Vref is applied to the terminal CONT of the oscillator 21. The reference voltage Vref is obtained by dividing the power voltage by a resistive voltage divider, for example. A signal Nref of the reference frequency f ref is input to one of the input terminals of a first phase comparator 23. The output signal of the oscillator 21 is supplied to the other input terminal of the comparator 23. The output signal of the comparator 23 is applied through a first low-pass filter 24 to the input terminal OFFSET of the oscillator 21. These circuits 21, 23, and 24 cooperate to form a PLL.
The output signal of a second phase comparator 25 is applied, as an input voltage Vin, to the voltage input terminal CONT of oscillator 22 through a second low-pass filter 26. The signal output from the filter 24 is applied to the input terminal OFFSET of the oscillator 22. With such a connection, when a voltage equal to the reference voltage Vref is applied to the input terminal CONT of the oscillator 22, the oscillator 22 oscillates at a frequency equal to that of the first oscillator 21.
In this way, the FIG. 1 circuit is controlled, independant of varied process parameters, so as to oscillate at the reference frequency when the input voltage to the second oscillator 22 is equal to the reference voltage. Thus, even if the process parameters vary, the FIG. 1 circuit constantly oscillates at the fixed frequency f ref if the input voltage is set to the reference voltage.
However, if the input voltage Vin shifts to differ in value from the reference voltage Vref, the oscillating frequency is influenced by the change in the process parameters. The oscillating frequency of the FIG. 1 circuit is given by
f=α(Vin+Voffset) (1)
where α is a proportional coefficient.
In the above equation, when the process parameters are varied, the proportional coefficient changes. The change of the α changes the inclination of a characteristic curve of the output frequency to input voltage. This is well illustrated in FIG. 2 in which the abscissa represents the input voltage Vin, and the ordinate, the output frequency f ref . In FIG. 2, a rectilinear curve I represents an ideal characteristic. Rectilinear curves II and III are depicted with increased and decreased α. As seen from these curves, when Vref=Vin, the output frequency of the oscillator 22 is, by necessity, equal to the frequency f ref . If not so, the output frequencies will not be invariable under influence by the process parameter variation.
Further, in the FIG. 1 circuit, the process gain variation results in a change in a gain as defined by the ratio of change in the oscillating frequency to a change in the input voltage, and hence, a change in the loop gain of the PLL. The loop gain variation leads to variation in important characteristics such as damping and pull-in characteristics as well as in the response characteristic.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a voltage controlled oscillator of which the input voltage vs. output frequency is not varied even if process parameters are varied when it is manufactured.
According to the present invention, there is provided a voltage controlled oscillator for producing an output signal with a frequency corresponding to an input voltage applied thereto, the voltage controlled oscillator comprising:
an oscillating section (30) having at least one first capacitor (47, 49), and receiving first and second input voltages, the first capacitor (47, 49) being charged by a first current corresponding to the first input voltage, and the oscillator (30) oscillating in response to a charged voltage across the first capacitor (47, 49) and the second input voltage;
a second capacitor (36);
means (32, 33) connected to the second capacitor (36) for receipt of the first input voltage, and for charging the second capacitor (36) for a predetermined time with a second current corresponding to the first input voltage; and
voltage control means (37, 31) connected to the second capacitor (36) for receipt of a predetermined reference voltage, for detecting a maximum value of the charged voltage across the second capacitor (36), for comparing the maximum voltage detected with the reference voltage, and for controlling the first input voltage so that the maximum voltage and said reference voltage will be equal to each other.
With such an arrangement, even if various process parameters, for example, capacitances of capacitors, gate lengths of transistors, threshold values of transistors are varied when the VCO circuits are integrated or fabricated, the output frequency of the circuit is free from the influence of the various process parameters. Therefore, a VCO circuit having an output frequency corresponding exactly to an input voltage can be fabricated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a prior voltage controlled oscillator;
FIG. 2 shows a graph depicting the voltage vs. output frequency characteristic of the FIG. 1 circuit;
FIG. 3 is a block diagram of a voltage controlled oscillator according to the present invention;
FIG. 4 is a circuit diagram of the oscillating section used in the FIG. 3 circuit;
FIGS. 5A to 5D, and FIGS. 6A to 6C show signal waveforms useful in explaining the operation of the FIG. 3 circuit;
FIG. 7 is a circuit diagram illustrating in detail a portion of the FIG. 3 circuit; excluding the timing control circuit and the oscillating section;
FIGS. 8A to 8F show signal waveforms useful in explaining the operation of the circuit of FIG. 7;
FIG. 9 is a circuit diagram of the timing control circuit;
FIG. 10 is a circuit diagram of a voltage controlled oscillator according to a second embodiment of the present invention;
FIGS. 11 and 12 are circuit diagrams of a comparator used in the above circuits;
FIG. 13 is a circuit diagram of another oscillating section used in the voltage controlled oscillator of the present invention; and
FIG. 14 shows a graph illustrating the results of an experiment with the voltage controlled oscillator of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A voltage controlled oscillator according to an embodiment of the present invention will be described referring to the accompanying drawings.
The circuit arrangement of the voltage controlled oscillator will first be described referring to FIG. 3. In FIG. 3, an oscillating section 30 produces, at the output terminal OUT, a signal of a frequency as defined by voltages applied to first and second voltage input terminals IN1 and IN2.
The output voltage Vc of an operational amplifier 31 is supplied as a first input voltage to the first voltage input terminal IN1. An input voltage Vin is supplied as a second input voltage to the second voltage input terminal IN2. The output frequency of the oscillating section 30 is controlled by the input voltage Vin.
The output terminal of the operational amplifier 31 is also coupled with the gate of a P channel MOS transistor 32. The transistor 32 operates in a saturation region and serves as a constant current source for generating a current dependent on the output voltage Vc. The source of the transistor 32 l is coupled with a terminal or a point to which power voltage VDD is applied. This terminal will frequently be called a VDD supply. The drain of the transistor 32 is connected to one of the fixed contacts of a first switch 33. The other fixed contact of the switch 33 is connected to one of the fixed contacts of a second switch 34. The other fixed contact of the second switch 34 is coupled with a terminal or a point to which ground potential VSS is applied. This terminal will be frequently called a VSS supply.
A node 35 between the first and second switches 33 and 34 is coupled with one of the electrodes of a capacitor 36. The other electrode of the capacitor 36 is connected to the VSS supply. The one electrode of the capacitor 36 is additionally coupled with the input terminal of a sample/hold circuit 37. The output terminal of the sample/hold circuit 37 is connected to a positive input terminal of the operational amplifier 31. A reference voltage Vref is supplied to a negative input terminal of the operational amplifier 31. A timing control circuit 38 is provided for controlling timings of the operations of the switches 33 and 34 and the sample/hold circuit 37. The timing control circuit 38 is connected to movable contacts of the first and second switches 33 and 34, and further to the sample/hold circuit 37. The timing control circuit 38, thus coupled, supplies a first control signal S1 to the first switch 33, a second control signal S2 to the second switch 34, , and third and fourth control signals S3 and S4 to the sample/hold circuit 37.
A circuit arrangement of the oscillating section 30 illustrated in block form in the FIG. 3 circuit will be given in detail referring to FIG. 4. The output terminal of the operational amplifier 31 is connected to the gate of a P channel MOS transistor 41. The transistor 41 is operated in the saturation region. As such it operates as a constant current source for feeding a current dependent on the output voltage Vc of the operational amplifier 31. The source of the transistor 41 is connected to the VDD supply. The drain of the transistor 41 is coupled with the source of a P channel MOS transistor 42. The drain of the P channel MOS transistor 42 is connected to the drain of an N channel MOS transistor 43. The source of the transistor 43 is connected to the VSS supply. The gates of the transistors 42 and 43, which serve as switches, are interconnected.
Similarly, the drain of the transistor 41 is connected to the source of a P channel MOS transistor 44. The drain of the transistor 44 s connected to the drain of an N channel MOS transistor 45. The source of the transistor 45 is grounded. These transistors 44 and 45 are interconnected at their gates and act as switches.
The connection point of the drains of the transistors 42 and 43 is connected to one of the electrodes of a capacitor 47. The capacitor 47 is connected to the VSS supply. Similarly, the connection point between the drains of the transistors 44 and 45 is connected to one of the electrodes of a capacitor 49. The other electrode of the capacitor 49 is connected to the VSS supply. The one electrode of the capacitor 47, i.e., the node 46 is connected to the positive input terminal of a first comparator 50. The one electrode of the capacitor 49, i.e., the node 48 is connected to the positive input terminal of a second comparator 51. The input voltage Vin is applied to the negative input terminals of the comparators 50 and 51.
The output signal of the first comparator 50 is connected to the set input terminal of a flip-flop (FF) 54. The output terminal of the second comparator 51 is coupled with the reset input terminal of the FF 54. The FF 54 is of the known type in which two NOR gates 52 and 53 are cross-coupled with each other.
The Q output terminal of the FF 54 is connected to the gates of the transistors 42 and 43. The Q output of the FF 54 is connected to the gates of the transistors 44 and 45. The Q output signal of the FF 54 is used as an output signal of the oscillating section 30.
The operation of the voltage controlled oscillator illustrated in FIGS. 3 and 4 will be described referring to the timing charts of FIGS. 5A to 5D and FIGS. 6A to 6C.
It is assumed that the FF 54 is set. On this assumption, the Q output signal of the FF 54 is logical "1" or high in level, while the Q output is logical "0" or low in level. Under this condition, the transistors 42 and 45 are turned off and the transistors 43 and 44 are turned on. This being the case, the current fed from the transistor 41 flows to ground through the transistor 44 and the capacitor 49. This current, of which the flow is indicated by a continuous line with an arrow head denoted as I1, charges the capacitor 49. With the charge, the potential VB of the one electrode of the capacitor 49 increases linearly with time, as shown in FIG. 5B. At this time, the transistor 43, as turned on, provides a discharge path for the capacitor 47, so that the capacitor 47 discharges, decreasing the potential VA, at its one electrode, to ground potential.
As the increasing potential VB reaches the input voltage Vin, the second comparator 51 produces a signal of logical "1". The logical "1" signal goes to the reset terminal of the FF 54. Then, the FF 54 is reset with the Q output being logical "0" and the Q output being logical "1", as shown in FIGS. 5C and 5D.
Responsive to the level changes of the Q signal and the Q signal, the transistors 42 and 45 are turned on, while the transistors 43 and 44 are turned off. As a result, the capacitor 49 is discharged through the transistor 45 and the potential VB is decreased to ground potential. Further, the output signal of the second comparator 51 becomes logical "1".
Turning on of the transistor 42 allows a current flow from the VDD supply to ground through the transistors 42 and the capacitor 47. The current I2 charges the capacitor 47. With progression of the charging, the potential VA at one side of the capacitor 47 increases linearly, as shown in FIG. 5A. As the increasing potential VA reaches the input voltage Vin, the output signal of the first comparator 50 becomes logical "1". The result is that the FF 54 is again set, with the Q output signal being logical "1" and the Q output signal being logical "0".
In response to the level changes of the Q and Q signals, the transistors 42 and 45 are turned off, while the transistors 43 and 44 are turned on. Then, the capacitor 47 is discharged while the capacitor 49 is charged by the current I1, with the potential VB being gradually increased.
Subsequently, an operation similar to the above is repeated. In this way, the Q and Q output signals each oscillate at a predetermined frequency. In this instant, the Q output signal is used as the output signal of the oscillating section 30, as described above.
The oscillating frequency of the output signal can be varied by changing the output voltage Vc of either the operational amplifier 31 or the input voltage Vin. The frequency f can be expressed by ##EQU1## where C47 and C49 are capacitances of the capacitors 47 and 49. I41 is the current flowing through the transistor 41. TD0 is a signal delay time of the first comparator 50. TD1 is a signal delay time of the second comparator 51.
If C47= C49= C, and TD0=TD1=TD, the equation (2) can be simplified as
f=I41/{2·(C·Vin+I41·TD)} (3)
The operation of the overall VCO shown in FIG. 3 will be described. The timing charts shown in FIGS. 6A to 6C illustrate the operation of the VCO except the oscillating section 30. The timing control circuit 38 produces the first and second control signals S1 and S2 at the timings shown in FIGS. 6A and 6B. As shown, in the signal S1, a logical "0" state continues for a period T0. In the signal S2, the logical "0" state still continues for a predetermined period of time after the signal S1 is pulsed to the high level or logical "1".
The first switch 33 keeps an ON state during the period T0 that the signal S1 is logical "0". For the logical "0" period, current flows through a path of the transistor 32, the switch 33, and the capacitor 36. This current charges the capacitor 36. As recalled, the value of the current depends on the output voltage Vc of the operational amplifier 31. As the charge progreses, the potential Vd of the one electrode of the capacitor 36 increases at a fixed rate of change. Then, when the signal S1 is logical "1", the first switch 33 is turned off, and the charging of the capacitor 36 stops. The capacitor 36 keeps the voltage Vd at the maximum value. Then, the second control signal S2 is pulsed from logical "0" to logical "1", and the second switch 34 is turned on. The capacitor 36 is discharged and the voltage Vd drops to logical "0". During the period that the signal S1 is logical "1" and the signal S2 is logical "0", the sample/hold circuit 37 operates to sample the maximum value of the voltage Vd and to produce it as the output voltage Ve. The held voltage, or the output voltage Ve of the sample/hold circuit 37 is applied to the operational amplifier 31. The operational amplifier 31 compares the voltage Ve with the reference voltage Vref. The voltage Vc representing the result of the comparison is applied to the gate of the transistor 32.
Such a sequence of operations is repeated, until, finally, the voltage Vc is controlled to have a value such that the voltages Ve and Vref are coincident with each other.
It is assumed now that the capacitance of the capacitor 36 is C36, and the current flowing through the transistor 32 is I32. Since the capacitor 36 of capacitance C36 is charged by the current I32 for the period T0, the final value Vem of the voltage Ve is
Vem=(T0·I32)/C36 (4)
When the voltage Vem is controlled such that it is equal to the reference voltage Vref, i.e.,
Vem=Vref, the following equation holds
Vref=(T0·I32)/C36 (5)
The gate of the transistor 32 is connected to the gate of the transistor 41 of the oscillating section 30. Therefore, the current I32 flowing through the transistor 32 is proportional to the current flowing through the transistor 41. It is assumed that G is a ratio of the currents I32 to I41, which depends on a ratio of geometrics between these transistors. With this relation, the equation (3) can be rewritten as ##EQU2## Rearranging the equation (5) with respect to I32, we have
I32=C36·Vref/T0 (6')
Substituting the above equation (6') into the equation (6), we then have ##EQU3##
Assuming that G=1, that is, the transistors 32 and 41 are equal in channel width and channel length, the capacitance of the capacitor C36 is C like the capacitors 47 and 49, and, further, the delay time TD is zero, the equation (7) can be simplified into
f=Vref/(2·Vin·T0) (8)
In the equation (8), the factor T0 can be set up exactly if a crystal oscillator for clock pulse oscillation is used for the timing control circuit 38, and an exact value of the reference voltage Vref can easily be realized. Hence, the equation (8) shows that the frequency of the output signal from the VCO under discussion depends solely on the input voltage Vin, that is, it is independent of the influences of the process parameters of MOS transistors. When Vin=Vref, the oscillating frequency f is equal to 1/(2·T0).
In connection with the IC fabrication of the VOC, the capacitances of the capacitors and the widths and lengths of the transistors in one chip are generally different from those in another chip. Within one chip, the absolute values of the capacitance and the gate length, may be changed, but the ratio of capacitances and gate lengths between or among the capacitors can be easily established as a constant. Accordingly, if one manufactured capacitor 47, for example, has a different capacitance from its designed value, those of the remaining ones 36 and 49 can change accordingly but in relation to their designed values. So the capacitance of the capacitors 36, 47, 49, and the channel width and channel length of the transistors 32 and 41 can equal each other. This fact can satisfy the condition for making the equation (8). Thus, according to the present invention, the variation problem of the oscillating frequencies among the semiconductor chips, which arises from the process parameter difference, can be eliminated.
In the embodiment described above, the capacitors 36, 47 and 49 have the same capacitance C, and the current ratio G is 1. Nonetheless, the present invention is not limited to this embodiment. The capacitors may have different capacitances, and the gate length and other structural features of each transistor may be changed.
Circuitry including the switches 33 and 34, the sample/hold circuit 37 and the reference voltage Vref, will be described referring to FIG. 7.
The first switch 33 is constructed with a P channel MOS transistor. One end of the current path of this MOS transistor is connected to the P channel MOS transistor 32, and the other end to the second switch 34. The gate of the MOS transistor of the first switch 33 is connected for reception to the first control signal S1. The second switch 34 is constructed with an N channel MOS transistor. One end of this MOS transistor is connected to the first first switch 33, while the other end is connected to the VSS supply. The gate of the MOS transistor receives the second control signal S2.
The sample/hold circuit 37 is comprised of first and second CMOS analog switches 61 and 62, and capacitors 63 and 64. The first analog switch 61 is made up of P channel and N channel MOS transistors of which the current paths are connected in parallel. The node of the interconnection between one set of ends of the current paths of the paired transistors is connected to one of the electrodes of the capacitor 36. The third control signal S3 is supplied to the gate of the N channel MOS transistor in the analog switch 61. The control signal S3 is inverted by an inverter and supplied to the gate of the P channel MOS transistor of the same switch 61. The output terminal of the first analog switch 61 is connected to one of the electrodes of a capacitor 63. The capacitor 63 is earthed at the other electrode. The analog switch 62 has substantially the same circuit arrangement as that of the first analog switch 61, and is under the control of the fourth control signal S4. The input terminal of the analog switch 62 is coupled with the output terminal of the first analog switch 61 and the capacitor 63. A capacitor 64 is inserted between the output terminal of the second analog switch and ground. The node between the output terminal of the second analog switch 62 and the capacitor 64 serves as an output terminal of the sample/hold circuit 37. The capacitor 64 may be a stray capacitance present in association with the output terminal of the second switch 62 and the input terminal of the operational amplifier 31.
The reference voltage Vref applied to the negative input terminal of the operational amplifier 31 is derived from a node between resistors 65 and 66, which are connected in series between the VDD supply and ground. Thus, the VDD voltage is divided according to the resistance ratio of these resistors. The divided voltage is used as the reference voltage Vref.
The operation of the voltage controlled oscillator as illustrated in FIG. 7 will be described referring to FIGS. 8A to 8F. The control signals S1 to S4 are formed using the clock pulses CLK shown in FIG. 8A. In this embodiment, the trailing edge of the signal S1 (FIG. 8B) is delayed by a given period td behind the trailing edge of the signal S2. This indicates that the charge time of the capacitor 36 is (T0-td).
When the signal S1 is logical "0", the first switch 33 is turned on. At this time, the signal S2 is logical "0" and the second switch 34 is in an off state. Under this condition, the capacitor 36 is charged. The charged voltage of the capacitor 36 rises linearly. When the signal S1 is logical "1", the first switch 33 is turned off to terminate the charging of the capacitor 36. Then, the signal S3 becomes logical "1", so that the charged potential across the capacitor 36 is kept by the capacitor 63. Subsequently, the signal S4 becomes logical "1", and the voltage across the capacitor 63 is kept by the capacitor 64. After the signal S3 becomes "1" in logical level, the signal S2 is pulsed to logical "1" to allow the discharge of the capacitor 36. The signal S4 maintains logical "1" level during the period that the capacitor 36 is charged by the transistor 32, and discharged by the switch 34. The charged voltage across the capacitor 64 is applied, as the output voltage of the sample/hold circuit 37, to the positive input terminal of the operational amplifier 31.
The purpose of providing the delay time td in the signal S1 is to compensate for the delay time TD in each of the comparators 50 and 51. If the delay time td is equal to the delay time TD, the charge time of the capacitor 36 is T0-TD. Therefore, in the equation (7), for example, the delay times TD and td are cancelled, remarkably reducing the effect by the delay time TD. Thus, even if the comparators 50 and 51 contain delay times, the VCO can produce an oscillating signal of an exact frequency.
A detailed circuit arrangement of the timing control circuit 38 will be described referring to FIG. 9. In FIG. 9, the clock pulses CLK are inverted and applied to the clock signal input of the latch 71. The Q output terminal of the latch 71 is coupled with the D input terminal of the latch 72. The Q output terminal of the latch 72 is coupled with the D input terminal of the latch 71. The clock input terminal of the latch 72 is coupled for reception with the clock pulses CLK. The Q bar output terminal of the FF 73 is connected to its D input terminal, and the Q output terminal thereof is coupled with the clock signal input terminal of an FF 74. The Q output terminal of the FF 74 is coupled with the D input terminal of the FF 74. With this connection, the output signal of the latch 72 is frequency-divided into a factor of two by the FF 73 at the succeeding stage. Then, the output signal of the FF 73 is further frequency divided into a factor of two by the succeeding stage FF 74. The Q output terminal of the FF 74 is input to a delay circuit 80.
The NOR gate 75 receives the Q output signals from the FFs 73 and 74, and produces the second control signal S2. The NAND gate 76 receives the Q output signal of the FF 73, as well as the Q output signal of the FF 74, and produces the fourth control signal S4. The NOR gate 77 is coupled for reception with the Q output signal of the latch 71, and produces the third signal S3.
An arrangement of the delay circuit 80 will be given. The Q output signal of the FF 74 is input to the input terminal of a CMOS inverter 81 including a pair of P and N channel MOS transistors. One end of the current path of the P channel of the inverter 81 is connected to one end of the current path of a P channel MOS transistor 82. The other end of the current path of this transistor 82 is coupled with the VDD supply. The gate of the transistor 82 is coupled with the gate and one end of the current path of a P channel MOS transistor 83. The transistor 83 is connected at the other end of the current path to the VDD supply. The transistors 82 and 83 cooperate to form a current mirror circuit 84 which feeds a predetermined current to the P channel transistor of the inverter 81.
The current path of an N channel MOS transistor 85 is inserted between the inverter 81 and a ground. The transistor 85 is biased to a fixed bias point by a bias source Vc. The transistor 85 feeds a fixed current to the N channel transistor of the inverter 81. The current path of an N channel MOS transistor 86 is inserted between the current mirror 84 and a ground. The same bias source Vc is applied to the gate of the transistor 86. The transistor 86 feeds a predetermined current to the current mirror 84. The output signal of the CMOS inverter 81 is input to an inverter 87. Both the output signal of the inverter 87 and the Q output signal of the FF 74 are applied to a NAND gate 88. The NAND gate 88 produces the first control signal S1.
A second embodiment of a voltage controlled oscillator according to the present invention will be described referring to FIG. 10. This embodiment is different from the first embodiment of FIG. 3 in the following points. The output terminal of the sample/hold circuit 37 is connected to the negative input terminal of the operational amplifier 31. The positive input terminal of the operational amplifier 31 is coupled with the reference voltage Vref. A capacitor is connected between the negative input terminal and the output terminal of the operational amplifier 31. The amplifier 31 and the capacitor comprise an integration circuit. The output terminal is connected to the gate of an N channel MOS transistor 91. Another P channel MOS transistor 92 whose gate and one current path are connected to one end of the transistor 91 and the gates of the transistors 32 and 41. The other end of the current path of the transistor 92 is coupled with the VDD supply. The other end of the current path of the transistor 91 is grounded. The transistor 92 serves as a current load for the transistor 91. The transistors 32, 92 and 41 form a current mirror.
In operation, the output voltage Vc of the operational amplifier 31 determines the current flowing through the transistors 91. This current causes a voltage drop across transistor 92. The transistor 92 and transistors 32 and 41 comprise current mirror circuits. The currents corresponding to the voltage Vc flow through the transistors 32 and 41.
A detailed circuit arrangement which is available for the operational amplifier 31 and the comparators 50 and 51 in the oscillating section 30 (FIG. 4) will be described referring to FIG. 11. In FIG. 11, one end of the current path of an N channel MOS transistor 101 is connected to one end of that of an N channel MOS transistor 102. These transistors 102 and 103 constitute a differential amplifier 103. The other end of the transistor 101 is connected to one end of that of a P channel 104. The other end of the current path of this transistor is coupled with the VDD supply. The other end of the current path of the transistor 102 is connected to one end of the current path of a P channel MOS transistor 105. Its other end is coupled with the VDD supply. The gates of these transistors 104 and 105 are connected to the connection point between the current paths of the transistors 102 and 105. The transistors 104 and 105 form a current mirror circuit 106, which serves as a load for the differential pair 103.
The connection point between the current paths of the transistors 101 and 102 is connected to one end of the current path of an N channel MOS transistor 107. The other end of the current path of this transistor is grounded. The transistor 107 serves as a current source to feed the operating current to the differential pair 103. A node between the transistors 101 and 104 is coupled with the gate of a P channel MOS transistor 108. The output signal of the differential pair 103 is supplied to the gate of the transistor 108. One end of the current path of the transistor 108 is connected to the VDD supply. Its other end is connected to one end of the current path of a N channel MOS transistor 109 is a current load for the transistor 108. The gate of the transistor 109 is connected to the gate of the transistor 107, and its other end is grounded. The gates of the transistors 107 and 109 are biased by a bias source 110.
In this circuit arrangement, the gate of the transistor 101 is used as the positive input terminal, while the gate of the transistor 102 is used as the negative input terminal. The output signal is derived from a node between the transistors 108 and 109.
Another example of the operational amplifier will be given referring to FIG. 12. In the figure, one end of the current path of an N channel MOS transistor 121 is connected to one end of that of an N channel MOS transistor 122. These transistors form a differential pair 123. A node between the transistors 121 and 122 is connected to one end of the current path of an N channel MOS transistor 124. The other end of the current path of this transistor 124 is grounded, and its gate is applied with a fixed voltage for biasing purposes.
The other end of the current path of the transistor 121 is connected to the gate and one end of the current path of a P channel MOS transistor 125. The other end of the current path of the transistor 125 is coupled with the VDD supply. The other end of the current path of the transistor 122 is connected to the gate and one end of the current path of a P channel MOS transistor 126. The other end of the current path of this transistor 126 is coupled with the VDD supply. The transistors 128 and 125 are interconnected at the gates. The transistor 125 and 128 form a current mirror 127.
The gate of a P channel MOS transistor 130 is connected to the gate of the transistor 126. The transistors 126 and 130 form a current mirror 129. The ends of the current paths of these transistors 128 and 130 are applied with the VDD supply. The other end of the current path of the transistor 128 is connected to the gate and one end of the current path of an N channel MOS transistor 131. The other end of the current path of this transistor 131 is grounded. The other end of the current path of the transistor 130 is connected to one end of the current path of an N channel MOS transistor 132. The other end of the current path of the transistor 132 is grounded. The gate of transistor 132 is connected to the gate of the transistor 131. The transistors 131 and 132 form a current mirror circuit 133.
The gate of the transistor 121 serves as an inverting input terminal, while that of the transistor 122 serves as a noninverting input terminal. The output signal is derived from a node between the transistors 130 and 132.
The oscillating section 30 may employ many circuit arrangements other than that of FIG. 4. One of such candidates is illustrated in FIG. 13. In the figure, like reference numerals are used for indicating like or equivalent portions in FIG. 4.
The two positive input terminals of a three-input comparator 140 are coupled for reception with the potential VA of the capacitor 47 and the potential VB of the capacitor 49. The input voltage Vin is applied to the negative input terminal of the comparator 140. The comparator 140 operates so as to compare the voltage Vin at the negative input terminal with either of the potentials at the positive input terminals for the purpose of determining which is higher than the other. The output signal of the comparator 140 is supplied through an inverter 141 to a select circuit 150.
The select circuit 150 is comprised of two AND gates 151 and 152, and an inverter 153. The input terminals of the AND gates 151 and 152 receive the output signal of the inverter 141. The other input terminal of the AND gate 151 is coupled for reception with the Q signal of the FF 54 through a delay circuit 60 to be given later. The delayed Q signal of the FF 54 is applied through an inverter 153 to the other input terminal of the AND gate 152. The output terminal of the AND gate 151 is connected to the set input terminal of the FF 54. The output terminal of the AND gate 152 is connected to the reset input terminal of the FF 54.
With such a connection, when the delay signal is logical "1", the output signal of the inverter 141 is applied to the set input terminal of the FF 54. When the delayed signal is logical "0", the output signal of the inverter 141 is supplied to the reset input terminal of the FF 54.
The Q output signal of the FF 54 is input to the delay circuit 160. The delay circuit 160 is comprised of an inverter 161 coupled for reception with the Q output signal of the FF 54, a capacitor 162 inserted between the output terminal of the inverter 161 and ground, another inverter 163 coupled for reception with the output signal of the inverter 161, and another capacitor 164 coupled between the output terminal of the inverter and ground. The output signal of the inverter 163 is applied, as a delayed signal, to the select circuit 150. The delayed signal and the Q signal are coupled for transmission with an exclusive OR gate 170. The output signal of the exclusive OR gate 170 is supplied to the gate of a P channel MOS transistor 171. The current path of this transistor 171 is placed between the output terminal of the comparator 140 and the VDD supply.
The operation of this embodiment is substantially the same as that of the FIG. 4 embodiment. The reason behind the provision of the delay circuit 160 will be given. A signal delay is inevitably involved in the comparator 140. Immediately after the logical state at the output of the FF 54 changes, it is returned to its original state due, as is highly possible, to the signal delay. In an extreme case, the FF 54 oscillates irrespective of the potentials VA and VB. This is an incorrect operation.
To cope with this, the present embodiment forcibly places the output signal of the comparator 140 into logical "1" for the signal delay time and by the delay circuit 160. Then, the select circuit 150 is switched to another state. In this way, the undesired inversion of the FF 54 is prevented.
The experiment was conducted for checking the operation of the voltage controlled oscillator as shown in FIG. 10. The results of the experiment were plotted in FIG. 14, where the abscissa represents the input voltage Vin and the ordinate represens the frequency fout of the output signal. In the experiment, the capacitance of each of the capacitors 36, 47 and 49 was 1010 pF; the reference voltage Vref 2.5 V, the VDD 5 V; and the period T0 for logical "0" of the first control signal S1, 25 uS.
As seen from FIG. 14, when Vin=Vref, f out is 20 KHz. This value satisfies the equation (8). It was confirmed that similar results were obtained even for different parameters. It should be understood that the present invention is not limited to the above-mentioned embodiments. For example, other suitable circuit arrangements are available for circuits 30, 31, 50, 51, 140, 33, 34, 37, and 38. Further, the polarity of each transistor may be inverted in each embodiment.
|
A voltage controlled oscillator includes an oscillator having at least one first capacitor. The oscillator receives first and second input voltages and charges the first capacitor with a first current corresponding to the first input voltage. The oscillator oscillates at a frequency corresponding to the first and second input voltages. To remove the adverse influence on the oscillating frequency by the change of process parameters caused in the stage of manufacturing the voltage controlled oscillators, a second capacitor is charged for a predetermined period by a current corresponding to the first voltage. After the charging of the second capacitor ends, a sample/hold circuit samples and holds the charged voltage across the second capacitor. An operational amplifier receives, at its positive input terminal, the output voltage of the sample/hold circuit, and, at its negative input terminal, the reference voltage. The operational amplifier controls the first voltage so that the output signal of the sample/hold circuit will be equal to the reference voltage. Repeating the sequence of the charging, sampling and comparing operations eliminates the influence upon the oscillating frequency by the change of the process parameters caused in the manufacturing stage.
| 7
|
BACKGROUND AND SUMMARY OF THE INVENTION
[0001] This application claims the priority of 101 03 074.6, filed Jan. 24, 2001, the disclosure of which is expressly incorporated by reference herein.
[0002] The invention relates to a supporting structure for a solar sail of a satellite consisting of support arms which are connected with a solar panel in a swiveling manner by way of unfolding joints and where a film is stretched between the support arms.
[0003] Solar generators on board satellites serve the energy supply of the existing satellite systems. A solar generator comprises several individual solar plates, so-called solar panels, which have a rigid supporting structure, and each supporting structure carries solar cells. This supporting structure is a lightweight construction and takes on a sandwich structure. It can be, for example, an aluminum honeycomb core with cover and base surfaces made of carbon fiber (CFK) laminate. These solar panels are connected with each other by way of hinge joints with the ability to rotate. With the help of endless cable control connections, the individual actuators, which are connected with the hinge joints, can swivel the solar panels relative to each other.
[0004] During transportation from Earth into the orbit of the satellite, the solar panels are folded. They are not unfolded until they have reached space. The unfolding process of the solar panels occurs smoothly, and the solar panels lock into an unfolded locking position nearly simultaneously.
[0005] In the unfolded state, all the solar panels are basically arranged in one plane. The solar generator is connected with the structure of the satellite by way of a yoke device. Such an arrangement of a solar generator with a yoke device is called a generator wing. Generally, a satellite has yet another, diametrically arranged generator wing.
[0006] Upon unfolding the solar panels into a generator wing, a so-called solar sail is also unfolded. The solar sail is a thin, elastic film, which serves the purpose of controlling the position of the generator wing. The solar sail works on the basis of a direct conversion of photon radiation from the sun into kinetic energy, which is used to control the position for the solar wing.
[0007] Starting from the yoke device, the solar panels are arranged one behind another in radial distance from the yoke device. The solar sail is installed on the second to last solar panel, which is arranged in radial direction starting from the yoke device. This solar panel, which holds the solar sail, is hereinafter referred to as the “second to the last solar panel”.
[0008] The second to the last solar panel has an unfolding mechanism for the solar sail. The unfolding mechanism comprises unfolding joints and locking devices. The unfolding of the solar sail using the unfolding mechanism must be considered in connection with the unfolding of the solar panels. Unfolding of the solar panels of a generator wing begins with the solar panel that is located the farthest away from the yoke device, the so-called outer, i.e. last, solar panel. This outer solar panel contains an endless cable control along its two opposite side edges via deflection rollers with a prestressed spring. With the pyrotechnic severing of the hold-down plates from a hold-down device, the kinetic energy of the prestressed springs is released and the outer panel is swiveled from the hold-down position by 90° vis-à-vis the second to the last panel via the deflection rollers of the cable controls. This unfolding process of the outer panel serves a so-called emergency unfolding. This supplies the satellite systems with a first additional emergency power supply, which can also be used for the continued unfolding process. The additional solar panels, which follow in the direction of the yoke device, contain cable control guides that are laterally offset in relation to each other. This allows for synchronized movement during the unfolding process until the locking in the unfolding position.
[0009] The solar sail is arranged in a folded position on the second to the last solar panel by way of its own unfolding mechanism. The unfolding mechanism contains several, e.g., as is known in the art, 5 unfolding joints between a side edge of the supporting, second to the last solar panel and ribs (support arms) of the solar sail. With their individual swiveling axes, the unfolding joints form a fictitious or imaginary, common swiveling axis.
[0010] Normally, the solar sail has a square or rectangular surface. Each unfolding joint has a prestressed spring, which applies force on the joint and which is taut in the folded position of the solar sail and contains stored kinetic energy.
[0011] In the folded position, the solar sail swings around the unfolding joints into a parallel position to the second to the last solar panel. Using a locking device, which is arranged between the third to the last and the second to the last solar panels, the solar sail is maintained in its folded position.
[0012] In known state of the art, the solar sail contains ribs (so-called support arms) for reinforcement purposes; these ribs are guided transversely in relation to the swiveling axis and are arranged longitudinally, at a distance, in relation to the swiveling axis of the solar sail. One end each of the ribs is connected with one of the unfolding joints, and the other end of the rib is locked in the folded position using the locking device. Several unfolding joints and several locking devices are required for this, depending on the size of the solar panel. The locking device consists of a tension hook on the second to the last solar panel and a locking wedge on the third to the last solar panel. In the folded state, the locking wedge and tension hook are engaged with each other. This design has the disadvantage that it leads to an increase in the overall weight of the generator wing. The fact that several ribs are installed also increases the weight.
[0013] The unfolding process shows, furthermore, that the aperture angle between the second to the last solar panel with the solar sail and the third to the last solar panel keeps increasing so that the locking wedges, which are arranged on the third to the last solar panel, release the tension hooks with a continually increasing aperture angle, thus releasing individual ribs. These released ribs swivel, due to the prestressed spring, in the unfolding joint so that with the release of the last rib the entire solar sail swings into an unfolded position. The angle of incidence in the unfolded position of the solar sail vis-à-vis the solar panel is for example 90 to 110°. In this unfolded position, power in the direction of all three space axes of the generator wing can be converted due to the sun's photon radiation. This also occurs with the generator wing that is arranged on the opposite side of the satellite. Thus, the solar sail serves to stabilize the position of the generator wing in space and its alignment.
[0014] We also know of another realization of the solar sail, which uses a rigid circumferential frame (4 frame parts), stretching around the solar sail and which is arranged on the second to the last solar panel, also with an unfolding mechanism.
[0015] An object of the invention is to simplify the constructions that are known in the art, while maintaining the existing functional safety, in order to achieve a considerable weight reduction.
[0016] This object is achieved in accordance with preferred embodiments of the invention by providing supporting structure for a solar sail of a satellite, formed by support arms which are connected with a solar panel through unfolding joints in a swiveling manner with a solar sail film stretched between the support arms, wherein a longitudinal connector which is arranged parallel to one side edge of the solar panel contains support arms which are located in a joint direction in the plane of the film forming at least one U-shaped supporting structure between which the film of the solar sail can be stretched, and wherein corner connectors are arranged in respective interior angle areas between the longitudinal connector and a respective support arm.
[0017] The invention proposes to use a U-shaped supporting structure for the solar sail. This U-shaped supporting structure contains on its base edge a longitudinal connector, on which support arms are arranged in one plane. The support arms are guided transversely to the longitudinal connector, pointing in one direction. The support arms and the longitudinal connector form the U-shaped supporting structure. The longitudinal connector is arranged parallel to a side edge of the second to the last solar panel. The longitudinal dimensions of both support arms and of the longitudinal connector influence the surface size of the solar sail.
[0018] In the interior angle area between the longitudinal connector and support arm, a buckle-proof profile with connecting points without torsional buckling is arranged on the longitudinal connector and support arm. Advantageously, this profile is designed in one piece and it is referred to as a corner connector. The corner connector can be mounted from two semi-shells, which can be inserted into each other in a positive-locking manner.
[0019] Alternatively, this support of the profile in the interior angle area can also be designed as two pieces by arranging a buckle-proof profile and a connection without torsional buckling between the longitudinal connector and the support arm. In the realization it is possible to join several U-shaped supporting structures into one common supporting structure.
[0020] Preferred embodiments of the invention have the advantage that they include only three components, i.e. two support arms and one longitudinal connector, for stretching the solar sail. Thus, the number of components as compared to the known state of the art can be reduced, which is reflected in a weight reduction. This arrangement into a U-shaped supporting structure for the solar sail is possible because with this arrangement the bending forces from the support arm can be introduced into the longitudinal connector in a torsion-rigid manner, and also the tension forces of the film can be introduced into the longitudinal connector over the support arms in a bending-rigid manner.
[0021] An advantageous realization shows a so-called rigid corner connector. This rigid corner connector is formed by placing two semi-shells on top of each other in the interior angle area of the intersecting area between the longitudinal connector and support arm, with these semi-shells enclosing the longitudinal connector and the support arm. The interior angle is thus completely enclosed by the two semi-shells.
[0022] Furthermore, the invention allows for the use of the lightest-weight film that is possible. This also contributes to the weight reduction. The invention also makes a fast production of the supporting structure possible. Only simple components need to be manufactured. There are fewer unfolding joints and fewer locking devices. The result is a noticeable weight reduction.
[0023] Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIG. 1 is a schematic perspective partial view of a satellite with solar generator, constructed according to a preferred embodiment of the present invention;
[0025] [0025]FIG. 2 is an enlarged view of a section of a generator wing with solar sail of the satellite of FIG. 1;
[0026] [0026]FIG. 2 a is a view showing supporting structure formed by two U-shaped supporting structures constructed according to another preferred embodiment of the invention;
[0027] [0027]FIG. 3 is a view of a corner connector in an interior angle area between a longitudinal connector and support arm of the supporting structure of FIGS. 1 and 2;
[0028] [0028]FIG. 3 a is a view showing semi-shells visable as corner connectors of FIG. 3; and
[0029] [0029]FIG. 3 b is a view similar to FIG. 3, showing two-piece corner connector.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] The figures are not shown true to dimension in order to better schematically depict the preferred embodiments of the invention.
[0031] [0031]FIG. 1 shows a satellite 13 with a solar generator. The solar generator is formed by a generator wing 12 and the diametrically arranged (not completely shown) generator wing 14 . The explanations below regarding the generator wing 12 also apply for the generator wing 14 .
[0032] The generator wing 12 comprises a yoke device 11 , which, on the one hand, is connected with the structure of the satellite 13 and, on the other hand, carries several solar plates. An individual solar plate is also called a solar panel. In the unfolded state, the solar panels are arranged in series adjacent to one another. FIG. 1 shows the unfolded state of the generator wing 12 . The generator wing 12 has five solar panels. A first solar panel 1 is fastened to the yoke device 11 . A second solar panel 2 , a third to the last solar panel 3 , a second to the last solar panel 4 and an outer solar panel 5 follow. The individual solar panels are connected by way of hinge joints. The hinge joints are coupled with deflection rollers, and along a side edge an endless cable control is guided via the deflection rollers. On the first solar panel, a cable control 8 . 1 is guided on the deflection rollers with hinge joints 9 . 1 and 9 . 2 . Alternating to the other side edge of the second solar panel 2 , the cable control 8 . 2 is guided there between the deflection rollers by way of hinge joints 9 . 3 and 9 . 4 . Again alternating to the other side edge of the third to the last solar panel 3 , a cable control 8 . 3 is guided via the deflection rollers by way of hinge joints 9 . 5 and 9 . 6 . The second to the last solar panel 4 has one cable control 8 . 4 each with deflection rollers and hinge joints 9 . 6 and 9 . 7 on both side edges as well as cable control 8 . 5 with deflection rollers and hinge joints 9 . 8 and 9 . 9 .
[0033] Furthermore, FIG. 1 shows that each individual solar panel consists of a rigid supporting structure 10 , which is coated with solar cells 6 . Each solar panel also contains bore holes, so-called hold-down points 7 ; however in the unfolded state these hold down points are not important.
[0034] The second to the last solar panel 4 has an unfolded solar sail 15 on a side edge. The solar sail 15 is always arranged on the second to the last solar panel 14 according to the illustrated preferred embodiments. Such a solar sail can also be found on the generator wing 14 .
[0035] [0035]FIG. 2 depicts a section from the generator wing 12 with the solar sail 15 . The solar sail 15 is stretched in a supporting structure, which is formed by one longitudinal connector 17 and two support arms 16 . 0 , 16 . 1 . In one direction, the two support arms 16 . 0 , 16 . 1 are arranged perpendicular in relation to the ends of the longitudinal connector 17 , and they are located in a joint plane. The supporting structure thus takes on a U-shaped design. A film 21 is tightened between the two support arms 16 . 0 , 16 . 1 and the longitudinal connector 17 . Film 21 is fastened to the supporting structure. The supporting structure and the film 21 form the solar sail 15 . One unfolding joint 18 . 0 , 18 . 1 , respectively, is arranged on the intersecting points between the longitudinal connector 17 and the support arms 16 . 0 , 16 . 1 . These unfolding joints are connected with the supporting structure of the second to the last solar panel 4 in the area of a side edge. FIG. 2 shows the unfolded state of the solar sail.
[0036] In the folded state, the solar sail 15 is swiveled with respect to the second to the last solar panel 4 , i.e. the film 21 is arranged adjacent and parallel in relation to the surface of the solar cells 5 . Meanwhile, one support arm 16 . 0 , 16 . 1 , respectively, is locked by one locking device, respectively, for as long as, in the folded state of the generator wing 12 , one locking wedge 20 . 0 , 20 . 1 of the third to the last solar panel 3 , respectively, holds the tension hooks 19 . 0 , 19 . 1 in its locking position. It is only when the generator wing 12 is unfolded that the third to the last solar panel 3 and the second to the last panel 4 are also unfolded so that the locking wedges 20 . 0 , 20 . 1 release the tension hooks 19 . 0 , 19 . 1 and that they release the support arms 16 . 0 , 16 . 1 of the solar sail. The solar sail 15 can then swivel into its end position due to the elastic force of the unfolding joints 18 . 0 , 18 . 1 . During the unfolding of the solar sail 15 , torsion forces and bending forces are transmitted by the support arms 16 . 0 , 16 . 1 to the longitudinal connector 17 . In order to achieve the required rigidity and firmness between the support arm 16 . 0 , 16 . 1 and the longitudinal connector 17 , the corner connectors 22 . 0 and 22 . 1 are arranged in the area of the interior angles 24 at that location. These corner connectors correspond to a buckle-proof profile with connecting points without torsional buckling on the longitudinal connector 17 and support arm 16 . 0 or 16 . 1 .
[0037] [0037]FIG. 2 a shows that with a larger surface expansion of the solar sail, for example, two U-shaped supporting structures can also be arranged adjacent to each other. The number of U-shaped supporting structures to be arranged is dependent on the dimensions of the solar sail. It is possible to arrange additional U-shaped supporting structures next to one another. According to FIG. 2 a , both U-shaped supporting structures have one joint longitudinal connector 17 .
[0038] According to FIG. 2 a the support arm 16 . 4 is also a joint support arm, which is connected with the longitudinal connector 17 in the perpendicular position. The support arm 16 . 4 , however, is connected with the longitudinal connector 17 on both sides through the corner connectors 22 . 4 , 22 . 5 , which are arranged in the plane of the film 21 .
[0039] [0039]FIG. 3 shows an advantageous corner connector 22 . 2 . This rigid corner connector 22 . 2 is formed by two semi-shells. Both semi-shells enclose the longitudinal connector 17 and the corresponding support arm 16 . 2 on half the side. Both semi-shells come into contact with each other at their seams and form a hollow space in the interior angle area.
[0040] [0040]FIG. 3 a shows a corner connector 22 . 2 consisting of two semi-shells 23 . 0 and 23 . 1 . These semi-shells 23 . 0 and 23 . 1 can be connected with each other in such a way, e.g. by way of gluing, that a section of the longitudinal connector as well as a section of the support arm are enclosed. In the assembled state, the corner connector 22 . 2 is one piece.
[0041] The supporting structure with corner connectors according to the invention meets the rigidity and firmness requirements and additionally offers a noticeable weight reduction.
[0042] In accordance with another embodiment as seen in FIG. 3 b , the corner connector 22 . 3 can also take on a two-piece design. This is possible, on the one hand, if a buckle-proof profile 25 , extending across the interior angle 24 , connects a support arm 16 . 3 with the longitudinal connector 17 and, on the other hand, if a connection without torsional buckling 26 is arranged in the intersecting area between the support arm 16 . 3 and longitudinal connector 17 . Such an alternative can contribute to further reducing the weight.
[0043] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
|
A supporting structure for a solar sail of a satellite is formed by support arms which are connected in a swiveling manner with a solar panel through unfolding joints, and a film is stretched between the support arms. A longitudinal connector is arranged parallel to one side edge of the solar panel, which has support arms that are arranged in a joint direction in the plane of the film and form at least one U-shaped supporting structure between which the film of the solar sail can be stretched. Corner connectors are arranged in the interior angle areas between the longitudinal connector and the support arms. This arrangement simplifies known constructions while maintaining the existing functional safety in order to allow for achieving a noticeable weight reduction.
| 1
|
BACKGROUND OF THE INVENTION
The present invention relates to a flat knitting machine with at least one needle bed and a carriage which is slidable along the needle beds and has at least one cam with needle selection device and stitch cams:
Sinking surfaces on the needle sinkers and the stitch cams position of the cam of a knitting machine determine the form and the size of a stitch. Depending on a knitting type, different stitch sizes and forms are desired. In double-surface R-R knittings, slim stitches of the finest stitch pattern are produced. This is achieved by a small sinking surface on the stitch cams. In single-surface smooth knittings, to the contrary, round stitches of the finest stitch pattern are produced. For producing these round stitches, wide sinking surfaces are required on the stitch cams, so that as many needles as possible are held simultaneously in the deepest sinking position. In this matter the tendency is reduced that the already pulled stitches are pulled from the preceding formed stitches by the produced pulling forces of substantially knit threads and thereby substantially reduce these stitches.
During high grade knitting, in the machine the stitch cams are exchanged when a new knitting must be produced with another binding type. In most cases, however needle sinkers are used which have a central sinking surface and thereby a compromise between the optimal stitch cams sinkers for R-R knitting and a single-surface smooth knitting is formed.
The form of the knitting surface can be also determined as to whether all needles are pulled simultaneously wide during sinking, or in the same needle sinking position they can be pulled differently wide.
In the patent document CH 448 358 a stitch cams is proposed which has two sinking surfaces for producing two different stitch sizes. The same needles which have a higher needle foot are sinking on one sinking surface and the needles with the lower needle feet are sinking on the different sinking surfaces. With the stitch cams, two different stitch sizes are produced, and each size ratio of the stitches are fixed relative to one another and not changeable.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a flat knitting machine, in which an influence of the stitch form and/or size is possible by changing the sinking surfaces without exchanging of the stitch cams.
In keeping with these objects and with others which will become apparent hereinafter, one feature of present invention resides, briefly stated, in a flat knitting machine of the above mentioned general type, in which a sinking element with the stitch cams, which sinking element is arranged movably on the stitch cams, and which depending on the stitch cams is controllable and together with the stitch cams, depending on its position, forms sinking surfaces of different sizes and/or forms.
With this sinking element it is possible to obtain an optimal stitch pattern during both double-surface R-R knitting and during single surface smooth knitting. The stitch cams can be provided for example with a small sinking surface, which is active alone when an R-R knitting must be produced. On the sinking element also a surface can be provided which during a corresponding adjustment of the sinking element expands the sinking surface of the needle sinker so that a wide sinking surface is produced, which is optimal for producing a single-surface smooth knitting.
The adjustment to different bonding types is also possible in the inventive flat knitting machine in a simple manner. An exchange of a stitch cams is no longer required. However, a corresponding control of the sinking elements must be provided. Depending on the adjustment of the sinking element, a small or a wide sinking surface can be adjusted. Further advantages are produced when the needle sinkers and/or the sinking element has positive guiding surface for the needle feet. Thereby an uncontrolled needle movement which provides non uniformities in the stitch pattern are excluded.
The sinking element can have also a guiding surface for the needle feet, which after sinking of a stitch activates a drive of the needle in a definite distance from the sinking surface. Thereby the tensioning which acts on the knitted thread can be reduced. The different knitting bindings must be realized with different knitting yarns. When the forces in the knitting threads during the knitting process become too high, they are torn. A knitted article with such thread torn parts (“splinters”) is a reject. Due to the guiding surface on the sinking element, it is however now possible, shortly after reaching the deepest sinking point, to drive the needles in a desired manner by a small distance and thereby to reduce the thread tension in the pulled-in stitch loop. During high knitting speeds a tearing of the knitting threads is prevented by these features.
The sinking element can also have a guiding surface for the needle foot, with which the pulling-in depth of predetermined needles relative to the pulling-in depth of the needle sinker-sinking surface is changeable. Thereby stitches can be formed, which have a size difference to corresponding stitches which are formed by the needle sinker-sinking surface. Therefore, a stepless adjustment of the stitch size difference by a stepless adjustment of the pulling-in depth of the predetermined needles can be performed.
For the adjustable arrangement of the sinking elements on a cam there are different possibilities. In a preferable embodiment of the present invention the sinking element is turnably arranged on the needle sinker.
It is especially advantageous when the sinking element is adjustable during the knitting process. The stitch form and size can be therefore adjusted without holding the machine during the knitting process. When the cams moreover operate in accordance with the pressing cam technique, it is also possible to definitely adjust the sinking surfaces for each individual stitch.
The novel features which are considered as characteristic for the present 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 drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view schematically showing a knitting cam of an inventive flat knitting machine at a side facing a needle bed;
FIG. 2 is a detailed view of a stitch cam with a sinking element of the knitting cam of FIG. 1, in a first adjustment position of the sinking element;
FIG. 3 is a view substantially corresponding to the view of FIG. 2, in a second adjustment position of the sinking element;
FIG. 4 is a view showing a section taken along the line IV—IV through an arrangement of FIG. 3;
FIG. 5 is a view substantially corresponding to the view of FIG. 2 and showing a stitch cam with a sinking element of a second embodiment;
FIG. 6 is a view substantially corresponding to the view of FIG. 2 and showing a stitch cam with a sinking element in accordance with a third embodiment;
FIG. 7 is a view substantially corresponding to the view of FIG. 2 and showing a stitch cams and a sinking element for stepless influence of the stitch size;
FIG. 8 is a view showing a section taken along the line VIII—VIII through the arrangement of FIG. 7 .
DESCRIPTION OF PREFERRED EMBODIMENTS
A knitting cam 100 shown in FIG. 1 has a needle driving out part 110 which cooperates with a limiting part 120 . Moreover, a forwardly running needle sinker 130 and a rearwardly running needle sinker 140 are provided on the knitting cam 100 , as considered in a movement direction identified with the arrow 150 . The needle sinker 130 is therefore outside operation. Moreover, the knitting cam 100 has two sinking elements 160 and 170 , which cooperate with the needle sinkers 130 , 140 as will be described herein below.
The arrangement 1 shown in FIG. 2 corresponds to the needle sinker 140 and the sinking element 170 of FIG. 1 . The needle sinker is here identified with reference numeral 2 and the sinking element is identified with reference numeral 3 . The sinking element 3 is supported on the needle sinker turnably around a turning point 40 . By acting in direction of the arrow 11 , the sinking element 3 is turned to its inner end position. A sinking surface 8 which is available on it is thereby set outside operation. The feet 10 of the not shown needles which participate in the knitting process slide along a plane 5 of the needle sinker 2 , until they reach a sinking position corresponding to the proper stitch size under a small sinking surface on the needle sinker 2 . In this sinking position the needle feet 10 are positively guided by a surface 7 on the needle sinker 2 , whereby a high uniformity of the stitch size is achieved. The smaller sinking surface 6 provides an optimal stitch pattern for R-R knitting.
FIG. 3 shows the arrangement 1 of FIG. 2, when the sinking element 3 is turned by acting in direction of the arrow 12 to its outer end position. Now the sinking surface 8 closes on the sinking surface 6 of the stitch cam 2 and thereby expands it. Due to the expanded surface 6 and 8 , now several needle feet 10 can be simultaneously held in the deepest sinking position. Thereby an optimal stitch pattern for a single-surface smooth knitting is obtained.
As can be seen in the section shown in FIG. 4, the sinking surfaces 8 of the stitch cam 2 and the sinking surfaces 8 of the sinking element 3 are located in different planes. This makes possible, in cooperation with not shown needle selection device and also not shown knitting cam with pressing cam technique, to achieve that each individual knitting needle can be preset so that it must be sinking over the small sinking surface 6 or over the wide sinking surface 6 plus 8 . Needle feet 10 which abut with half foot height against the stitch cam 2 are sinking on the small surface 6 , and the needle feet 10 which abut against the whole foot height on the stitch cam are sinking on the surface 6 plus 8 . In this manner it is possible in the knittings in which within one knitting row in exchange of a single-surface binding type to a double-surface binding type occurs, to form each stitch in the optimal form.
The arrangement 60 shown in FIG. 5 corresponds to the arrangement 1 of FIGS. 2 and 3, but with the additional possibilities that the needles after reaching the sinking position can perform a definite unloading movement. The arrangement has again a stitch cam 2 and a sinking element 30 which is turnable to its inner end position around the point 40 and assumes the position shown in FIG. 2 . The sinking element 30 has however an additional guiding surface 9 which presses the needle feet 10 after sinking against the small sinking surface 6 of the stitch cam 2 again a little upwardly and thereby somewhat drives out the needles, whereby the tension in the knitting threads is reduced. A positive guiding surface 15 is provided on the stitch cam 2 to bring the needles to their immovable position. In cooperation with the not shown needle selecting device and also not shown cam, with pressing cam technique for each individual knitting needle it can be determined whether they must perform the unloading movement or not. The needle feet 10 which about only with half foot height against the stitch cam perform no unloading movement, while the needle feet which abut with the whole foot height against the stitch cam are engaged by the curved surface 9 and thereby perform the unloading movement.
When with this structural shape of the sinking element 30 it is turned to its outer end position (not shown), the selected needles can be sinking either on the small sinking surface 6 or on the wide sinking surface 6 plus 8 .
The arrangement 50 shown in FIGS. 6 and 7 makes possible the formation of stitches with another stitch size than the stitches formed with the sinking surface 6 of the needle sinkers 2 . The arrangement has also a stitch cam 2 with a small sinking surface 6 , as well as a positive guiding surface 7 . The associated sinking element 31 is again supported turnably about a rotary point 41 , and in FIG. 6 is shown in its inner end position by loading in direction of the arrow 11 ″. The needle feet which only with a half foot height against the stitch cam 2 are sinking against the small surface 6 . The sinking surfaces 6 and the surface 7 form a positive guide. The feet which abut against the whole foot height against the needle stitch cam 2 are sinking on the wide sinking surface 6 plus 8 . The positive guidance is formed by the surfaces 7 as well as a further surface 14 on the sinking element 31 .
FIG. 7 shows the sinking element 31 which is turned under the action in direction of the arrow 12 ″ to its outer end position. The feet of the needles which form a stitch side corresponding to the needle sinking position are located with the half foot height against the stitch cam 2 and are sinking over the surface 6 . The surfaces 6 and 7 form a positive guide for these needles.
The feet of the needles which must form a greater stitch than that which corresponds to the needle sinking position, abut with the whole foot height against the stitch cam 2 . Their path for sinking extends over the planes 5 and 6 formed by the stitch cam 2 , to the plane 13 formed on the sinking element 31 , and then to the surface 81 . This surface 81 is the sinking surface for the greater stitches and forms a positive guide with the guide stitch limiting surface 14 which can be formed on the sinking element 31 .
The sinking element 31 can be turned from its inner turning position shown in FIG. 6 to its outer position shown in FIG. 7 . This makes possible a stepless increase of the stitches which are formed on the sinking surface 81 , when compared with those which are formed on the sinking surface 6 . The adjustment of the sinking element 31 can be performed during the knitting process, so that it is possible to produce individual stitches of the stitch row in different sizes.
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 types described above.
While the invention has been illustrated and described as embodied in flat knitting 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.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims.
|
A flat knitting machine has at least one needle bed, a carriage which slides along the needle bed which has at least one cam with needle section means and stitch cams, a sinking element which cooperates with the stitch cams and is arranged movably on the stitch cams, the sinking element being controllable independently from the stitch cams and together with the stitch cams forms sinking surfaces of different size and/or form depending on its position.
| 3
|
BACKGROUND OF THE INVENTION
1. Field of the Invention.
The present invention relates to devices for aerating liquids.
2. Description of the Prior Art.
In the purification of waste water and other liquids it is usual to aerate the liquid. For this purpose there has been proposed a disc or cone-shaped body disposed substantially in the middle of an aeration tank and mounted on a vertical shaft, the body being provided with vanes adapted to contact the liquid surface in the aeration tank, so as to disturb the liquid surface on rotation of said body for introducing air into the liquid.
A disadvantage of such surface aerators in that liquid droplets are displaced upwardly from the surface of the liquid by the body and may fall outside the confines of the aeration tank, which will lead to pollution and contamination of the surroundings. Screening by covering the aeration tank is expensive, and will also obstruct the access of air to the liquid.
SUMMARY OF THE INVENTION
According to the present invention, there is provided in a device for aerating liquid within a tank, a rotatable body, said body including vanes, means mounting said body for rotation about a substantially vertical axis, said vanes contacting the surface of the liquid in the tank such that the surface of the liquid is disturbed upon rotation of the body whereby the liquid is aerated, and a guard located above the body and extending transversely to the rotational axis of the body, the height of the guard above the body and the size of the guard being such that liquid displaced upwardly from the surface of the liquid during rotation of the body is reflected downwardly by the guard within the area defined by the tank, said guard including means defining at least one air supply opening.
BRIEF DESCRIPTION OF THE DRAWING
Embodiments of the invention will now be described, by way of example only, with reference to the accompanying diagrammatic drawing, in which:
FIG. 1 is a section of an aeration device according to the present invention;
FIG. 2 is a section of another embodiment of the device; and
FIG. 3 is a plan view of the aerator shown in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The device shown in FIG. 1 comprises a conical body 2 mounted on a substantially vertical shaft 1, and provided at its lower side with vanes 3 which are, at least partially, submerged in liquid within an aeration tank so as to disturb the liquid surface 4 and, thus, to mix it with air. Such aeration will, however, lead to a rather violent movement of the liquid, with the result that the liquid may splash over the confines of the aeration tank in which the liquid is contained, which will lead to pollution of the surroundings.
In order to avoid this effect, a guard 5 is arranged at a predetermined height above the highest point of the body 2. The height of the guard 5, and the distance of the outer edge of the guard from the shaft 1 are chosen so that any liquid discharged upwardly from the surface of the liquid within the tank is reflected downwards within the confines of the aeration tank. In its center portion, the guard 5 is provided with an opening 6 having dimensions which substantially correspond with those of the body 2. Air can enter through the opening 6, and the body 2 lies directly beneath the opening so that no liquid will be discharged through the opening.
FIGS. 2 and 3 show an advantageous embodiment of the splashing guard. This guard consists of groups of mutually parallel slats 7 which are symmetrically arranged around the shaft 1, openings 8 being defined between adjacent slats. The slats 7 have a predetermined inclination with respect to the horizontal plane, this inclination being such that, as viewed in the direction in which upwards discharge of liquid occurs, each slat covers the outer adjacent opening 8 so that liquid is not discharged through the openings 8.
The advantage of this construction is that additional air can flow inwardly through the openings 8 and furthermore, since air will be entrained with the liquid droplets reflected by the slats, a certain suction effect will be obtained so that the assembly operates in the manner of an ejector pump.
The inclination of the slats 7 can, furthermore, gradually increase outwardly in order to obtain a better confinement of the reflected drops.
Instead of such an assembly of slats, the guard can comprise rows of lips punched out from a plate. The lips in alternate rows can be off-set so that screening of the openings situated behind the lips is obtained, and any liquid discharged upwardly by the body will meet a lip or plate part against which reflection takes place. The openings will also provide for additional air supply. The inclination of the lips may gradually increase outwardly.
A disc-shaped body may be used as an alternative to the conical body 2 shown in the drawings.
The guard shown in the drawing is relatively inexpensive and will not cause obstruction of the air flow to the liquid.
|
A device for aerating liquid in a tank comprises a rotating body having vanes which contact the surface of the liquid. A splash guard is disposed above the body to reflect into the tank liquid droplets discharged upwardly by the body.
| 8
|
FIELD
[0001] The present disclosure relates to music playback systems, and more particularly to virtual jukebox music systems.
BACKGROUND
[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0003] The traditional music jukebox with actual albums or compact discs were previously the focal point of restaurants, bars, home recreation rooms, and other gathering places. Music fans would often gather around the music jukebox and engage in the ritual of flipping through the displayed albums or CD covers, via mechanical levers, in search of the perfect song to suit the mood and setting.
[0004] Music jukeboxes containing the actual physical albums or compact discs are difficult, however, to maintain with up to date music given the amount, and production rate, of new popular music. Music fans expect a large selection of varied music choices. The availability of digital music files online compounds the problem. Satellite music services are available to provide music fans up to date music. Satellite music service players, however, lack the physical gathering point of the music jukebox. Traditional digital music players, such as mp3 players, and the like, are capable of storing a large amount of digital music. Digital music players, however, lack the focal-point appeal of a music jukebox. Thus, music fans do not gather around the traditional mp3 player to engage in the ritual of selecting music.
SUMMARY
[0005] A virtual music jukebox system includes a music database stored in a removable hard drive. A music creator module is connected to a CD drive, an input module, and a computer readable medium for storing a music data management algorithm executable by the music creator module. A music player module plays music files in a music queue. A music selector module is connected to a touch screen I/O module, the music player module, the music queue, and another computer readable medium for storing at least one music selection algorithm executable by the music selector module. The music database is selectively connectable to the music selector module and the music creator module.
[0006] The music data management algorithm includes instructions for the music creator module to retrieve music files from the CD drive, convert the music files to a predetermined music database format, and store the music files in the music database. The music selection algorithm includes instructions for the music selector module to selectively retrieve the music files from the music database and place the music files in the music queue in response to the input received from the touch screen I/O module.
[0007] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0008] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0009] FIG. 1 is a schematic illustration of an exemplary virtual jukebox music system;
[0010] FIG. 2 is a schematic illustration of an exemplary virtual jukebox music system;
[0011] FIG. 3 is a schematic illustration of an exemplary virtual jukebox music system;
[0012] FIG. 4 is a diagram of an exemplary data structure of an exemplary music database;
[0013] FIG. 5 is a flowchart illustrating a music data management algorithm;
[0014] FIG. 6 is a flowchart illustrating a music data modification algorithm;
[0015] FIG. 7 is a flowchart illustrating a music data creation algorithm;
[0016] FIG. 8 is a screenshot of music data management options;
[0017] FIG. 9 is a flowchart illustrating a music selection algorithm;
[0018] FIG. 10 is a flowchart illustrating a music selection by cover algorithm;
[0019] FIG. 11 is a flowchart illustrating a music selection by category algorithm;
[0020] FIG. 12 is a flowchart illustrating a music selection by artist algorithm;
[0021] FIG. 13 is a flowchart illustrating a music selection by song title algorithm;
[0022] FIG. 14 is a flowchart illustrating a music playlist display algorithm;
[0023] FIG. 15 is a flowchart illustrating an internet music selection algorithm;
[0024] FIG. 16 is a flowchart illustrating a music player algorithm;
[0025] FIG. 17 is a screenshot of music selection options;
[0026] FIG. 18 is a screenshot of music selection by cover options;
[0027] FIG. 19 is a screenshot of CD song selection options;
[0028] FIG. 20 is a screenshot of music selection by category options;
[0029] FIG. 21 is a screenshot of music selection by artist options; and
[0030] FIG. 22 is a screenshot of music selection by song options;
DETAILED DESCRIPTION
[0031] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
[0032] As used herein, the term module refer to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality. Further, as used herein, computer-readable medium refers to any medium capable of storing data for a computer. Computer-readable medium may include, but is not limited to, CD-ROM, floppy disk, magnetic tape, other magnetic or optical medium capable of storing data, memory, RAM, ROM, PROM, EPROM, EEPROM, flash memory, or any other medium capable of storing data for a computer.
[0033] With reference to FIG. 1 , a virtual jukebox music system 100 includes a music database 102 , a music creator module 104 , a music selector module 106 , and a music player module 108 . Digital audio files are created by the music creator module 104 from CDs in a connected CD drive 110 and stored in the music database 102 . The music creator module 104 converts audio files from the CDs into a predetermined digital audio format, such as mp3, and stores the converted audio files in the music database 102 . The music creator module 104 is operable by a user via the connected input/output module(s) 112 , such as a mouse, keyboard, monitor, or other suitable input/output devices. The algorithms executed by the music creator module 104 are stored in a computer-readable medium 114 accessible to the music creator module 104 .
[0034] The music creator module 104 is connected to the internet 116 via a dial-up, DSL, cable, or other suitable TCP/IP network connection. The music creator module 104 receives digital audio files from the internet 116 . The received digital audio files are converted to the predetermined digital audio format and stored in the music database 102 . Additionally, the music creator module 104 may receive digital audio files from other sources, such as a portable computer readable medium. For example, the music creator module 104 may receive digital audio files from a connected USB memory device.
[0035] The music creator module 104 is preferably implemented in software executed by a personal computer or other suitable computing device. The music database 102 is preferably contained in a removable hard drive that may be selectively connected to the music creator module 104 and the music selector module 106 . The removable hard drive is preferably accessible via a USB connection.
[0036] The music selector module 106 accesses the digital audio files in the predetermined format stored in the music database 102 and selects music from the music database 102 based on user input. The music selector module 106 is operable by a user via a touch screen input/output module 118 , or touch screen I/O module 118 . Music selection algorithms executed by the music selector module 106 are stored in a computer-readable medium device 120 .
[0037] The music selector module 106 is also connected to the internet 116 via a dial-up, DSL, cable, or other suitable TCP/IP network connection. The music selector module 106 may receive digital audio files from the internet 116 . The music selector module 106 may also receive streamed digital audio files from the internet 116 via an internet radio broadcast.
[0038] Based on input received via the touch screen I/O Module 118 , the music selector module 106 places digital audio files from the music database 102 into a music queue 122 . The music selector module 106 also places digital audio files received form the internet 116 from an internet music website or from an internet radio broadcast.
[0039] The music player module 108 is connected to speakers 126 through a receiver/amplifier 124 and sequentially plays the digital audio files in the music queue 122 . The music selector module 106 , music player module 108 , and music queue 122 are preferably implemented in software. The music selector module 106 , music player module 108 , music queue 122 , computer-readable medium 120 , together with the touch screen I/O module 118 , may comprise an integrated jukebox with touch screen unit 130 . Alternatively, the music selector module 106 , music player module 108 , music queue 122 , and computer-readable medium 120 may comprise an integrated jukebox unit 128 separate from the touch screen I/O module 118 .
[0040] With reference to FIG. 2 , the integrated jukebox with touch screen unit 130 includes an LCD monitor 200 and a touch screen 202 . While shown as separate devices in FIG. 2 , in practice the touch screen 202 is positioned on top of the viewable screen of the LCD monitor 200 . In this way, the LCD Monitor 200 displays selectable options to the user, for example, as push buttons. When the user “depresses” the button displayed by the LCD monitor 200 , the touch screen 202 responds appropriately.
[0041] The LCD monitor 200 and touch screen 202 are connected to a main motherboard 204 . The LCD monitor 200 is connected to the monitor output of the main motherboard 204 . The touch screen 202 is connected to the main motherboard via a USB driver 206 and USB Port 208 . The remaining USB Port 208 is connected to a removable hard drive 210 . The removable hard drive contains the music database 102 . The removable hard drive 210 is connected to the USB Port 208 via a USB plug 211 and USB slot 213 .
[0042] The main motherboard 204 includes a CPU 212 and RAM 214 , and is connected to a flash card 216 via a flash card adapter 218 and IDE bus 220 . The flash card 216 stores software that is executed by the CPU 212 . The music selector module 106 , music player module 108 , and music queue 122 are implemented in software stored on the flash card 216 and executed by the CPU 212 .
[0043] Power is delivered to the main motherboard 204 from an AC source 222 via an AC/DC transformer 224 and power supply 226 . Power is controlled by an on/off switch 228 . A fan 215 cools the CPU 212 and main motherboard 204 .
[0044] The main motherboard 204 is also connected to the internet 116 via suitable internet connection devices 250 , 252 . For example, the main motherboard 204 may be configured with an on-board network connector 250 , for receiving an RJ-45 connector device.
[0045] The CPU 212 selectively retrieves and plays digital audio files from the music database 102 on the removable hard drive 210 and from the internet 116 in response to user input received from the touch screen 202 . The audio output generated by the CPU is delivered to female RCA audio plugs 230 . Other suitable audio outputs may be used. The audio output is delivered to the Receiver/Amplifier 124 via corresponding male RCA plugs 232 .
[0046] In practice, the integrated jukebox with touch screen unit 130 is mountable and may be located in a bar, restaurant, recreation room, or the like. The integrated jukebox with touch screen unit may be mounted to a wall, a counter-top, a bar-top, or other suitable location. Additionally, the integrated jukebox with touch screen unit 130 may be mounted or located in a vehicle, such as a limousine, car, bus, recreational vehicle, or airplane. The music database 102 on the removable hard drive 210 is loaded with CDs and then connected to the integrated jukebox with touch screen unit 130 via the USB plug 211 and USB slot 213 .
[0047] With reference to FIG. 3 , the integrated jukebox unit 128 is similar to the integrated jukebox with touch screen unit 130 of FIG. 2 . The integrated jukebox unit 128 is separate, however, from the touch screen I/O module 118 , comprised of the LCD monitor 200 and touch screen 202 . In practice, the touch screen I/O module 118 may be mounted to a wall, a counter-top, a bar-top, or other suitable location. The integrated jukebox unit 128 may then be hidden from view under the counter-top, bar-top, or the like. In all other respects, the integrated jukebox unit 128 and the integrated jukebox with touch screen unit 130 include similar components and operate in a similar fashion.
[0048] Referring now to FIG. 4 , digital audio files 400 and other music data are stored in a data structure 402 in the music database 102 . The data structure 402 includes a separate CD directory 404 for each CD stored in the music database 102 . Each CD directory includes a CD data file 406 , CD graphics files 408 , and an audio file 400 for each song on the CD. The CD data file 406 includes the title 410 and artist 412 as well as the name of the associated CD graphics file(s) 414 . The CD data file 406 includes the category 413 of the CD, e.g., pop/rock, r & b, etc. The CD data file 406 contains a song entry 416 for each song on the CD. Each song entry 416 includes the song name 418 , artist name 420 , and associated audio file name 422 . The artist name 420 will be identical to the artist field 412 if the artist is the same for all songs on the CD. If the CD includes various artists, then the artist name 420 will vary across the songs on the CD.
[0049] Referring now to FIG. 5 , a music data management algorithm 500 is shown. The music data management algorithm 500 is executed by the music creator module 104 . In step 501 , the music creator module 104 connects to the music database 102 . The music creator module 104 retrieves a listing of CDs and a listing of songs for each CD from the music database 102 . In step 502 the music creator module 104 displays a listing of the CDs. With additional reference to FIG. 8 , a screen shot shows the CD list 800 . In step 504 ( FIG. 5 ) the first CD in the list is selected and displayed as the default selection. As shown in FIG. 8 , the first CD in the CD list 800 is highlighted. In FIG. 8 a screen shot of music data management options is shown. The songs for the selected CD are shown in the song list 802 ( FIG. 8 ).
[0050] In step 506 ( FIG. 5 ), the user is presented with a number of options. The user may change the CD selection, edit the selected CD, delete the selected CD, or add a CD. To change the CD selection, the user highlights a different CD in the CD list 800 ( FIG. 8 ). When the user changes the CD selection, the newly selected CD is displayed as the current CD selection in step 508 ( FIG. 5 ). The songs associated with the new CD selection are displayed in the song list 802 ( FIG. 8 ). After displaying the current CD selection, the music creator module 104 returns to step 506 and waits for the next user input.
[0051] The user may delete the selected CD by pressing the delete CD button 804 ( FIG. 8 ). When the user selects delete CD, the music creator module 104 removes the files associated with the selected CD from the music database in step 510 ( FIG. 5 ). To remove the files associated with the selected CD, the music creator module 104 deletes the associated CD directory from the music database 102 . The music creator module 104 then returns to step 506 and waits for the next user input.
[0052] The user may edit the data associated with the selected CD by pressing the edit CD button 806 ( FIG. 8 ). As described in more detail below, the music creator module 104 edits the data associated with the selected CD, based on user input, in step 512 ( FIG. 5 ). The music creator module 104 then returns to step 506 and waits for the next user input.
[0053] The user may add a CD to the music database 102 by pressing the add CD button 808 ( FIG. 8 ). As described in more detail below, the music creator module 104 adds a CD to the music database 102 in step 514 ( FIG. 5 ). The music creator module 104 then returns to step 506 and waits for the next user input.
[0054] With reference now to FIG. 6 , a music data modification algorithm 600 is shown. The music data modification algorithm 600 is executed by the music creator module 104 when the user presses the edit CD button 806 ( FIG. 8 ). It is understood that the steps shown in FIG. 6 are encapsulated in step 512 of FIG. 5 . In step 601 , the music creator module 104 receives the “edit selected CD” input from the user. The user is presented with various choices in step 602 .
[0055] The user may choose to edit CD info. In step 604 , the music creator module 104 edits the selected informational data based on user input. The CD title, artist, category, names of audio files, etc., may be edited in step 604 . Editable text boxes are provided to edit CD data 810 ( FIG. 8 ). The music creator module 104 returns to step 602 and waits for user input.
[0056] The user may save the CD changes by pressing the Save CD button 812 ( FIG. 8 ). The music creator module 104 saves the CD changes to the music database 102 in step 606 ( FIG. 6 ).
[0057] The user may select a specific song to edit from the song list 802 . ( FIG. 8 ). The music creator module 104 then waits for a user selection in step 608 ( FIG. 6 ). When a specific song is selected for editing, the user may delete the selected song by pressing the delete song button 814 or edit the song information by pressing the edit song button 816 ( FIG. 8 ). When the delete song button 814 is depressed, the music creator module 104 deletes the selected song from the music database 102 in step 610 and returns to step 602 ( FIG. 6 ).
[0058] When the edit song button 816 ( FIG. 8 ) is depressed, the music creator module 104 edits song information in step 612 ( FIG. 6 ). The user may edit the song name, artist, name of associated audio file, etc. The music creator module 104 then returns to step 602 .
[0059] The user may insert a song by depressing the insert song button 818 ( FIG. 8 ). The music creator module 104 inserts a song after the selected song in the song list 802 . In step 614 ( FIG. 6 ), the user browses and chooses an audio file for insertion after the selected song. The audio file may be retrieved from the CD Drive 110 , from the internet 116 , or from another suitable music source. The music creator module 104 then returns to step 602 . When the CD and song editing is finished, the music creator module 104 exits the edit CD algorithm 600 .
[0060] With reference now to FIG. 7 , a music data creation algorithm 700 is shown. The music data creation algorithm 700 is executed by the music creator module 104 to add a CD to the music database 102 . It is understood that the steps shown in FIG. 7 are encapsulated in step 514 of FIG. 5 .
[0061] In step 702 , the music creator module 104 receives the “Add CD” input from the user. With reference to FIG. 8 , the user depresses the add CD button 808 . In step 704 ( FIG. 7 ), the music creator module 104 determines whether a CD is in the CD Drive 110 . When a CD is in the CD Drive 110 , the music creator module 104 proceeds to step 706 and gets the encoded CD number from the CD. Music CDs contain a unique encoded CD number that identifies the music data, such as artist, CD title, etc. In step 708 , the music creator module 104 logs in to a CD information service and submits the encoded CD number. For example, a CD information service, such as CDDB provided by Gracenote®, provides CD information via the internet based on the encoded CD number. In step 710 , the music creator module 104 receives the CD Name from the CD information service based on the encoded CD number.
[0062] In step 704 when a CD is not in the CD Drive 110 , the music creator module 104 proceeds to step 712 . In step 712 , the user is prompted for the name of the CD. The music creator module 104 receives the CD name input, and proceeds to step 714 . In step 714 , the user confirms the CD name. When the CD name is not correct, the music creator module 104 loops back to step 704 . When the CD Name is correct, the music creator module 104 proceeds to step 716 .
[0063] In step 716 , the music creator module 104 creates a new CD directory in the music database 102 for the CD. In step 718 , the user selects whether to download CD information from the CD information service, or to manually input the CD information. When the user selects download, the remaining CD information is retrieved from the CD information service in step 720 . When the user selects manual input, the music creator module 104 receives the CD information input in step 722 . In step 724 , the music creator module 104 receives any user edits to the CD information.
[0064] When the CD information is complete, the music creator module 104 repeats an encoding loop 726 for each song track on the CD. In step 728 , the CD track is encoded. In step 730 , the encoded CD track is saved as an audio file in the appropriate CD directory in the music database 102 .
[0065] In step 732 , the CD graphic files are copied to the CD directory. The CD graphic files may include CD cover artwork and the like. The music data creation algorithm 700 ends in step 734 .
[0066] With reference now to FIG. 9 , a music selection algorithm 900 is executed by the music selector module 106 . The music selection algorithm 900 is executed by the music selector module 106 after the music database is connected to the music selector module 106 . For example, the music selection algorithm 900 may be executed after the removable hard drive 210 is connected. In step 902 , the main menu options are displayed. The main menu options include: select music options, clear all songs, reject song, toggle random on/off, view playlist, and access internet music. With reference to FIG. 17 , a screenshot of music selection options is shown. The screenshot is displayed by the touch screen I/O module 118 . It is understood that the touch screen I/O module 118 shown in FIG. 17 may or may not be integrated with the music selector module 106 , music player module, music queue 122 , and computer-readable medium 120 .
[0067] In step 904 , when the user selects “clear all songs,” the music selector module 106 clears all songs from the music queue 122 in step 906 . The music selector module 106 then returns to step 902 and displays the main menu options again.
[0068] In step 904 , when the user selects “reject song,” the music selector module 106 clears the current song from the music queue 122 in step 908 , and skips to the next song in the music queue 122 . The music selector module 106 then returns to step 902 and displays the main menu options again.
[0069] In step 904 , when the user selects “toggle random on/off,” the music selector module 106 toggles a random-enable flag in step 910 . When the random-enable flag is on, the music selector module 106 retrieves a random song from the music database 102 when the music queue 122 is empty. When the random-enable flag is off, the music queue 122 remains empty when the last song from the music queue 122 finishes playing. The music selector module 106 returns to step 902 and displays the main menu options again.
[0070] In step 904 , when the user desires to select music to play, the user may select music by CD Cover, by category, by artist, and by song title. Music is selected based on CD covers in step 916 , based on category in step 918 , based on artist in step 920 , and based on song title in step 922 . When music is selected in steps 916 , 918 , 920 and 922 , the music selector module 106 adds the selected music to the music queue. When a single song is selected, the song is added to the end of the music queue. When an entire CD is selected, all of the songs of the selected CD are added to the end of the music queue 122 in order.
[0071] The user generally continues to select music until the user selects a “return to main menu” option, wherein the music selector module 106 returns to step 902 and displays the main menu options again.
[0072] In step 904 , when the user selects view playlist, the playlist is displayed for viewing in step 926 . When the playlist is displayed, the current song being played is displayed along with the songs to be played next. For example, the next fifteen songs “waiting” in the Music Queue 122 may be displayed.
[0073] In step 904 , when the user selects the internet option, internet music is accessed in step 928 . The user may select an internet radio broadcast to be played. Alternatively, the user may select an internet music website with digital music files available for downloading. In such case, the user may download digital music files directly from the website. The downloaded music files are stored in the music database 102 and placed in the Music Queue 122 for playing by the Music Player Module 108 .
[0074] The integrated jukebox unit 128 may be equipped with suitable input/output connections to allow communication with a keyboard and/or mouse (not shown). For example, the integrated jukebox unit 128 may include an IR keyboard/mouse connection to allow internet browsing by the integrated jukebox unit 128 .
[0075] With reference now to FIG. 10 , a music selection by cover algorithm 1000 is executed by the music selector module 106 . It is understood that the steps shown in FIG. 10 to select music based on CD cover correspond to step 916 of FIG. 9 . In step 1002 , the music selector module 106 initializes a pointer to the first CD cover in the CD list. The CD list is a listing of all CDs in the music database 102 . The CD list may be organized alphabetically, or by other suitable organizational means. In step 1004 , the music selector module 106 displays “J” Covers from the pointer position in the CD list, where J is a predetermined number. For example, with reference to FIG. 18 , 8 CD covers are displayed on the touch screen I/O module 118 . In FIG. 18 a screenshot of music selection by cover options is shown.
[0076] In step 1008 , the user selection is received. The user may page forward or page back. When page forward is selected, the music selector module 106 moves the pointer down J CDs in step 1010 , and displays the next J CDs in the CD list in step 1004 . When page back is selected, the music selector module 106 moves the pointer up J CDs in step 1012 , and displays the previous J CDs in the CD list in step 1004 .
[0077] The user may select an alphabet letter by pressing a letter displayed on the touch screen I/O module 118 , as shown in FIG. 16 . When the user selects an alphabet letter, the music selector module 106 moves the pointer to the CD in the CD list closest to the selected letter in step 1014 . The music selector module 106 then returns to step 1004 and displays J covers from the pointer position in the CD list.
[0078] When the user selects one of the CD covers, the song list for the selected CD is displayed in step 1016 . With reference to FIG. 19 , when a CD is selected, the CD Cover is displayed alongside a listing of the songs of the CD. In FIG. 19 , a screenshot of music selection by cover options is shown. When the particular CD is part of a multi-disc set, the covers of the other CDs in the multi-disc set are displayed as smaller CD Cover graphics below the current selected CD.
[0079] The user selection from the song list is received in step 1018 . The user may select a single song from the CD's song list. The user may also select all of the songs from the CD's song list. When music is selected in step 1018 , the selected music is added to the music queue 122 in step 1020 . After selecting a song or songs from the song list in step 1020 , the song list continues to be displayed in step 1016 . The user may continue to select songs from the CD until selecting “Back” or “Return to Main Menu” in step 1018 . When the user selects “Back,” the CD covers are again displayed in step 1004 .
[0080] In both step 1008 and step 1018 , the user may select to return to the main menu. When the main menu is selected, the music selector module 106 returns to step 902 ( FIG. 9 ) and displays the main menu options. In step 1018 , the user may select “Back” without selecting any music. When “Back” is selected, the music selector module 106 returns to step 1004 and displays J covers from the current pointer position in the CD list.
[0081] With reference now to FIG. 11 , a selection by category algorithm 1100 is executed by the music selector module 106 . It is understood that the steps shown in FIG. 11 to select music based on category correspond to step 918 of FIG. 9 . In step 1102 music categories are displayed. With reference to FIG. 20 , for example, music categories are displayed on the touch screen I/O module 118 , including Pop/Rock, R & B, Country, and Classic/Oldies. In step 1104 the category selection is received. In step 1106 , the display selection options are displayed.
[0082] The user may select based on CD covers, artist, or song title. The user selection is received in step 1108 . When the user chooses to browse by CD covers, music is selected based on CD covers from within the selected category of music in step 1110 . When the user chooses to browse by artist, music is selected based on artists from within the selected category of music in step 1112 . When the user chooses to browse by song title, music is selected based on song title from within the selected category of music in step 1114 . The user may also choose to return to the main menu in step 1116 .
[0083] When music is selected in steps 1110 , 1112 , and 1114 , the selected music is added to the music queue 122 . When the music selection concludes, the algorithm returns to the main menu in step 1116 .
[0084] With reference now to FIG. 12 , a selection by artist algorithm 1200 is executed by the music selector module 106 . It is understood that the steps shown in FIG. 12 to select music based on artist name correspond to step 920 of FIG. 9 . In step 1202 , a pointer is initialized to the first artist name in an artist list. The artist list is a listing of all artists in the music database 102 . The artist list may be organized alphabetically, or by other suitable organizational means.
[0085] In step 1204 , the music selector module 106 displays N names from the current pointer position in the name list. “N” is a predetermined number of artist names. For example, with reference to FIG. 21 , five artists are displayed on the touch screen I/O module 118 . In step 1206 a user selection is received. The user may choose to page forward, page back, select a letter A-Z, back space, select an artist, or return to main menu.
[0086] In step 1206 , when the user chooses page forward, the pointer is moved down N artists in the name list in step 1208 . The music selector module 106 then displays N names from the current pointer position in the name list in step 1204 . In step 1206 , when the user chooses page back, the pointer is moved up N artists in the name list in step 1210 . The music selector module 106 then displays N names from the current pointer position in the name list in step 1204 .
[0087] In step 1206 , when the user chooses to select a letter A-Z, the selected letter is appended to a search string in step 1212 . In step 1214 , the pointer is moved to the location in the name list corresponding to the current search string. For example, with reference to FIG. 21 , “Artist C” has been entered as the search string. Artist C, followed by the 4 artist names which follow Artist C in the name list, are displayed on the touch screen I/O module 118 in FIG. 21 . In step 1216 , when the user chooses to back space, the last letter from the search string is cleared. The pointer is moved to the location in the name list corresponding to the current search string in step 1214 . The music selector module 106 then returns to step 1204 and displays N names from the current pointer position in the name list.
[0088] When an artist is selected from the name list, the list of CDs for the selected artist is displayed in step 1218 . The user then makes a selection in step 1220 . The user may select a CD, go back to the Name List display, or Return to the Main Menu. The user selection based on the displayed Song List is received in step 1226 . In step 1226 , the user may select a song or songs from the Song List, go Back to the Name List, or Return to the Main Menu.
[0089] In step 1226 the user may select a song from the Song List, or all of the Songs on the Song List for the CD. The selected songs are added to the Music Queue in step 1228 . After the songs are added to the music queue, the song list is again displayed in step 1224 .
[0090] In steps 1206 , 1220 and 1226 , when the user selects “Back”, the Name List is displayed in step 1204 . In steps 1206 , 1220 , and 1226 , the user may choose to return to the main menu. The music selector module 106 returns to the main menu in step 1222 , and proceeds with the main menu selection algorithm 900 .
[0091] With reference now to FIG. 13 , a selection by song title algorithm 1300 is executed by the music selector module 106 . It is understood that the steps shown in FIG. 13 to select music based on song title correspond to step 922 of FIG. 9 . In step 1302 , a pointer is initialized to the first song title in a song list. The song list is a listing of all songs in the music database 102 . The song list may be organized alphabetically, or by other suitable organizational means.
[0092] In step 1304 , the music selector module 106 displays S songs from the current pointer position in the song list. “S” is a predetermined number of songs. For example, with reference to FIG. 22 , five songs are displayed on the touch screen I/O module 118 . In step 1306 a user selection is received. The user may choose to page forward, page back, select a letter A-Z, back space, select a song, or return to main menu.
[0093] In step 1306 , when the user chooses page forward, the pointer is moved down S songs in the song list in step 1308 . The music selector module 106 then displays S songs from the current pointer position in the song list in step 1304 . In step 1306 , when the user chooses page back, the pointer is moved up S songs in the song list in step 1310 . The music selector module 106 then displays S songs from the current pointer position in the song list in step 1304 .
[0094] In step 1306 , when the user chooses to select a letter A-Z, the selected letter is appended to a search string in step 1312 . In step 1314 , the pointer is moved to the location in the song list corresponding to the current search string. In step 1316 , when the user chooses to back space, the last letter from the search string is cleared. The pointer is moved to the location in the song list corresponding to the current search string in step 1314 . The music selector module 106 then returns to step 1304 and displays S songs from the current pointer position in the song list.
[0095] When a song is selected from the song list, the selected music is added to the music queue 122 in step 1324 . In step 1306 the user may choose to return to the main menu. The music selector module 106 returns to the main menu in step 1322 , and proceeds with the main menu selection algorithm 900 .
[0096] Referring now to FIG. 14 , a playlist display algorithm 1400 is executed by the music selector module 106 . It is understood that the steps shown in FIG. 14 correspond to step 926 of FIG. 9 . In step 1402 the current song being played along with additional songs in the music queue 122 are displayed. The user may select the number of “waiting” songs to be displayed. For example, the user may select that five, ten, or fifteen upcoming songs be displayed. In step 1404 , the music selector module 106 determines whether the current song is finished. When the current song is not finished, the music selector module 106 loops back to step 1404 and the current display remains unchanged. When the current song is finished, the display is updated with the next current song and with the current songs “waiting” in the music queue 106 in step 1406 . The music selector module 106 then loops back to step 1404 .
[0097] Referring to FIG. 15 , an algorithm for accessing music on the internet is executed by the music selector module 106 . In step 1502 a user selection is received. The selection may include an internet radio selection or an internet music site selection.
[0098] In step 1504 , when internet radio is selected, the music selector module 106 receives streamed music files from the selected internet radio web site. The internet radio web site may broadcast an internet radio program comprising a series of music files for play. The internet radio broadcast is played until a user selection is received in step 1506 . In step 1506 , the user may select “back” to return to step 1502 or “main menu” to return to the main menu in step 1514 .
[0099] In step 1502 , when the user selection an internet music site, the selected internet music site may be displayed in step 1508 . The user may browse the internet to arrive at the desired internet music site. As described above, input/output devices such as an IR keyboards and/or an IR mouse may be used to facilitate internet browsing. In step 1508 the selected internet music site is loaded for viewing.
[0100] In step 1510 the user makes a selection based on the loaded web site. The user may select to return to the main menu and proceed to step 1514 . The user may select “back” to return to step 1502 . Additionally, the user may select a music file from the website. In such case, the selected music file is downloaded in step 1512 . The selected music file is stored in the music database 102 and inserted in the music queue 122 . After downloading the music file, the internet music site is again loaded or renewed in the display in step 1508 . In this way, internet music is accessed by the music selector module 106 .
[0101] Referring to FIG. 16 , a music player algorithm 1600 is executed by the music player module 108 . In step 1602 the music player module 108 reads the music queue 122 . In step 1604 , the music player module 108 determines whether the music queue 122 is empty, the music player module 108 loops back to step 1602 . When in step 1604 the music queue is not empty, the music player module 108 proceeds to step 1606 and plays the next song in the music queue 122 . When the music player module 108 plays a song, it is outputted to the female RCA audio plugs 230 ( FIGS. 2 and 3 ). In step 1608 the music player module 108 waits for the song to finish. When the song finishes, the music player module 108 proceeds to step 1402 and reads the music queue 122 again.
[0102] In this way, music is selected and played on the virtual jukebox music system 100 . CDs are loaded into the music database 102 . Music fans may then gather around the touch screen I/O module 118 either as part of an integrated jukebox with touch screen unit 130 or as part of a separate from an integrated jukebox unit 128 . Music selections are made either from the music database 102 or from the internet and loaded into the music queue 122 .
|
A virtual jukebox music system includes a music database stored in a removable hard drive, a music creator module, a music player module, and a music selector module. The music creator module is connected to a CD drive, an input module, and a first computer readable medium for storing a music data management algorithm executable by said music creator module. The music player module plays music files in a music queue. The music selector module is connected to a touch screen input/output module, the music player module, the music queue, and a second computer readable medium for storing a music selection algorithm executable by the music selector module. The music database is selectively connectable to the music selector module and the music creator module. The music data management algorithm includes instructions for the music creator module to retrieve music files from the CD drive, convert the music files to a predetermined music database format, and store the music files in the music database. The music selection algorithm includes instructions for the music selector module to selectively retrieve the music files from the music database and place the music files in the music queue in response to input received from the touch screen input/output module.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
Leptospirosis, caused by Leptospira interrogans, is a disease of animals and humans which has a worldwide distribution. L. interrogans is an immunologically diverse species and contains several distinct genetic groups. At least six serologically distinct types (serovars) have been identified in North America and about 190 serovars throughout the world. In North America, the most common cause of bovine leptospirosis is L. interrogans serovar hardjo-type hardjo-bovis. Hardjo-bovis and the reference strain for serovar hardjo, hardjoprajitno, are both associated in cattle with the causation of abortions, stillbirths, production of weak offspring, and infertility. In addition, cattle infected with serovar hardjo develop persistent renal infections and shed leptospires in their urine. Exposure to urine containing hardjo-bovis is considered to be the primary source of infections within herds.
The two hardjo types can be differentiated by restriction endonuclease analysis of genomic DNA. However, the existence of similar antigens shared by hardjo-bovis and hardjoprajitno prevents these two bacteria from being differentiated by classical serological techniques.
This invention relates to a sensitive diagnostic probe for distinguishing hardjo-bovis from other pathogenic leptospires, particularly those which commonly infect domestic animals in North America.
2. Description of the Prior Art
Diagnosis of leptospirosis usually depends upon demonstration of serum antibodies. The serologic method of choice is the microscopic agglutination test reported by Cole et al. [Appl. Microbiol. 25: 976-980 (1973)]. However, interpretation of microscopic agglutination test results is often subjective and is complicated by numerous factors, including previous vaccination or infection and antigenic heterogeneity among L. interrogans. Since cattle infected with hardjo-bovis may fail to produce detectable antibodies, an accurate diagnosis of infection with hardjo-bovis requires direct demonstration of L. interrogans in tissues, blood, or urine. This is achieved either by bacteriological culture or by immunological techniques. Isolation of serovar hardjo from clinical specimens is labor intensive and inconsistent and requires weeks or months before results are obtained. Similarly, antigens may be degraded or blocked in some clinical specimens and thus prevent immunological detection of bacteria.
Several investigators have utilized DNA-DNA hybridization methods for rapid and reliable detection of L. interrogans in biological samples (blood, urine, and tissue homogenates) [B. D. Millar et al., Vet. Microbiol. 15: 71-78 (1987); W. J. Terpstra et al. I, J. Gen. Microbiol. 133: 911-914 (1987); and W. J. Terpstra et al. II, J. Med. Microbiol. 22: 23-28 (1986)]. The probes for these hybridizations consist of genomic DNA labeled by nick translation with radiolabeled or biotinylated nucleotides. Although these probes are specific for L. interrogans, they demonstrate extensive cross-hybridization among pathogenic serovars (Terpstra et al. II, supra). LeFebvre [J. Clin. Microbiol. 25: 2236-2238 (1987)] and Van Eys et al. [J. Gen. Microbiol. 134: 567-574 (1988)] disclose cloned DNA probes which differentiate hardjo-bovis from hardjoprajitno in DNA blot hybridization studies. These probes have not been well characterized, nor used to detect hardjo-bovis in biological material. Whereas the probe described by Lefebvre recognizes a discrete fragment of the hardjo-bovis genome which apparently exists as a single copy, probes described by Van Eys et al. may exist as several copies in the hardjo-bovis genome. The restriction enzyme maps of the probes described by Van Eys et al. are distinct from the probes described herein and are likely to detect different sequences than the probes of the invention.
SUMMARY OF THE INVENTION
I have now discovered a repetitive sequence element from hardjo-bovis and have cloned this fragment to develop a sensitive diagnostic single-stranded RNA probe for the detection of hardjo-bovis shed in the urine of infected cattle. This probe not only distinguishes hardjo-bovine from other pathogenic leptospires known to infect domestic animal species in North America, but it is also useful for distinguishing L. interrogans isolates of wildlife species as well. The probe is designed to bind specifically to the repetitive sequences contained within the hardjo-bovine genome while not cross-hybridizing with the genomic sequences of many other commonly encountered pathogenic leptospires.
In accordance with this discovery, it is an object of the invention to provide a probe for diagnosis of bovine leptospirosis, and particularly a probe which is specific for L. interrogans serovar hardjo-type hardjo-bovis. The probe is envisioned for use primarily as a replacement for bacteriological culture or fluorescent antibody screening techniques for the diagnosis of bovine leptospirosis.
It is also an object of the invention to provide plasmids carrying template DNA for transcribing the novel probes.
It is also an object of the invention to provide a sensitive, reliable, and rapid assay for hardjo-bovis suitable for large-scale herd screening.
More specifically, it is an object of the invention to identify infected cattle shedding hardjo-bovis in their urine.
Another object of the invention is to provide a probe for use in conjunction with restriction fragment length polymorphism (RFLP) technology as an epidemiological tool for distinguishing among different hardjo-bovis isolates.
A further object of the invention is to provide a diagnostic basis for designing an effective control program for hardjo-bovis in cattle herds.
Other objects and advantages of this invention will become readily apparent from the ensuing description.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram depicting the restriction map of plasmid pLI16.
FIG. 2 is a schematic diagram depicting the restriction map of plasmid pLI17.
FIG. 3 is a schematic diagram depicting the restriction map of plasmid pLI18.
FIG. 4 is a schematic diagram depicting the restriction map of plasmid pLI20.
FIG. 5 is an autoradiograph comparing genomic DNA fragments from L. interrogans serovars wolffi and romanica produced by digestion with EcoRI (lanes 1 and 2), HindIII (lanes 3 and 4), or XmnI (lanes 5 and 6) and which hybridize radiolabeled probe RNA.
Glossary
For purposes of this invention, the following standard abbreviations and terms used herein have been defined below. Also included are a listing of biological materials and reagents mentioned in the specification.
ABBREVIATIONS
bp=basepairs
CAP=calf-alkaline phosphatase
DEAE=diethylaminoethanol
DNA=deoxyribonucleic acid
dH 2 O=distilled water
dpm=disintegrations per minute
EDTA=ethylenediaminetetraacetic acid
FA=fluorescent antibody
kb=kilobases (1000 basepairs)
kd=kilodalton
nt=nucleotide
PAGE =preparative agarose gel electrophoresis
REA=restriction enzyme analysis
RFLP=restriction fragment length polymorphism
RNA=ribonucleic acid
SDS=sodium dodecyl sulfate
SSC=0.15M sodium chloride and 0.015M sodium citrate
ssRNA=single stranded RNA
TE=10 mM Tris-HCl (pH 8.0), 1 mM EDTA
TERMS
clone/cloning: in reference to DNA, the product or process of isolating a segment of DNA, linking it to a vector, and introducing it into a host for propagation.
cloning vector: a plasmid or other nucleic acid sequence which is able to replicate in a host cell characterized by one or a small number of restriction endonuclease recognition sites at which the sequence may be cut in a predetermined fashion, and which contains a marker suitable for use in the identification of transformed cells, e.g., tetracycline resistance or ampicillin resistance.
downstream: refers to the direction toward the 3' end of the DNA template.
DNA sequence: a linear series of nucleotides connected one to the other by phosphodiester bonds between the 3' and 5' carbons of adjacent pentoses.
transcription vector: a plasmid or other nucleic acid sequence comprising a polymerase promoter which is able to induce transcription of an inserted gene or sequence of heterologous DNA to single-stranded RNA.
gene: a segment of DNA which encodes a specific protein or polypeptide.
genome/genomic: referring to the complete set of genetic instructions for an organism as defined by the chromosomal nucleic acid.
heterologous DNA: a DNA sequence inserted within or connected to another DNA sequence which codes for polypeptides not coded for in nature by the DNA sequence to which it is joined.
hybridization: the pairing together or annealing of complementary single-stranded regions of nucleic acids to form double-stranded molecules.
infection: the introduction of bacteria or virus into cells or into a living organism wherein the bacteria or virus can replicate.
linker: synthetic oligonucleotide containing a site for a restriction enzyme.
multiple cloning site: a DNA sequence containing a multitude of different restriction enzyme sites.
nucleotide: a monomeric unit of DNA or RNA consisting of a sugar moiety (pentose), a phosphate, and a nitrogenous heterocyclic base. The base is linked to the sugar moiety via the glycosidic carbon (1' carbon of the pentose) and that combination of base and sugar is a nucleoside. The base characterizes the nucleotide. The four DNA bases are adenine ("A"), guanine ("G"), cytosine ("C") and thymine ("T"). The four RNA bases are A, G, C and uracil ("U"). "N" is commonly used to represent any of these five bases.
phage: a bacteriophage; a virus which infects bacteria.
plasmid: a non-chromosomal, double-stranded DNA sequence capable of autonomous replication within a host cell.
polylinker: synthetic oligonucleotide containing multiple restriction enzyme sites.
probe: a nucleic acid sequence (DNA or RNA) that can be used to detect, by hybridization or complementary base-pairing, another nucleic acid sequence which is homologous or complementary.
promoter: a recognition sequence defining a site for binding of RNA polymerase and initiating transcription.
recombinant DNA molecule: a hybrid DNA sequence comprising at least two DNA sequences, the first sequence not normally being found together in nature with the second.
restriction site: A nucleotide sequence, usually 4 to 6 basepairs long, which is recognizes and susceptible to cleavage in a specific fashion by a restriction enzyme.
sequence: two or more DNA or RNA nucleotides in a given order.
serogroup: serological classification of Leptospira in which all strains in the same serogroup share a common "serogroup" antigen which is not present in strains outside of this serogroup.
serovar: serological classification of Leptospira in which strains within the same serogroup are serologically distinct from each other.
subclone: in reference to DNA, the product or process of cloning a portion of an already cloned DNA segment.
transcription: the process of producing messenger RNA (mRNA) from a structural gene.
transform: to change in a heritable manner the characteristics of a host cell in response to DNA foreign to that cell.
transformant/transformation system: a host cell such as E. coli which has been transformed by intoduction of a vector containing DNA foreign to the cell.
type: classification term for Leptospira in which two strains serologically classified as belonging to the same serovar may be differentiated on the basis of restriction endonuclease analysis.
vector: a derivative of a virus or plasmid constructed by recombinant DNA techniques and having a cloning site or sites for inserting new DNA sequences.
BIOLOGICAL MATERIALS AND REAGENTS
______________________________________ Source______________________________________Enzymes:T4 DNA ligase New England BioLabs, Inc.Genes:Ap.sup.r = ampicillin resistance gene on pBSM13-galactosidase gene on pBSM13-Plasmids: Accession No.pBSM13- Stratagene Corp.pLI16 NRRL B-18461pLI17 NRRL B-18462pLI18 NRRL B-18463pLI19pLI20 NRRL B-18464pUC19 Bethesda Research Lab. Inc.Polymerases:T3: bacteriophage T3 Bethesda Research Lab. Inc.T4: bacteriophage T4 Bethesda Research Lab. Inc.T7: bacteriophage T7 New England BioLabs, Inc.______________________________________
______________________________________Restriction Enzymes: Cleavage SiteAccI ##STR1##ClaI 5'. .AT.sup. OGAT. .3'DraII ##STR2##EcoRI 5'. .G.sup. AATTC. .3'EcoRV 5'. .GAT.sup. ATC. .3'HhaI 5'. .GOG.sup. C. .3'HindIII 5'. .A.sup. AGCTT. .3'HinPI 5'. .G.sup. OGC. .3'NarI 5'. .GG.sup. CGCC. .3'PstI 5'. .CTGCA.sup. G. .3'SacI 5'. .GAGCT.sup. C. .3'XmnI 5'. .GAANN.sup. NNTTC. .3'Transformation Systems: SourceE. coli strain JM107 J. Neill, NADC______________________________________
The L. interrogans bacterial strains disclosed herein are summarized below in Table I.
TABLE I__________________________________________________________________________Bacterial StrainsOrganism and serogroup Serovar Type and/or strain Source.sup.a__________________________________________________________________________L. interrogansSejroe hardjo Hardjo-bovis 93U NADC hardjo Hardjoprajitno CDC/NADCCanicola portland-vere Lt63-69 CDC/NADCGrippotyphosa grippotyphosa RM-52 NADCIcterohaemorrhagiae copenhageni M20 CDC/NADCPomona pomona Kennewicki RM211 NADCShermani babudieri CI40 CDCIcterohaemorrhagiae birkini Birkin CDCCanicola broomi patane CDCPyrogenes camlo LT64-47 CDCGryppotyphosa canalzonae cz188 CDCBallum castellonis castelloni 3 CDCCelledoni celledoni celledoni CDCCynopteri cynopteri 3522C CDCJavanica flumininse Aa3 CDCAutumnalis fortbragg fort bragg CDCDjasiman gurungi gurung CDCLouisiana lanka R740 CDCAustralis meunchen Munchen c-90 CDCBataviae paidjan paidjan CDCSarmin rio Rr5 CDCSejroe romanica LM294 CDCPomona tropica Ca299U CDCSejroe wolffi 3705 CDCL. biflexaSemaranga Patoc Patoc I N. Charon__________________________________________________________________________ .sup.a NADC strains are from the National Leptospirosis Reference Laboratory, National Animal Disease Center, Ames, IA. N. Charon is from West Virginia University, Morgantown. CDC strains are from K. Sulzer at the Center for Disease control, Atlanta, GA. CDC/NADC strains are originally from the Center for Disease Control.
DETAILED DESCRIPTION OF THE INVENTION
The original single-stranded RNA (ssRNA) probes of the invention were isolated as a result of discovering a repetitive sequence element which occurs collectively about 40-50 times within the hardjo-bovis genome and putative plasmid DNA. The 35-40 copies in the genome constitute about 2% of the genomic DNA. This element was identified by restriction endonuclease analysis (REA) of purified genomic DNA revealing a 1.4-kb NarI fragment which is present at a high copy number within the hardjo-bovis genome. This fragment was isolated by preparative agarose gel electrophoresis (PAGE) and thereafter cloned into the plasmid vector pUC19 to yield plasmid pLI16. Upon digestion of pLI16 with the restriction endonuclease HindIII, a 1,100 basepair (bp) fragment was recovered, and this fragment was subcloned into the RNA transcription vector, pBSM13-. Hybridization probes were synthesized from SacI-digested template DNA in the resulting plasmid, pLI17, by runoff transcription using phage T3 RNA polymerase and [α -32 P]uridine triphosphate.
Contemplated within the scope of this invention are ssRNA probes which are complementary to, and will hybridize with, the repetitive element described above; that is, with the element comprising the 1.4-kb NarI fragment. Generally, the complementary portion of these probes should be at least about 250 bp in length so that the hybridization products can be visualized by autoradiograph or other assay. Probes having a length of about 250-350 are preferred for the reason that they tend to be more specific than longer probes in hybridizing to target DNA. For the purpose of differentiating hardjo-bovis from hardjoprajitno genomic DNA, at least about 80% homology is required between the probe and the target DNA. Noncomplementary sequences may flank the complementary portion of the probe provided that such sequences do not interfere with the hybridization of the DNA in the repetitive element to the extent that the hybridization products are not identifiable. Such extraneous sequences may arise at the 5' end of the probe as a result of transcription initiation by RNA polymerase within vector sequences prior to the heterologous DNA located 3' to the initiation site. It is likely that the terminal ends of the repetitive element are clipped by the NarI enzyme. Other endonucleases which would preserve these ends or a portion thereof could be substituted for the NarI in providing suitable template DNA for synthesis of the ssRNA probes.
For visualization by autoradiography, the probes are of course suitably labeled as with [α- 32 P]uridine triphosphate. This is readily achieved by labeling about 50% of the uridine triphosphate provided in the transcription medium during synthesis of the RNA probe.
Also contemplated by this invention are the templates and other progenitor DNA sequences for these probes, including plasmids useful in cloning and transcribing these sequences. An exemplary cloning plasmid is the above-mentioned pLI16 (FIG. 1) derived by insertion of the 1.4-kb NarI fragment into the pUC19 cloning vector which has been digested with NarI and AccI. This plasmid can be used to transform E. coli for expansion of the DNA insert. The above-described plasmid pLI17 (FIG. 2) illustrates a suitable plasmid for the synthesis of the ssRNA probes. As mentioned, it is constructed by excising the 1,100 bp HindIII fragment from the NarI insert of pLI16 and inserting this fragment into the transcription vector pBSM13-. In addition to the probe template, pLI17 comprises the promoter and other regulatory sequences for T3 and T7 RNA polymerases. Other transcription plasmids similarly derived from pLI16 include pLI18 (FIG. 3), pLI19 described in Example 5 and pLI20 (FIG. 4) described in Example 9 below. Plasmids pLI16, pLI18, and pLI20 have been deposited under the Budapest Treaty with the Agricultural Research Service Culture Collection in Peoria, IL, and have been assigned Accession Nos. NRRL B-18461, NRRL B-18462, NRRL B-18463 and NRRL B-18464, respectively.
It is envisioned that plasmids substantially equivalent to those which have been deposited could be readily derived by the skilled artisan by following the procedures described herein. Functional derivatives of these plasmids may also be prepared by making minor deletions, substitutions, or insertions in the nucleotides of the probe template DNA and/or by making deletions, substitions, or insertions in the vector sequences.
The ssRNA probes are useful in DNA blot experiments utilizing restriction endonuclease digested DNA (Southern blots). Briefly, the L. interrogans DNA is immobilized on a membrane, and the membrane is washed in a solution of a radiolabeled probe. The probe binds to the appropriate segment of the repetitive element by complementary basepairing and can be detected by autoradiography. The probes can also be used in slot blot analysis of urine or other body fluid from infected livestock. Insofar as L. interrogans is also known to infect humans, it is understood that reference herein to body fluids and tissues of animals is meant to include the same from humans as well.
The strategy of repetitive sequence DNA used in this invention is attractive for the development of diagnostic probes, since the target sequences for probes are amplified naturally within the genome. This attribute enables detection of fewer organisms with the probes directed to repetitive sequence elements compared with probes directed to single-copy sequences. It is imperative for diagnostic purposes that the minimal number of cells detectable by a probe be relevant to the levels of bacteria shed by infected animals. As illustrated in Example 2 below, the probes contemplated herein detect as few as 1×10 2 cells/ml. These probes therefore detect typical levels of hardjo-bovis shed in the urine of cattle and offer an effective method to rapidly identify potential sources of hardjo-bovis infections within herds. The sensitivity and consistency of the repetitive element-based probe compares favorably with existing techniques but does not require prior cultivation of the organism.
The other significant attribute of diagnostic probes manifested by those of the invention is selectivity. As illustrated in Example 4, the subject probes demonstrates little detectable hybridization with any of the serovars commonly isolated from domestic animals in North America (serovars grippotyphosa, hardjo, copenhageni, pomona, and portland-vere) except for hardjo-bovis. Likewise, little cross-hybridization is observed with hardjoprajitno, the reference strain for serovar hardjo.
On the other hand, the ssRNA probes cross-hybridize with the DNA from several L. interrogans serovars isolated from wildlife. The presence of these serovars probably represent commensal infections. The selectivity against isolates of domestic animals and cross-reactivity with wildlife isolates render the ssRNA probes suitable for epidemiological studies in determining the origin and migration of a given isolate. Furthermore, the ability to type L. interrogans isolates, particularly those obtained from wildlife, using repetitive element-based probes, provides a more rapid typing system than using serological methods.
For distinguishing differences among isolates in epidemiology studies of hardjo-bovis infections, the enzymes EcoRI, HhaI, and XmnI were found to be most suitable for digesting the genomic DNA prior to probing. For RFLP analysis for identifying serovars, the enzymes EcoRI, ClaI, BamHI, HindIII, and XmnI were found to be most useful.
The following examples are intended only to further illustrate the invention and are not intended to limit the scope of the invention which is defined by the claims.
EXAMPLE 1
Isolation of the Repetitive Element
The repetitive element was cloned by digesting 10 μg L. interrogans serovar hardjo-type hardjo-bovis strain 93U DNA (prepared by the method of Thiermann et al., [J. Clin. Microbiol. 21: 585-587 (1985)] with approximately 10 units of restriction endonuclease NarI at 37° C. for 6 hr in a solution containing 10 mM Tris-Hcl (pH 7.4), 10 mM MgCl 2 , 10 mM 2-mercaptoethanol. The resulting restriction fragments were resolved in a 1% agarose gel buffered with 89 mM Tris, 89 mM boric acid, 2 mM EDTA at 50 V for 20 hr. The gel was stained with 1 μg ethidium bromide/ml for 1 hr and the DNA visualized by illumination with ultraviolet light. The 1.4 kb NarI fragment was excised from the gel and transferred to an NA-45 DEAE membrane (Schleicher and Schuell, Inc.) by electrophoresis at 100 V for 2 hr. The membrane was rinsed with electrophoresis buffer and the DNA eluted in 200 μl, 1.0M NaCl, 0.1 mM EDTA, 20 mM Tris-Hcl (pH 8.0), at 60° C. for 2 hr. The membrane was discarded and the solution volume brought to 500 μl with distilled water (dH 2 O). This DNA was precipitated with 50 μl 3M sodium acetate (pH 5.2), and 1 ml 95% ethanol, and harvested by centrifugation at 11,000×g for 15 min. The precipitate was suspended in 500 μl TE [10 mM Tris-HCl (pH 8.0), 1 mM EDTA] and extracted twice with 500 μl phenol-chloroform-isoamyl alcohol (50:50:1). DNA was recovered from the aqueous phase by precipitation with sodium acetate and ethanol, and the precipitate washed with 500 μl 70% ethanol. The precipitate was suspended in 20 μl dH 2 O and 10 μl (ca. 100 ng) was mixed with approximately 100 ng pUC19 which had previously been digested with NarI and AccI, and treated with calf-alkaline phosphatase (CAP). This mixture was treated with 400 units of phage T4 DNA ligase in a 20 μl reaction volume containing 50 mM Tris-Hcl (pH 7.8), 10 mM MgCl 2 , 20 mM dithiothreitol, 1 mM adenosine triphosphate, and 50 μg bovine serum albumin/ml at 16° C. for 6 hr. The mixture was heated at 65° C. for 15 min then used to transform Escherichia coli JM107 to ampicillin resistance by standard technique. Transformants harboring recombinant plasmids were identified by inactivation of the vector-encoded lacZ gene by using the chromogenic lactose analog 5-bromo-4-chloro-3-indolyl-β-D-galactopyranoside [J. Messing, Methods Enzymol. 101: 20-78 (1983)]. Plasmid DNA was prepared from randomly picked transformants using an alkaline lysis technique [D. Ish-Horowitcz et al., Nucl. Acids Res. 9: 2989-2996 (1981)] and examined by REA. One of these clones, pLI16 was used for subsequent analysis and subcloning. A schematic restriction enzyme map of pLI16 is shown in FIG. 1, wherein the ampicillin resistance gene is indicated as "Ap r ." Vector DNA sequences are shown as double lines, whereas cloned hardjo-bovis DNA is shown as single lines.
Construction of Probe DNA Template by Subcloning Hardjo-Bovis DNA into pBSM13-.
pLI16 (ca. 10 μg) as prepared above was digested with 10 units of HindIII in 100 μl of a solution containing 50 mM NaCl, 50 mM Tris-HCl (pH 8.0), 10 mM MgCl 2 at 37° C. for 6 hr. The digestion products were fractionated by electrophoresis in a 1% agarose gel and the 1100 bp HindIII fragment isolated onto NA-45 membrane as described above. The DNA was eluted from the NA-45 membrane, concentrated, and ligated to HindIII-digested, CAP-treated RNA transcription vector pBSM13- by the method described above for ligating the bacterial DNA to the digested pUC19. Plasmid pBSM13- contains the RNA polymerase promoters for both bacteriophage T3 and T7. E. coli JM107 was transformed to ampicillin resistance with the ligation mixture and plasmid DNA isolated from randomly picked transformants and examined by REA. One plasmid, pLI17, was used for subsequent probe synthesis. The restriction map of pLI17 is shown in FIG. 2, wherein T7 and T3 represent the T7 and T3 promoters, respectively.
Preparation of ssRNA Probe
Five micrograms of purified pLI17 DNA was digested with 5 units of restriction endonuclease SacI at 37° C. for 2 hr in a solution containing 10 mM Tris-HCl (pH 7.4), 10 mM MgCl 2 , 10 mM 2-mercaptoethanol, and a final volume of 50 μl. The plasmid DNA was precipitated by addition of 5 μl 3 M sodium acetate (pH 5.2) and 200 μl 95% ethanol, harvested by centrifugation for 15 min at 11,000×g, and then washed with 500 μl 70% ethanol. The precipitated DNA was dissolved in solution by sequential addition of 2 μl 0.1M dithiothreitol, 2.4 μl 0.1 mM uridine triphosphate, 4 μl/2.5 mM each ATP, GTP, CTP, 1 μl dH 2 O, 5 μl [α- 32 P]uridine triphosphate [ca. 650 Curies (Ci)/mmol, 10 mCi/ml)], 4 μl buffer [200 mM Tris-HCl (pH 8.0), 40 mM MgCl 2 , 10 mM spermidine, 125 mM NaCl] and the reactions initiated with 10 units of phage T3 RNA polymerase. After incubating the reaction at 37° C. for 1 hr, it was terminated by addition of 1 μl 20% sodium lauryl sulfate, 75 μl dH 2 O, 10 μl 3M sodium acetate (pH 5.2), and 500 μl 95% ethanol. The DNA template was harvested by centrifugation and washed as before. The resultant 1,100 bp radiolabeled single-stranded RNA (ssRNA) probe was suspended in 100 μl TE, heated at 85° C. for 5 min, and then quickly chilled on ice in preparation for use in the hybridization analyses described below in Example 2.
EXAMPLE 2
Diagnostic Screening
Positive urine samples were collected from four experimentally infected animals demonstrating no clinical signs of disease 4, 8, and 12 wk after exposure to hardjo-bovis and from one naturally infected cow. In this experiment, the negative-control sample was a composite from nine animals collected prior to experimental infection.
The slot blot analyses were performed by using a modification of the procedure described by Millar et al. [Vet. Microbiol. 15: 71-78 (1987)]. Bacteria were concentrated from 1-10 ml of the collected urine by centrifugation at 11,000×g for 5-15 min. The cells were suspended in 100 μl phosphate buffered saline, mixed with an equal volume of 0.5M NaOH, 1.5M NaCl, and incubated at room temperature for 1 hr. Solutions were neutralized with 200 μl 1M Tris-HCl (pH 8.0), 1.5M NaCl and filtered through nylon membrane filters (Hybond-N, Amersham Corporation) using a commercially available filtering apparatus (Minifold II, Schleicher and Schuell Corporation). The filters were rinsed with 2×SSC (1×SSC: 0.15M NaCl, 0.015M sodium citrate), and air dried. Membranes were incubated for a minimum of 2 hr at 61° C. in hybridization solution [6×SSC, 5×Denhardts solution (1×Denhardts: 0.02% Ficoll, 0.02% polyvinylpyrrolidone, 0.02% bovine serum albumin), 1% sodium lauryl sulfate, 100 μg denatured salmon sperm DNA/ml, and 100 μg yeast RNA/ml]. This prehybridization solution was discarded, replaced by fresh hybridization solution containing the radiolabeled ssRNA probe prepared in Example 1 and incubated overnight at 61° C. These filters were then washed twice in 2×SSC at room temperature for 15 min each, twice in 2×SSC at 61° C. for 15 min each, and twice in 2×SSC, 0.1% SDS at 61° C. for 30 min each. Blots were used to expose autoradiographic film (Eastman Kodak, Inc.) at -80° C. for 1-3 da before developing.
Autoradiographic images were quantitated by scanning the autoradiographs with a laser densitometer (Ultrascan XL, LKB Instruments, Inc., Rockville, MD) and subsequent analysis with Gelscan XL software (LKB Instruments).
To quantitate the amount of hardjo-bovis shed in the urine of infected cattle, autoradiographic signals obtained in the urine samples were compared to signals obtained with specific cell numbers. The cell concentration of cultured bacteria was determined with a Petroff-Hauser counting chamber by using dark-field microscopy. Cell concentrations were adjusted to 5×10 7 cells per ml with phosphate-buffered saline and serially diluted, by using twofold dilutions, to 2.5×10 4 cells per ml. Samples (100 μl) of these diluted cell suspensions were mixed with 100 μl of 0.5M NaOH-1.5M NaCl and incubated for 1 hr at room temperature. These suspensions were neutralized with 200 μl of 1M Tris hydrochloride-1.5M NaCl, pH 8.0, and 40 μl of the suspension was applied to Hybond-N by using a slot blot apparatus (Schleicher & Schuell).
The results of this experiment are summarized in Table II below and demonstrate that the pLI17-derived probe detects hardjo-bovis shed in urine from infected animals. The number of leptospires detected in the urine of infected animals ranged from <1×10 2 cells per ml to approximately 3×10 4 cells per ml. Most but not all of the urine samples tested were found to contain hardjo-bovis either by culture or by fluorescent antibody (FA). Additionally, culture and FA results of urine samples from cow 86 taken at other times during the infection were positive, thus confirming that this cow was infected and shedding L. interrogans in its urine.
TABLE II______________________________________Test of pLI17 Probe with Cattle Urine Samples Time postinfection ConcnSample (mo).sup.a (cells/ml).sup.b Culture.sup.c FA.sup.d______________________________________Negative control <1 × 10.sup.2 - -Cow 103 1 3 × 10.sup.2 + + 2 4 × 10.sup.3 - + 3 1 × 10.sup.2 + +Cow 79 2 7 × 10.sup.3 + + 3 2 × 10.sup.3 - +Cow 86 2 4 × 10.sup.2 - - 3 1 × 10.sup.2 - -Cow 80 2 3 × 10.sup.4 + +40U 4 × 10.sup.3 + +______________________________________ .sup.a Time following experimental infection of cattle with hardjobovis. 40U was naturally infected, and time of exposure could not be determined. .sup.b Bacterial cell concentrations in urine normalized to cells per milliliter as determined with pLI17. .sup.c Results of attempts to culture urine samples. .sup.d Results of fluorescent antibody with antihardjo-bovis conjugate.
EXAMPLE 3
Sensitivity and Selectivity Comparison of ssRNa Probe and DNA-Probe
The sensitivity of the radiolabeled ssRNA probe synthesized from pLI17 in Example 1 was compared with that of a radiolabeled genomic DNA probe. Various serovars and types of L. interrogans and L. biflexa were cultured and then were serially diluted from 5×10 7 cells per ml to 2.5×10 4 cells per ml and lysed. The DNA was denatured, and a portion of these suspensions was filtered through a nylon membrane. The immobilized DNA was used to hybridize either the pLI17-derived radiolabeled ssRNA probe or serovar hardjo-type hardjo-bovis genomic DNA radiolabeled by nick translation. Both of these probes were radiolabeled to specific activities of approximately 10 9 dpm/μg of nucleic acid. The resulting autoradiographs demonstrated that the pLI17-generated probe can detect as few as 1×10 3 hardjo-bovis cells, while the detection limit for the radiolabeled genomic DNA probe was approximately 4×10 3 cells. The level of specificity of these two probes for hardjo-bovis was assessed by quantitating autoradiographic signals by scanning laser densitometry and then comparing the values obtained in heterologous reactions with those obtained in homologous reactions. The results of this analysis (Table III) indicate that the pLI17-derived probe is more specific for hardjo-bovis than the genomic hardjo-bovis DNA probe. Both probes were species specific, as where was no detectable cross-hybridization between either probe and the saprophyte. L. biflexa serovar patoc.
TABLE III______________________________________Quantitative Comparison of pLI17 and GenomicDNA Probe Specificities % Hybridization with nucleic acid probe from:Organism and serovar.sup.a pLI17.sup.b Hardjo-bovis.sup.c______________________________________L. interrogansHardjo-type hardjo-bovis 100 100Hardjo-type hardjoprajitno 8 11Pomona-type kennewicki 2 5Grippotyphosa 5 16Portland-vere 1 27Copenhageni 1 11L. biflexaPatoc <1 <1______________________________________ .sup.a Samples containing 2.5 × 10.sup.5 cells. .sup.b Comparison of autoradiographic signals with signals obtained with hardjobovis using pL117 probe. .sup.c Comparison of autoradiographic signals with signals obtained with hardjobovis using hardjobovis genomic probe.
EXAMPLE 4
Selectivity of pLI17-Derived ssRNA Probe Against Domestic Animal Isolates
The selectivity of the ssRNA probes synthesized from pLI17 as described in Example 1 for the 1.4 kb NarI repetitive fragment characteristic of hardjo-bovis was demonstrated by Southern blot analysis. Genomic DNA (2.5 μg) isolated from each of L. interrogans serovars hardjo-type hardjo-bovis, hardjo-type hardjoprajitno, pomona-type kennewicki, grippotyphosa, copenhageni, and portland-vere was digested with NarI. Digestion products were fractionated by electrophoresis at 50 V overnight in 0.7% agarose gels as described previously. The gels were treated with 0.5M NaOH, 1.5M NaCl for 1-2 hr, and then neutralized with 1M Tris-HCl (pH 8.0), 1.5M NaCl for 1-2 hr. DNA was blotted to nylon membranes by capillary action overnight with 20×SSC. The nylon membranes were washed with 2×SSC, air dried, prehybridized, and hybridized with the 32 P-labeled ssRNA probe as described in Example 2. The membranes were washed as in Example 2 with an additional wash of 0.2×SSC at 61° C. The membranes were used to expose AR film at -80° C. for 1 hr before developing. The autoradiographs indicated at least 12 distinct bands for the hardjo-bovis DNA and no bands for any of the other serovar or type DNA assayed.
EXAMPLE 5
Preparation of pLI18- and pLI19-Derived Probes
Following the procedure of Example 1 for construction of a probe DNA template and preparation of ssRNA probe, pLI16 was digested with HinPI, and a recovered 1,000 bp fragment was inserted into the AccI site of pBSM13-. The two selected plasmids, pLI18 and pLI19 carry this fragment in opposite orientations. pLI18 is shown schematically in FIG. 3.
Probes generated by runoff transcription of Eco-RI-digested pLI18 detect some fragments which are not detectable with pLI17-derived probes since these fragments are homologous to the small EcoRI-NarI fragment of the repetitive element missing in pLI17.
EXAMPLE 6
Selectivity of the pLI18-Derived ssRNA Probe Against Wildlife Isolates
The ability of the ssRNA probe from pLI18 prepared in Example 1 to distinguish two L. interrogans wildlife isolates, serovars wolffi and romanica, from one another was determined. These serovars are genetically similar and cannot be differentiated by restriction endonuclease analysis of genomic DNA. Genomic DNA from cultured cells of these serovars was prepared by the method of Thiermann as referenced in Example 1 and digested with EcoRI, HindIII, or XmnI. The resulting fragments were fractionated by agarose gel electrophoresis, blotted to a nylon membrane, and probed with the radiolabeled probe as in Example 2, except the hybridization and washing were conducted at 58° C. The subtle differences between these two serovars could be detected as illustrated by the autoradiograph of FIG. 5. The odd-numbered lanes represent wolffi, and the even-numbered lanes represent romanica. The DNA of lanes 1 and 2 was digested with EcoRI, that of lanes 3 and 4 was digested with HindIII, and that of lanes 5 and 6 was digested with XmnI. The arrows depict bands representing fragments not characteristic of the related serovar.
EXAMPLE 7
Differentiation of Hardjo-Bovis Isolates with pLI17-Derived Probe
Genomic DNA (2.5 μg) from six hardjo-bovis isolates originally obtained from cattle in Iowa, Colorado, Florida, Alberta (Canada), Switzerland, and Chile were digested with HhaI or EcoRI. The digestion products were electrophoresed in agarose, blotted to a nylon membrane, and probed with the pLI17-derived probe, all as described in Example 4. Autoradiographs showed distinct patterns among the isolates for each of the enzyme digests. This experiment demonstrates the usefulness of the ssRNA probes in differentiating isolates from different geographical locations.
EXAMPLE 8
Differentiation of L. interrogans Serovars
Genomic DNA (2.5 μg) from L. interrogans serovars meunchen, fortbragg, castellonis, paidjan, lanka, broomi, celledoni, cynopteri, rio, gurungi, canalzonae, birkini, flumininse, tropica, camlo, babudieri were digested with EcoRI, electrophoresed in a 0.7% agarose gel, and blotted to a nylon membrane, essentially as described in Example 6. Radiolabeled probes were synthesized by the procedure of Example 1 except the pLI17 plasmid was digested with EcoRV and the transcription was initiated with phage T7 RNA polymerase. The autoradiograph hybridization pattern representing each of the 16 serovars was distinct, thereby providing a basis for distinguishing one from the other.
EXAMPLE 9
Preparation of pLI20 Derived Probe
Following the procedure of Example 1 for construction of a probe DNA template and preparation of ssRNA probe, pLI18 was digested with EcoRI and a recovered 3,450 bp fragment was self-ligated using T4 DNA ligase. The resulting plasmid, pLI20, differs from pLI18 by the deletion of a 750 bp EcoRI fragment. pLI20 contains approximately 250 bp of hardjo-bovis DNA inserted between the EcoRI and AccI sites of pBSM13- and is shown schematically in FIG. 4. Radiolabeled ssRNA probes are synthesized from HinPI-digested pLI20 by run-off transcription with T7 phage RNA polymerase.
It is understood that the foregoing detailed description is given merely by way of illustration and that modification and variations may be made therein without departing from the spirit and scope of the invention.
|
A distinctive repetitive genomic element of Leptospira interrogans serovar hardjo-type hardjo-bovis permits distinguishing this pathogen type from other commonly found leptospires in North American cattle using single-stranded RNA probes. Plasmids carrying DNA templates for useful probes have been deposited as NRRL Accession Nos. B-18462, B-18463, and B-18464. The probes are sufficiently sensitive to detect hardjo-bovis in as few as 1×10 2 cells/ml. The diagnostic capabilities of the probes render them useful not only as herd management tools, but also in epidemiology studies designed to determine the origin and migration of L. interrogans isolates.
| 2
|
PRIORITY CLAIM
This application claims the benefit of U.S. Design Application No. 29/248,685, filed Aug. 29, 2006, the content of which is hereby incorporated by reference herein in its entirety for all purposes.
BACKGROUND OF THE INVENTION
This invention relates to portable floors and more specifically, to portable floors formed from a plurality of interconnecting, floor panels preferably joined by a tongue and groove coupling mechanism.
Portable floors have existed for many years. U.S. Pat. No. 3,310,919 issued to Bue et al. discloses a lockable tongue and groove structure for connecting adjacently situated floor panels. This locking structure includes a groove or channel element associated with one floor panel and a tongue element associated with an adjacent floor panel. Access holes are provided in the floor panels situated along the length of the panels above the groove elements. These access holes are aligned to correspond with bores made through an upper leg portion of the channel element. An externally threaded set screw is inserted from above the dance floor surface into each access hole and aligned with the bore until the bottom of the set screw contacts and compresses the inserted tongue, thus locking the floor panels together. Typically, the tongue has a thick forward end and is tapered rearwardly to a thinner cross-section at its juncture with the floor panel on which it is mounted.
Another prior art example of portable floors, U.S. Pat. No. 5,070,662 issued to Niese incorporates the tongue and groove lockable sections of Bue et al. along with the use of a metal insert having a flared bottom end which is disposed within the bore of each access hole. The flared bottom end, along with a set screw was alleged to prevent stripping of the threads associated with previous tongue and groove locking devices.
A third prior art example of portable floors, U.S. Pat. No. 6,128,881 issued to Bue et al. discloses a plurality of tapered rectangular edge trim panels adapted for connection to the periphery of the dance floor to form an extended floor surface. This prior art uses the tongue and groove locking mechanism not only for floor panel connections but also with the trim panels to form a tapered border about the periphery of the dance floor to prevent not only warping of the dance floor but also to prevent individuals from tripping when stepping onto or off-from the dance floor.
A fourth prior art example is U.S. Patent Application Publication by Rybalov, US 2006/0130378 published Jun. 22, 2006. The Rybalov publication illustrates a floor advertising means whereby a light diffusion plate is arranged between a light source and a top translucent panel. In this way, advertising and information images disposed on the surface of the light diffusion plate, can be viewed through the top panel.
Portable flooring are typically formed of a plurality of floor panels. Each panel itself is typically constructed of a base layer, preferably made of plywood or other material for providing stability and support for a top layer, the surface of which is used for individuals to dance or walk upon. As a result, each sectional panel is relatively heavy.
While it is possible to interchange floor panels having different top surfaces to create a different dance floor surface appearance, realistically, because of the size and weight of each floor panel, it is not economical for a consumer to purchase additional panels which may not be adequately used as well as the additional storage space requirements.
Accordingly, it is an object of this invention to provide the ability to alter the surface appearance of a portable floor without requiring the purchase of additional floor panels which have a top surface permanently attached to a base layer.
A further objective of this invention is the ability to alter the surface appearance of a portable floor in a time efficient manner.
SUMMARY OF THE INVENTION
The portable floor of the present invention provides a temporary floor surface that permits the surface appearance to be changed without requiring the need to purchase or maintain inventory of additional floor panels.
My portable floor is comprised of a plurality of connectable floor panels, preferably 4-sided and most preferably, rectangular. Each floor panel has a structural supporting base layer preferably made of plywood. These floor panels are connected along their edges to form a portable floor.
In a preferred embodiment, each floor panel includes a top flooring layer; a sheeting layer disposed between the top flooring layer and base layer; and, four elongated framing elements that are attached around the periphery of a respective base layer, one per side, and having mitered ends, i.e. forty five (45) degree angled ends that are complementary to form a right angled corner with the framing elements of the same floor panel on either adjacent side.
Each floor panel is temporarily attached to adjacent floor panels or peripheral trim panels using tongue and groove locking mechanisms. Each floor panel includes two framing elements having a horizontally extending tongue and two framing elements having complimentary groove for receiving the tongue of an adjacent panel.
My portable floor uses a transparent top flooring layer which is sufficiently durable to withstand foot traffic and dancing while still permitting an image or design on the top surface of the sheeting material to be viewable. The top flooring layer is made of a sufficiently thick and durable layer of transparent acrylic, plexiglass, tempered glass, or other translucent material.
However, rather than have the top flooring layer adhesively bonded or otherwise permanently attached to the base layer, at least one of the floor panels of my portable floor permit removable of a sheeting layer disposed between the base layer and the top flooring layer. This removable sheeting layer can have a top surface of any desired color, pattern or design. By way of example only, the sheeting layer can be paper, metallic or photo film and the top surface could be black matte, or it can have a top surface which is holographic, or it can be designed to illuminate using light emitting diodes or neon lights operably connected to a power source.
Therefore, the same base layer and transparent top flooring layer can be used while the sheeting layer disposed therebetween can be replaced as desired. In this way, additional storage is only necessary for other/replacement sheeting layers.
For each framing element on a floor panel having a complimentary groove, a hole having a common axis of symmetry is provided, extending from the top flooring layer, through the sheeting layer and base layer and threaded through the top wall of the framing element. A set screw is thereafter provided, the length of which does not protrude from the top surface of the top flooring layer when the set screw is in frictional engagement with the tongue of an adjacent panel within the groove.
In my preferred embodiment, each floor panel is constructed so that one of the four framing elements is capable of being temporarily detached and the other three framing elements are permanently attached to the base layer. In this way, the sheeting material and top flooring layer can be removably slid away from contact with the remaining framing elements.
Each of the four framing elements include an elongated top lid portion vertically distant from the top surface of the base layer and which extends horizontally a short distance over its respective floor panel. The space bounded by the top lip portion and base layer surface defines a channel. The vertical distance between the top surface of the base layer and the bottom surface of the top lip portion is sized so that the channel will accept the combined wall thickness of the sheeting layer and the top flooring layer snugly. Thus, the periphery of the top flooring layer is substantially disposed underneath the top lip portions of the four framing elements. In this way, when the top flooring layer is properly in position, the top lip portions preclude vertical removal of the top flooring layer.
The sheeting layer and the top flooring are dimensionally sized to be positioned upon the top surface of the base layer so that their peripheral edges extend within the channels formed by the top lip portions of the four framing elements. In other words, once the sheeting layer and the top flooring layer are in position within the channels formed on three sides, the detached framing element is then attached; thus completing the floor panel. The floor panel is now in a condition to be connected with other adjoining floor panels or the peripheral trim panels. Where peripheral tapered edge trim panels are to be used, corner panels should also be provided having complimentary ends.
Using a transparent top flooring layer, by changing the sheeting layer present in at least one floor panel, the viewable design of the dance floor can be changed to suit the mood of a particular event. By example, one even may require a holographic appearance while another event may require a black matte appearance. Instead of stocking multiple panel sections of varied appearance, all that is necessary is to have the desired sheets and the labor to install.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the portable floor comprising a plurality of floor panels and trim panels.
FIG. 2 is a perspective view of two connected floor panels with one of the floor panels illustrated in an exploded view.
FIG. 3 is a view taken along line 3 - 3 of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates the make-up of my portable floor 10 which is comprised of multiple floor panels 12 . It is to be understood that any number of rows of floor panels 12 can be assembled to form the desired size of portable floor subject to the dimensions of the floor panels used. Typically, the dimensions of the floor panels are 4 feet by 3 feet.
As better viewed in FIG. 2 and FIG. 3 , each floor panel comprises a base layer 14 , and four framing elements attached, one on each peripheral side.
Each floor panel 12 is rectangular, with a preferred dimension of 3 ft×4 ft. Base layer 14 is made of plywood for structural support and the framing elements are made from extruded aluminum.
One of the four framing elements is detachable from its respective floor panel 12 as shown in FIG. 2 . When detached, top flooring layer 20 and sheeting layer 22 can be removed and then replaced with the same top flooring layer and a different sheeting layer having a different top surface design. In this way, some or all of the floor panels 12 can have their respective sheeting layer 22 replaced with a sheeting layer having different top surface designs.
Two of the framing elements are tongue framing elements 16 t and the other two are groove framing elements 16 g . Each of the groove framing elements 16 g further comprise a threaded hole for accepting a complimentary set screw 24 for locking adjacent framing elements 16 t and 16 g into position as illustrated in FIG. 3 .
Framing elements 16 g and 16 t utilize respective upper arms 17 g and 17 t , and respective lower arms 18 g and 18 t as well as an elongated top lip 19 . Each top lip 19 extends horizontally in a direction opposite of the adjacent panel section.
Upper arms 17 t and 17 g and lower arms 18 t and 18 g are secured to the base layer 14 of respective floor panel 12 . Base layer 14 is preferably constructed from plywood. Base layer 14 comprises a peripheral groove appropriately sized to accept the upper arm 17 g or 17 t of either framing element.
Further, below the peripheral groove, each base layer 14 has a reduced vertical wall thickness. This reduced wall thickness is substantially the wall thickness of the lower arm 18 t and 18 g of the framing element intended to be attached. In this way, when the tongue or groove framing elements are fitted to base layer 14 , the exposed bottom surfaces of both the framing element and base layer 14 are substantially flush with one another, thereby providing a uniform flat surface.
Screws 30 can be threaded through respective lower arms 18 t and 18 g in order to secure the respective framing element to base layer 14 . Additionally, it is preferable that three of the four framing elements of floor panel 12 are permanently attached to base layer 14 either by adhesive or other means.
Each upper arm, 17 t or 17 g , when inserted into the groove of base layer 14 , fits snugly. Although an alternative embodiment to the peripheral groove would be routing or otherwise reducing the wall thickness of the base layer 14 , this is undesirable since it would create a non-uniform top surface upon which the sheeting layer 22 would be disposed. A non-uniform surface may cause unnecessary and undesired damage to sheeting layer 22 .
As mentioned earlier, the framing elements include an elongated top lip 19 which extends horizontally inward. Therefore, each framing element 16 t and 16 g is appropriately dimensioned so that the spacing between its upper arm and top lip 19 is sufficient to not only accept the thickness of base layer 14 above the upper arm, but also provides the necessary space for receiving the combined thickness of top flooring layer 20 and sheeting layer 22 .
In a preferred embodiment, floor panels 12 are rectangular in dimension. Three of the four framing elements are bonded or otherwise permanently secured to the base layer. The fourth framing element, preferably located on one of the short sides of rectangular shaped floor panel 12 , is detachable. The reason for removability will now be discussed.
When three of the four framing elements are secured to base layer 14 , a top channel is formed, being defined as the space between the top lips 19 of the three framing elements, and the top surface of base layer 14 . Sheeting layer 22 having an upper surface design intended for viewing as a dance floor is provided, having appropriate dimensions for covering substantially the entire top surface of base layer 14 and fitting within the top channels of the respective floor panel 12 . Sheeting layer 22 can have any design desired, including holographic or the ability to provide lighting. In the case of lighting, appropriate electrical connections must be provided to connect to an adjoining floor panel, preferably joined in series and connected to a power source.
Further, the top channel discussed above, is appropriately sized to accept the combined thickness of sheeting layer 22 and top flooring layer 20 , the top surface of which is the substantial dance floor. Top flooring layer 20 must be of sufficient thickness to bear the weight of individuals dancing upon its surface. yet must also be sufficiently transparent so that sheeting layer 22 immediately below can be viewed. Preferably, top flooring layer 20 is made of a plexiglass material although any other plastic or acrylic material is suitable so long as it meets the conditions expressed earlier in this paragraph.
In practice, with a short side framing element temporarily detached, top flooring layer 20 and sheeting layer 22 can be slid into position. Once top flooring layer 20 and sheeting layer 22 are in position, the detached framing element can be reattached.
It is preferable to have a short side removable since this allows top flooring layer 20 and sheeting layer 22 to be positioned more easily. However, for purposes of my invention, one can also use a detachable long side framing element.
Because it is necessary to lock adjoining floor panels, use of the set screws described earlier requires that top flooring layer 20 and sheeting layer 22 each have a hole having a common axis of symmetry with each hole present in framing elements 16 g as best illustrated in FIG. 3 . Because there are two framing elements 16 g comprising each floor panel 12 , it will be necessary for there to be at least two holes in each top flooring layer 20 and sheeting layer 22 so that respective set screws can be used to temporarily secure an adjacent panel having a tongue framing element 16 t positioned for engagement.
The vertical wall thickness of top lip 19 should only be as necessary for providing structural support. Excessive thickness will create a noticeable difference in height between the surface of top flooring layer 20 and top lip 19 which could cause tripping of an individual. Accordingly, the framing elements are constructed from a suitable material for providing the necessary structural support. In my preferred embodiment, the material selected is extruded aluminum.
Once the portable floor is assembled, it would be preferable to include transitional edge trim panels 26 as disclosed in prior art reference Bue et al. discussed earlier. These trim panels would incorporate either a groove to engage the edges of a floor panel having a tongue or they would have a tongue to be received within the edges of a floor panel have a complementary groove. Threaded holes 28 would be used to secure groove framing elements 16 g of adjacent floor panels 12 by set screws in a similar manner to that shown in FIG. 3 for securing floor panels.
|
A portable dance floor is disclosed. The portable dance floor is comprised of floor panels which are fitted together with a tongue and groove locking method well known in the art. Each floor panel has a base layer, a transparent top flooring layer and a sheeting layer disposed therebetween. The top flooring layer is preferably made of a clear acrylic sheet having suitable physical characteristics capable of supporting the weight of individuals thereupon. Each floor panel is designed so that the sheeting layer can be removed and replaced with a different sheeting layer which can comprise a holographic top surface or a light capable display which is viewable through the transparent top flooring layer.
| 4
|
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/081,351, filed on Nov. 15, 2013, which is a continuation of U.S. patent application Ser. No. 13/941,431 filed on Jul. 12, 2013, now U.S. Pat. No. 8,589,599, which is a continuation of U.S. patent application Ser. No. 13/430,650 filed on Mar. 26, 2012, which is a continuation of U.S. patent application Ser. No. 12/699,846 filed on Feb. 3, 2010, now U.S. Pat. No. 8,149,829, which is a continuation of U.S. patent application Ser. No. 11/728,246 filed on Mar. 23, 2007, now U.S. Pat. No. 7,756,129, which is a continuation of U.S. patent application Ser. No. 10/894,406 filed on Jul. 19, 2004, now U.S. Pat. No. 7,218,633, which is a continuation of U.S. patent application Ser. No. 09/535,591 filed on Mar. 27, 2000, now U.S. Pat. No. 6,804,232, which is related to U.S. patent application Ser. No. 09/536,191 filed on Mar. 27, 2000, all of which are incorporated herein by reference in their entirety for all purposes.
BACKGROUND AND FIELD OF THE INVENTION
[0002] A. Field of the Invention
[0003] The present invention relates to network protocols and, more particularly, to attachment protocols for use in a network.
[0004] B. Description of Related Art
[0005] Over the last decade, the size and power consumption of digital electronic devices has been progressively reduced. For example, personal computers have evolved from laptops and notebooks into hand-held or belt-carriable devices commonly referred to as personal digital assistants (PDAs). One area of carriable devices that has remained troublesome, however, is the coupling of peripheral devices or sensors to the main processing unit of the PDA. Generally, such coupling is performed through the use of connecting cables. The connecting cables restrict the handling of a peripheral in such a manner as to lose many of the advantages inherent in the PDA's small size and light weight. For a sensor, for example, that occasionally comes into contact with the PDA, the use of cables is particularly undesirable.
[0006] While some conventional systems have proposed linking a keyboard or a mouse to a main processing unit using infrared or radio frequency (RF) communications, such systems have typically been limited to a single peripheral unit with a dedicated channel of low capacity.
[0007] Based on the foregoing, it is desirable to develop a low power data network that provides highly reliable bidirectional data communication between a host or server processor unit and a varying number of peripheral units and/or sensors while avoiding interference from nearby similar systems.
SUMMARY OF THE INVENTION
[0008] Systems and methods consistent with the present invention address this need by providing a wireless personal area network that permits a host unit to communicate with peripheral units with minimal interference from neighboring systems.
[0009] A system consistent with the present invention includes a hub device and at least one unattached peripheral device. The unattached peripheral device transmits an attach request to the hub device with a selected address, receives a new address from the hub device to identify the unattached peripheral device, and communicates with the hub device using the new address.
[0010] In another implementation consistent with the present invention, a method for attaching an unattached peripheral device to a network having a hub device connected to multiple peripheral devices, includes receiving an attach request from the unattached peripheral device, the attach request identifying the unattached peripheral device to the hub device; generating a new address to identify the unattached peripheral device in response to the received attach request; sending the new address to the unattached peripheral device; and sending a confirmation message to the unattached peripheral device using the new address to attach the unattached peripheral device.
[0011] In yet another implementation consistent with the present invention, a method for attaching an unattached peripheral device to a network having a hub device connected to a set of peripheral devices, includes transmitting an attach request with a selected address to the hub device; receiving a new address from the hub device to identify the unattached peripheral device; and attaching to the network using the new address.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and, together with the description, explain the invention. In the drawings:
[0013] FIG. 1 is a diagram of a personal area network (PAN) in which systems and methods consistent with the present invention may be implemented;
[0014] FIG. 2 is a simplified block diagram of the Hub of FIG. 1 ;
[0015] FIG. 3 is a simplified block diagram of a PEA of FIG. 1 ;
[0016] FIG. 4 is a block diagram of a software architecture of a Hub or PEA in an implementation consistent with the present invention;
[0017] FIG. 5 is an exemplary diagram of communication processing by the layers of the software architecture of FIG. 4 ;
[0018] FIG. 6 is an exemplary diagram of a data block architecture within the DCL of the Hub and PEA in an implementation consistent with the present invention;
[0019] FIG. 7A is a detailed diagram of an exemplary stream usage plan in an implementation consistent with the present invention;
[0020] FIG. 7B is a detailed diagram of an exemplary stream usage assignment in an implementation consistent with the present invention;
[0021] FIG. 8 is an exemplary diagram of a time division multiple access (TDMA) frame structure in an implementation consistent with the present invention;
[0022] FIG. 9A is a detailed diagram of activity within the Hub and PEA according to a TDMA plan consistent with the present invention;
[0023] FIG. 9B is a flowchart of the Hub activity of FIG. 9A ;
[0024] FIG. 9C is a flowchart of the PEA activity of FIG. 9A ;
[0025] FIGS. 10A and 10B are high-level diagrams of states that the Hub and PEA traverse during a data transfer in an implementation consistent with the present invention;
[0026] FIGS. 11 and 12 are flowcharts of Hub and PEA attachment processing, respectively, consistent with the present invention; and
[0027] FIG. 13 is a flowchart of PEA detachment and reattachment processing consistent with the present invention.
DETAILED DESCRIPTION
[0028] The following detailed description of the invention refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims.
[0029] Systems and methods consistent with the present invention provide a wireless personal area network that permits a host device to communicate with a varying number of peripheral devices with minimal interference from neighboring networks. The host device uses tokens to manage all of the communication in the network, and automatic attachment and detachment mechanisms to communicate with the peripheral devices.
Network Overview
[0030] A Personal Area Network (PAN) is a local network that interconnects computers with devices (e.g., peripherals, sensors, actuators) within their immediate proximity. These devices may be located nearby and may frequently or occasionally come within range and go out of range of the computer. Some devices may be embedded within an infrastructure (e.g., a building or vehicle) so that they can become part of a PAN as needed.
[0031] A PAN, in an implementation consistent with the present invention, has low power consumption and small size, supports wireless communication without line-of-sight limitations, supports communication among networks of multiple devices (over 100 devices), and tolerates interference from other PAN systems operating within the vicinity. A PAN can also be easily integrated into a broad range of simple and complex devices, is low in cost, and is capable of being used worldwide.
[0032] FIG. 1 is a diagram of a PAN 100 consistent with the present invention. The PAN 100 includes a single Hub device 110 surrounded by multiple Personal Electronic Accessory (PEA) devices 120 configured in a star topology. Other topologies may also be possible. Each device is identified by a Media Access (MAC) address.
[0033] The Hub 110 orchestrates all communication in the PAN 100 , which consists of communication between the Hub 110 and one or more PEA(s) 120 . The Hub 110 manages the timing of the network, allocates available bandwidth among the currently attached PEAs 120 participating in the PAN 100 , and supports the attachment, detachment, and reattachment of PEAs 120 to and from the PAN 100 .
[0034] The Hub 110 may be a stationary device or may reside in some sort of wearable computer, such as a simple pager-like device, that may move from peripheral to peripheral. The Hub 110 could, however, include other devices.
[0035] The PEAs 120 may vary dramatically in terms of their complexity. A very simple PEA might include a movement sensor having an accelerometer, an 8-bit microcontroller, and a PAN interface. An intermediate PEA might include a bar code scanner and its microcontroller. More complex PEAs might include PDAs, cellular telephones, or even desktop PCs and workstations. The PEAs may include stationary devices located near the Hub and/or portable devices that move to and away from the Hub.
[0036] The Hub 110 and PEAs 120 communicate using multiplexed communication over a predefined set of streams. Logically, a stream is a one-way communications link between one PEA 120 and its Hub 110 . Each stream has a predetermined size and direction. The Hub 110 uses stream numbers to identify communication channels for specific functions (e.g., data and control).
[0037] The Hub 110 uses MAC addresses to identify itself and the PEAs 120 . The Hub 110 uses its own MAC address to broadcast to all PEAs 120 . The Hub 110 might also use MAC addresses to identify virtual PEAs within any one physical PEA 120 . The Hub 110 combines a MAC address and a stream number into a token, which it broadcasts to the PEAs 120 to control communication through the network 100 . The PEA 120 responds to the Hub 110 if it identifies its own MAC address or the Hub MAC address in the token and if the stream number in the token is active for the MAC address of the PEA 120 .
Exemplary Hub Device
[0038] FIG. 2 is a simplified block diagram of the Hub 110 of FIG. 1 . The Hub 110 may be a battery-powered device that includes Hub host 210 , digital control logic 220 , radio frequency (RF) transceiver 230 , and an antenna 240 .
[0039] Hub host 210 may include anything from a simple microcontroller to a high performance microprocessor. The digital control logic (DCL) 220 may include a controller that maintains timing and coordinates the operations of the Hub host 210 and the RF transceiver 230 . The DCL 220 is specifically designed to minimize power consumption, cost, and size of the Hub 110 . Its design centers around a time-division multiple access (TDMA)-based network access protocol that exploits the short range nature of the PAN 100 . The Hub host 210 causes the DCL 220 to initialize the network 100 , send tokens and messages, and receive messages. Responses from the DCL 220 feed incoming messages to the Hub host 210 .
[0040] The RF transceiver 230 includes a conventional RF transceiver that transmits and receives information via the antenna 240 . The RF transceiver 230 may alternatively include separate transmitter and receiver devices controlled by the DCL 220 . The antenna 240 includes a conventional antenna for transmitting and receiving information over the network.
[0041] While FIG. 2 shows the exemplary Hub 110 as consisting of three separate elements, these elements may be physically implemented in one or more integrated circuits. For example, the Hub host 210 and the DCL 220 , the DCL 220 and the RF transceiver 230 , or the Hub host 210 , the DCL 220 , and the RF transceiver 230 may be implemented as a single integrated circuit or separate integrated circuits. Moreover, one skilled in the art will recognize that the Hub 110 may include additional elements that aid in the sending, receiving, and processing of data.
Exemplary PEA Device
[0042] FIG. 3 is a simplified block diagram of the PEA 120 . The PEA 120 may be a battery-powered device that includes a PEA host 310 , DCL 320 , RF transceiver 330 , and an antenna 340 . The PEA host 310 may include a sensor that responds to information from a user, an actuator that provides output to the user, a combination of a sensor and an actuator, or more complex circuitry, as described above.
[0043] The DCL 320 may include a controller that coordinates the operations of the PEA host 310 and the RF transceiver 330 . The DCL 320 sequences the operations necessary in establishing synchronization with the Hub 110 , in data communications, in coupling received information from the RF transceiver 330 to the PEA host 310 , and in transmitting data from the PEA host 310 back to the Hub 110 through the RF transceiver 330 .
[0044] The RF transceiver 330 includes a conventional RF transceiver that transmits and receives information via the antenna 340 . The RF transceiver 330 may alternatively include separate transmitter and receiver devices controlled by the DCL 320 . The antenna 340 includes a conventional antenna for transmitting and receiving information over the network.
[0045] While FIG. 3 shows the exemplary PEA 120 as consisting of three separate elements, these elements may be physically implemented in one or more integrated circuits. For example, the PEA host 310 and the DCL 320 , the DCL 320 and the RF transceiver 330 , or the PEA host 310 , the DCL 320 , and the RF transceiver 330 may be implemented as a single integrated circuit or separate integrated circuits. Moreover, one skilled in the art will recognize that the PEA 120 may include additional elements that aid in the sending, receiving, and processing of data.
Exemplary Software Architecture
[0046] FIG. 4 is an exemplary diagram of a software architecture 400 of the Hub 110 in an implementation consistent with the present invention. The software architecture 400 in the PEA 120 has a similar structure. The software architecture 400 includes several distinct layers, each designed to serve a specific purpose, including: (1) application 410 , (2) link layer control (LLC) 420 , (3) network interface (NI) 430 , (4) link layer transport (LLT) 440 , (5) link layer driver (LLD) 450 , and (6) DCL hardware 460 . The layers have application programming interfaces (APIs) to facilitate communication with lower layers. The LLD 450 is the lowest layer of software. Each layer may communicate with the next higher layer via procedural upcalls that the higher layer registers with the lower layer.
[0047] The application 410 may include any application executing on the Hub 110 , such as a communication routine. The LLC 420 performs several miscellaneous tasks, such as initialization, attachment support, bandwidth control, and token planning. The LLC 420 orchestrates device initialization, including the initialization of the other layers in the software architecture 400 , upon power-up.
[0048] The LLC 420 provides attachment support by providing attachment opportunities for unattached PEAs to attach to the Hub 110 so that they can communicate, providing MAC address assignment, and initializing an NI 430 and the layers below it for communication with a PEA 120 . The LLC 420 provides bandwidth control through token planning. Through the use of tokens, the LLC 420 allocates bandwidth to permit one PEA 120 at a time to communicate with the Hub 110 .
[0049] The NI 430 acts on its own behalf, or for an application 410 layer above it, to deliver data to the LLT 440 beneath it. The LLT 440 provides an ordered, reliable “snippet” (i.e., a data block) delivery service for the NI 430 through the use of encoding (e.g., 16-64 bytes of data plus a cyclic redundancy check (CRC)) and snippet retransmission. The LLT 440 accepts snippets, in order, from the NI 430 and delivers them using encoded status blocks (e.g., up to 2 bytes of status information translated through Forward Error Correction (FEC) into 6 bytes) for acknowledgments (ACKs).
[0050] The LLD 450 is the lowest level of software in the software architecture 400 . The LLD 450 interacts with the DCL hardware 460 . The LLD 450 initializes and updates data transfers via the DCL hardware 460 as it delivers and receives data blocks for the LLT 440 , and processes hardware interrupts. The DCL hardware 460 is the hardware driven by the LLD 450 .
[0051] FIG. 5 is an exemplary diagram of communication processing by the layers of the software architecture 400 of FIG. 4 . In FIG. 5 , the exemplary communications involve the transmission of a snippet from one node to another. This example assumes that the sending node is the Hub 110 and the receiving node is a PEA 120 . Processing begins with the NI 430 of the Hub 110 deciding to send one or more bytes (but no more than will fit) in a snippet. The NI 430 exports the semantics that only one transaction is required to transmit these bytes to their destination (denoted by “(1)” in the figure). The NI 430 sends a unique identifier for the destination PEA 120 of the snippet to the LLT 440 . The LLT 440 maps the PEA identifier to the MAC address assigned to the PEA 120 by the Hub 110 .
[0052] The LLT 440 transmits the snippet across the network to the receiving device. To accomplish this, the LLT 440 adds header information (to indicate, for example, how many bytes in the snippet are padded bytes) and error checking information to the snippet, and employs reverse-direction status/acknowledgment messages and retransmissions. This is illustrated in FIG. 5 by the bidirectional arrow between the LLT 440 layers marked with “(n+m).” The number n of snippet transmissions and the number m of status transmissions in the reverse direction are mostly a function of the amount of noise in the wireless communication, which may be highly variable. The LLT 440 may also encrypt portions or all of the snippet using known encryption technology.
[0053] The LLT 440 uses the LLD 450 to provide a basic block and stream-oriented communications service, isolating the DCL 460 interface from the potentially complex processing required of the LLT 440 . The LLT 440 uses multiple stream numbers to differentiate snippet and status blocks so that the LLD 450 need not know which blocks contain what kind of content. The LLD 450 reads and writes the hardware DCL 460 to trigger the transmission and reception of data blocks. The PEA LLT 440 , through the PEA LLD 450 , instructs the PEA DCL 460 which MAC address or addresses to respond to, and which stream numbers to respond to for each MAC address. The Hub LLT 440 , through the Hub LLD 450 , instructs the Hub DCL 460 which MAC addresses and stream numbers to combine into tokens and transmit so that the correct PEA 120 will respond. The Hub DCL 460 sends and receives (frequently in a corrupted form) the data blocks across the RF network via the Hub RF transceiver 230 ( FIG. 2 ).
[0054] The Hub LLT 440 employs FEC for status, checksums and error checking for snippets, and performs retransmission control for both to ensure that each snippet is delivered reliably to its client (e.g., PEA LLT 440 ). The PEA LLT 440 delivers snippets in the same order that they were sent by the Hub NI 430 to the PEA NI 430 . The PEA NI 430 takes the one or more bytes sent in the snippets and delivers them in order to the higher-level application 410 , thereby completing the transmission.
Exemplary DCL Data Block Architecture
[0055] FIG. 6 is an exemplary diagram of a data block architecture 600 within the DCL of the Hub 110 and the PEA 120 . The data block 600 contains a MAC address 610 designating a receiving or sending PEA 120 , a stream number 620 for the communication, and a data buffer 630 which is full when sending and empty when receiving. As will be described later, the MAC address 610 and stream number 620 form the contents of a token 640 . When the LLD 450 reads from and writes to the hardware DCL 460 , the LLD 450 communicates the MAC address 610 and stream number 620 with the data buffer 630 . When a PEA 120 receives a data block, the DCL 460 places the MAC address 610 and stream number 620 contained in the preceding token 640 in the data block 600 to keep track of the different data flows.
Exemplary Stream Architecture
[0056] The LLD 450 provides a multi-stream data transfer service for the LLT 440 . While the LLT 440 is concerned with data snippets and status/acknowledgements, the LLD 450 is concerned with the size of data blocks and the direction of data transfers to and from the Hub 110 .
[0057] FIG. 7A is a detailed diagram of an exemplary stream usage plan 700 in an implementation consistent with the present invention. A single stream usage plan may be predefined and used by the Hub 110 and all PEAs 120 . The PEA 120 may have a different set of active streams for each MAC address it supports, and only responds to a token that specifies a MAC address of the PEA 120 and a stream that is active for that MAC address. In an implementation consistent with the present invention, every PEA 120 may support one or more active Hub-to-PEA streams associated with the Hub's MAC address.
[0058] The stream usage plan 700 includes several streams 710 - 740 , each having a predefined size and data transfer direction. The plan 700 may, of course, have more or fewer entries and may accommodate more than the two data block sizes shown in the figure. In the plan 700 , streams 0-2 ( 710 ) are used to transmit the contents of small data blocks from the PEA 120 to the Hub 110 . Streams 3-7 ( 720 ) are used to transmit the contents of larger data blocks from the PEA 120 to the Hub 110 . Streams 8-10 ( 730 ), on the other hand, are used to transmit the contents of small data blocks from the Hub 110 to the PEA 120 . Streams 11-15 ( 740 ) are used to transmit the contents of larger data blocks from the Hub 110 to the PEA 120 .
[0059] To avoid collisions, some of the streams are reserved for PEAs desiring to attach to the network and the rest are reserved for PEAs already attached to the network. With such an arrangement, a PEA 120 knows whether and what type of communication is scheduled by the Hub 110 based on a combination of the MAC address 610 and the stream number 620 .
[0060] FIG. 7B is a detailed diagram of an exemplary stream usage assignment by the LLT 440 in an implementation consistent with the present invention. The LLT 440 assigns different streams to different communication purposes, reserving the streams with small block size for status, and using the streams with larger block size for snippets. For example, the LLT 440 may use four streams (4-7 and 12-15) for the transmission of snippets in each direction, two for odd parity snippets and two for even parity snippets. In other implementations consistent with the present invention, the LLT 440 uses different numbers of streams of each parity and direction.
[0061] The use of more than one stream for the same snippet allows a snippet to be sent in more than one form. For example, the LLT 440 may send a snippet in its actual form through one stream and in a form with bytes complemented and in reverse order through the other stream. The alternating use of different transformations of a snippet more evenly distributes transmission errors among the bits of the snippet as they are received, and hence facilitates the reconstruction of a snippet from multiple corrupted received versions. The receiver always knows which form of the snippet was transmitted based on its stream number.
[0062] The LLT 440 partitions the streams into two disjoint subsets, one for use with Hub 110 assigned MAC addresses 750 and the other for use with attaching PEAs' self-selected MAC addresses (AMACs) 760 . Both the LLT 440 and the LLD 450 know the size and direction of each stream, but the LLT 450 is responsible for determining how the streams are used, how MAC numbers are assigned and used, and assuring that no two PEAs 120 respond to the same token (containing a MAC address and stream number) transmitted by the Hub 110 . One exception to this includes the Hub's use of its MAC address to broadcast its heartbeat 770 (described below) to all PEAs 120 .
Exemplary Communication
[0063] FIG. 8 is an exemplary diagram of a TDMA frame structure 800 of a TDMA plan consistent with the present invention. The TDMA frame 800 starts with a beacon 810 , and then alternates token broadcasts 820 and data transfers 830 . The Hub 110 broadcasts the beacon 810 at the start of each TDMA frame 800 . The PEAs 120 use the beacon 810 , which may contain a unique identifier of the Hub 110 , to synchronize to the Hub 110 .
[0064] Each token 640 ( FIG. 6 ) transmitted by the Hub 110 in a token broadcast 820 includes a MAC address 610 ( FIG. 6 ) and a stream number 620 for the data buffer 630 transfer that follows. The MAC address 610 and stream number 620 in the token 640 together specify a particular PEA 120 to transmit or receive data, or, in the case of the Hub's MAC address 610 , specify no, many, or all PEAs to receive data from the Hub 110 (depending on the stream number). The stream number 620 in the token 640 indicates the direction of the data transfer 830 (Hub 110 to PEA 120 or PEA 120 to Hub 110 ), the number of bytes to be transferred, and the data source (for the sender) and the appropriate empty data block (for the receiver).
[0065] The TDMA plan controls the maximum number of bytes that can be sent in a data transfer 830 . Not all of the permitted bytes need to be used in the data transfer 830 , however, so the Hub 110 may schedule a status block in the initial segment of a TDMA time interval that is large enough to send a snippet. The Hub 110 and PEA 120 treat any left over bytes as no-ops to mark time. Any PEA 120 not involved in the data transfer uses all of the data transfer 830 bytes to mark time while waiting for the next token 640 . The PEA 120 may also power down non-essential circuitry at this time to reduce power consumption.
[0066] FIG. 9A is an exemplary diagram of communication processing for transmitting a single data block from the Hub 110 to a PEA 120 according to the TDMA plan of FIG. 8 . FIGS. 9B and 9C are flowcharts of the Hub 110 and PEA 120 activities, respectively, of FIG. 9A . The reference numbers in FIG. 9A correspond to the flowchart steps of FIGS. 9B and 9C .
[0067] With regard to the Hub activity, the Hub 110 responds to a token command in the TDMA plan [step 911 ] ( FIG. 9B ) by determining the location of the next data block 600 to send or receive [step 912 ]. The Hub 110 reads the block's MAC address 610 and stream number 620 [step 913 ] and generates a token 640 from the MAC address and stream number using FEC [step 914 ]. The Hub 110 then waits for the time for sending a token 640 in the TDMA plan (i.e., a token broadcast 820 in FIG. 8 ) [step 915 ] and broadcasts the token 640 to the PEAs 120 [step 916 ]. If the stream number 620 in the token 640 is zero (i.e., a NO-DATA-TRANSFER token), no PEA 120 will respond and the Hub 110 waits for the next token command in the TDMA plan [step 911 ].
[0068] If the stream number 620 is non-zero, however, the Hub 110 determines the size and direction of the data transmission from the stream number 620 and waits for the time for sending the data in the TDMA plan (i.e., a data transfer 830 ) [step 917 ]. Later, when instructed to do so by the TDMA plan (i.e., after the PEA 120 identified by the MAC address 610 has had enough time to prepare), the Hub 110 transmits the contents of the data buffer 630 [step 918 ]. The Hub 110 then prepares for the next token command in the TDMA plan [step 919 ].
[0069] With regard to the PEA activity, the PEA 120 reaches a token command in the TDMA plan [step 921 ] ( FIG. 9C ). The PEA 120 then listens for the forward error-corrected token 640 , having a MAC address 610 and stream number 620 , transmitted by the Hub 110 [step 922 ]. The PEA 120 decodes the MAC address from the forward error-corrected token [step 923 ] and, if it is not the PEA's 120 MAC address, sleeps through the next data transfer 830 in the TDMA plan [step 924 ]. Otherwise, the PEA 120 also decodes the stream number 620 from the token 640 .
[0070] All PEAs 120 listen for the Hub heartbeat that the Hub 110 broadcasts with a token containing the Hub's MAC address 610 and the heartbeat stream 770 . During attachment (described in more detail below), the PEA 120 may have two additional active MAC addresses 610 , the one it selected for attachment and the one the Hub 110 assigned to the PEA 120 . The streams are partitioned between these three classes of MAC addresses 610 , so the PEA 120 may occasionally find that the token 640 contains a MAC address 610 that the PEA 120 supports, but that the stream number 620 in the token 640 is not one that the PEA 120 supports for this MAC address 610 . In this case, the PEA 120 sleeps through the next data transfer 830 in the TDMA plan [step 924 ].
[0071] Since the PEA 120 supports more than one MAC address 610 , the PEA 120 uses the MAC address 610 and the stream number 620 to identify a suitable empty data block [step 925 ]. The PEA 120 writes the MAC address 610 and stream number 620 it received in the token 640 from the Hub 110 into the data block [step 926 ]. The PEA 120 then determines the size and direction of the data transmission from the stream number 620 and waits for the transmission of the data buffer 630 contents from the Hub 110 during the next data transfer 830 in the TDMA plan [step 927 ]. The PEA 120 stores the data in the data block [step 928 ], and then prepares for the next token command in the TDMA plan [step 929 ].
[0072] FIGS. 9A-9C illustrate communication of a data block from the Hub 110 to a PEA 120 . When the PEA 120 transfers a data block to the Hub 110 , similar steps occur except that the Hub 110 first determines the next data block to receive (with its MAC address 610 and stream number 620 ) and the transmission of the data buffer 630 contents occurs in the opposite direction. The Hub 110 needs to arrange in advance for receiving data from PEAs 120 by populating the MAC address 610 and stream number 620 into data blocks with empty data buffers 630 , because the Hub 110 generates the tokens for receiving data as well as for transmitting data.
[0073] FIGS. 10A and 10B are high-level diagrams of the states that the Hub 110 and PEA 120 LLT 440 ( FIG. 4 ) go through during a data transfer in an implementation consistent with the present invention. FIG. 10A illustrates states of a Hub-to-PEA transfer and FIG. 10B illustrates states of a PEA-to-Hub transfer.
[0074] During the Hub-to-PEA transfer ( FIG. 10A ), the Hub 110 cycles through four states: fill, send even parity, fill, and send odd parity. The fill states indicate when the NI 430 ( FIG. 4 ) may fill a data snippet. The even and odd send states indicate when the Hub 110 sends even numbered and odd numbered snippets to the PEA 120 . The PEA 120 cycles through two states: want even and want odd. The two states indicate the PEA's 120 desire for data, with ‘want even’ indicating that the last snippet successfully received had odd parity. The PEA 120 communicates its current state to the Hub 110 via its status messages (i.e., the state changes serve as ACKs). The Hub 110 waits for a state change in the PEA 120 before it transitions to its next fill state.
[0075] During the PEA-to-Hub transfer ( FIG. 10B ), the Hub 110 cycles through six states: wait/listen for PEA-ready-to-send-even status, read even, send ACK and listen for status, wait/listen for PEA-ready-to-send-odd status, read odd, and send ACK and listen for status. According to this transfer, the PEA 120 cannot transmit data until the Hub 110 requests data, which it will only do if it sees from the PEA's status that the PEA 120 has the next data block ready.
[0076] The four listen for status states schedule when the Hub 110 asks to receive a status message from the PEA 120 . The two ‘send ACK and listen for status’ states occur after successful receipt of a data block by the Hub 110 , and in these two states the Hub 110 schedules both the sending of Hub status to the PEA 120 and receipt of the PEA status. The PEA status informs the Hub 110 when the PEA 120 has successfully received the Hub 110 status and has transitioned to the next ‘fill’ state.
[0077] Once the PEA 120 has prepared its next snippet, it changes its status to ‘have even’ or ‘have odd’ as appropriate. When the Hub 110 detects that the PEA 120 has advanced to the fill state or to ‘have even/odd,’ it stops scheduling the sending of Hub status (ACK) to the PEA 120 . If the Hub 110 detects that the PEA 120 is in the ‘fill’ state, it transitions to the following ‘listen for status’ state. If the PEA 120 has already prepared a new snippet for transmission by the time the Hub 110 learns that its ACK was understood by the PEA 120 , the Hub 110 skips the ‘listen for status’ state and moves immediately to the next appropriate ‘read even/odd’ state. In this state, the Hub 110 receives the snippet from the PEA 120 .
[0078] The PEA 120 cycles through four states: fill, have even, fill, and have odd (i.e., the same four states the Hub 110 cycles through when sending snippets). The fill states indicate when the NI 430 ( FIG. 4 ) can fill a data snippet. During the fill states, the PEA 110 sets its status to ‘have nothing to send.’ The PEA 120 does not transition its status to ‘have even’ or ‘have odd’ until the next snippet is filled and ready to send to the Hub 110 . These two status states indicate the parity of the snippet that the PEA 120 is ready to send to the Hub 110 . When the Hub 110 receives a status of ‘have even’ or ‘have odd’ and the last snippet it successfully received had the opposite parity, it schedules the receipt of data, which it thereafter acknowledges with a change of status that it sends to the PEA 120 .
Exemplary Attachment Processing
[0079] The Hub 110 communicates with only attached PEAs 120 that have an assigned MAC address 610 . An unattached PEA can attach to the Hub 110 when the Hub 110 gives it an opportunity to do so. Periodically, the Hub 110 schedules attachment opportunities for unattached PEAs that wish to attach to the Hub 110 , using a small set of attach MAC (AMAC) addresses and a small set of streams dedicated to this purpose.
[0080] After selecting one of the designated AMAC addresses 610 at random to identify itself and preparing to send a small, possibly forward error-corrected, “attach-interest” message and a longer, possibly checksummed, “attach-request” message using this AMAC and the proper attach stream numbers 620 , the PEA 120 waits for the Hub 110 to successfully read the attach-interest and then the attach-request messages. Reading of a valid attach-interest message by the Hub 110 causes the Hub 110 believe that there is a PEA 120 ready to send the longer (and hence more likely corrupted) attach-request.
[0081] Once a valid attach-interest is received, the Hub 110 schedules frequent receipt of the attach-request until it determines the contents of the attach-request, either by receiving the block intact with a valid checksum or by reconstructing the sent attach-request from two or more received instances of the sent attach-request. The Hub 110 then assigns a MAC address to the PEA 120 , sending the address to the PEA 120 using its AMAC address.
[0082] The Hub 110 confirms receipt of the MAC address by scheduling the reading of a small, possibly forward error-corrected, attach-confirmation from the PEA 120 at its new MAC address 610 . The Hub 110 follows this by sending a small, possibly forward error-corrected, confirmation to the PEA 120 at its MAC address so that the PEA 120 knows it is attached. The PEA 120 returns a final small, possibly forward error-corrected, confirmation acknowledgement to the Hub 110 so that the Hub 110 , which is in control of all scheduled activity, has full knowledge of the state of the PEA 120 . This MAC address remains assigned to that PEA 120 for the duration of the time that the PEA 120 is attached.
[0083] FIGS. 11 and 12 are flowcharts of Hub and PEA attachment processing, respectively, consistent with the present invention. When the Hub 110 establishes the network, its logic initializes the attachment process and, as long as the Hub 110 continues to function, periodically performs attachment processing. The Hub 110 periodically broadcasts heartbeats containing a Hub identifier (selecting a new heartbeat identifier value each time it reboots) and an indicator of the range of AMACs that can be selected from for the following attach opportunity [step 1110 ] ( FIG. 11 ). The Hub 110 schedules an attach-interest via a token that schedules a small PEA-to-Hub transmission for each of the designated AMACs, so unattached PEAs may request attachment.
[0084] Each attaching PEA 120 selects a new AMAC at random from the indicated range when it hears the heartbeat. Because the Hub 110 may receive a garbled transmission whenever more than one PEA 120 transmits, the Hub 110 occasionally indicates a large AMAC range (especially after rebooting) so that at least one of a number of PEAs 120 may select a unique AMAC 610 and become attached. When no PEAs 120 have attached for some period of time, however, the Hub 110 may select a small range of AMACs 610 to reduce attachment overhead, assuming that PEAs 120 will arrive in its vicinity in at most small groups. The Hub 110 then listens for a valid attach-interest from an unattached PEA [step 1120 ]. The attach-interest is a PEA-to-Hub message having the AMAC address 610 selected by the unattached PEA 120 .
[0085] Upon receiving a valid attach interest, the Hub 110 schedules a PEA-to-Hub attach-request token with the PEA's AMAC 610 and reads the PEA's attach-request [step 1130 ]. Due to the low-power wireless environment of the PAN 100 , the attach-request transmission may take more than one attempt and hence may require scheduling the PEA-to-Hub attach-request token more than once. When the Hub 110 successfully receives the attach-request from the PEA, it assigns a MAC address to the PEA [step 1140 ]. In some cases, the Hub 110 chooses the MAC address from the set of AMAC addresses.
[0086] The Hub 110 sends the new MAC address 610 in an attach-assignment message to the now-identified PEA 120 , still using the PEA's AMAC address 610 and a stream number 620 reserved for this purpose. The Hub 110 schedules and listens for an attach-confirmation response from the PEA 120 using the newly assigned MAC address 610 [step 1150 ].
[0087] Upon receiving the confirmation from the PEA 120 , the Hub 110 sends its own confirmation, acknowledging that the PEA 120 has switched to its new MAC, to the PEA 120 and waits for a final acknowledgment from the PEA 120 [step 1160 ]. The Hub 110 continues to send the confirmation until it receives the acknowledgment from the PEA 120 or until it times out. In each of the steps above, the Hub 110 counts the number of attempts it makes to send or receive, and aborts the attachment effort if a predefined maximum number of attempts is exceeded. Upon receiving the final acknowledgment, the Hub 110 stops sending its attach confirmation, informs its NI 430 ( FIG. 4 ) that the PEA 120 is attached, and begins exchanging both data and keep-alive messages (described below) with the PEA 120 .
[0088] When an unattached PEA 120 enters the network, its LLC 420 ( FIG. 4 ) instructs its LLT 440 to initialize attachment. Unlike the Hub 110 , the PEA 120 waits to be polled. The PEA 120 instructs its DCL 460 to activate and associate the heartbeat stream 770 ( FIG. 7B ) with the Hub's MAC address and waits for the heartbeat broadcast from the Hub 110 [step 1210 ] ( FIG. 12 ). The PEA 120 then selects a random AMAC address from the range indicated in the heartbeat to identify itself to the Hub 110 [step 1220 ]. The PEA 120 instructs its DCL 460 to send an attach-interest and an attach-request data block to the Hub 110 , and activate and associate the streams with its AMAC address [step 1230 ]. The PEA 120 tells its driver to activate and respond to the selected AMAC address for the attach-assignment stream.
[0089] The unattached PEA 120 then waits for an attach-assignment with an assigned MAC address from the Hub 110 [step 1240 ]. Upon receiving the attach-assignment, the PEA 120 finds its Hub-assigned MAC address and tells its driver to use this MAC address to send an attach-confirmation to the Hub 110 to acknowledge receipt of its new MAC address [step 1250 ], activate all attached-PEA streams for its new MAC address, and deactivate the streams associated with its AMAC address.
[0090] The PEA 120 waits for an attach confirmation from the Hub 110 using the new MAC address [step 1260 ] and, upon receiving it, sends a final acknowledgment to the Hub 110 [step 1270 ]. The PEA 120 then tells its NI 430 that it is attached.
[0091] The PEA 120 , if it hears another heartbeat from the Hub 110 before it completes attachment, discards any prior communication and begins its attachment processing over again with a new AMAC.
Exemplary Detachment and Reattachment Processing
[0092] The Hub 110 periodically informs all attached PEAs 120 that they are attached by sending them ‘keep-alive’ messages. The Hub 110 may send the messages at least as often as it transmits heartbeats. The Hub 110 may send individual small, possibly forward error-corrected, keep-alive messages to each attached PEA 120 when few PEAs 120 are attached, or may send larger, possibly forward error-corrected, keep-alive messages to groups of PEAs 120 .
[0093] Whenever the Hub 110 schedules tokens for PEA-to-Hub communications, it sets a counter to zero. The counter resets to zero each time the Hub 110 successfully receives a block (either uncorrupted or reconstructed) from the PEA 120 , and increments for unreadable blocks. If the counter exceeds a predefined threshold, the Hub 110 automatically detaches the PEA 120 without any negotiation with the PEA 120 . After this happens, the Hub 110 no longer schedules data or status transfers to or from the PEA 120 , and no longer sends it any keep-alive messages.
[0094] FIG. 13 is a flowchart of PEA detachment and reattachment processing consistent with the present invention. Each attached PEA 120 listens for Hub heartbeat and keep-alive messages [step 1310 ]. When the PEA 120 first attaches, and after receiving each keep-alive message, it resets its heartbeat counter to zero [step 1320 ]. Each time the PEA 120 hears a heartbeat, it increments the heartbeat counter [step 1330 ]. If the heartbeat counter exceeds a predefined threshold, the PEA 120 automatically assumes that the Hub 110 has detached it from the network 100 [step 1340 ]. After this happens, the PEA 120 attempts to reattach to the Hub 110 [step 1350 ], using attachment processing similar to that described with respect to FIGS. 11 and 12 .
[0095] If the Hub 110 had not actually detached the PEA 120 , then the attempt to reattach causes the Hub 110 to detach the PEA 120 so that the attempt to reattach can succeed. When the PEA 120 is out of range of the Hub 110 , it may not hear from the Hub 110 and, therefore, does not change state or increment its heartbeat counter. The PEA 120 has no way to determine whether the Hub 110 has detached it or how long the Hub 110 might wait before detaching it. When the PEA 120 comes back into range of the Hub 110 and hears the Hub heartbeat (and keep-alive if sent), the PEA 120 then determines whether it is attached and attempts to reattach if necessary.
CONCLUSION
[0096] Systems and methods consistent with the present invention provide a wireless personal area network that permit a host device to communicate with a varying number of peripheral devices with minimal power and minimal interference from neighboring networks by using a customized TDMA protocol. The host device uses tokens to facilitate the transmission of data blocks through the network.
[0097] The foregoing description of exemplary embodiments of the present invention provides illustration and description, but is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The scope of the invention is defined by the claims and their equivalents.
|
A device comprises circuitry configured for being communicatively coupled to a transceiver. In operation, the device is configured to receive a first message from another device to support at least one aspect of attachment of the device and the another device and to send, to the another device, a second message after the first message and prior to attachment. In operation, the device is further configured to receive, from the another device, a third message that is sent after the second message and prior to attachment and send, directly to the another device, data utilizing at least one channel for data transfer utilizing a second one of the addresses for identification in association with the device on the shared wireless communication medium, for data transfer after attachment in connection with a group that is controlled by the another device.
| 8
|
BACKGROUND INFORMATION
1. Field of the Invention
The invention relates to a hinge for an airbag cover that is used particularly in the interiors of motor vehicles.
2. Description of the Prior Art
Airbag covers are arranged, for example, in dashboards, and cover up the non-deployed airbag arranged beneath them. Airbag covers are also located, for example, in headrests, backrests, and other sites in the interiors of motor vehicles.
When an airbag is triggered during an accident, the opening airbag (“airbag release”) exerts pressure on the airbag cover, which then detaches, for example, from the area surrounding the airbag cover in the region of predetermined breaking points and then swings about a hinge, thus opening up space for the opening airbag.
It can be problematic during airbag release, if the airbag cover detaches entirely or partially from the surrounding area, because this may present a risk to persons inside the motor vehicle.
The generic DE 10 2004 010 643 entitled “Trim Panel with Airbag Flap Area”, previously disclosed a flexible, two-dimensional element as a hinge between the airbag flap and the airbag flap area. The two-dimensional element has an extra length that typically is used to form a loop, which serves to prevent the airbag cover from detaching from the flap area. This loop serves to prevent, on the one hand, complete detachment of the airbag flap when the airbag flap folds out, and, on the other hand, prevents the airbag flap from closing automatically following the airbag release.
This type of hinge is disadvantageous with regard to manufacturing, because it is very resource-intensive to construct the loop of the two-dimensional textile element in the course of production, and difficult to control its precise positioning. Faulty positioning of the loop, however, can result in a malfunction, when the airbag flap opens during airbag release.
BRIEF SUMMARY OF THE INVENTION
The underlying task of the invention is to construct a hinge for an airbag cover that is, on the one hand, inexpensive and, on the other hand, safe, so that there is no risk of the airbag cover uncontrollably detaching from its surrounding area, either entirely or partially, during airbag release.
This underlying task of the invention is achieved by the teachings of the independent claim.
In other words, a hinge for the airbag cover is proposed, wherein the hinge is essentially a two-dimensional textile element that is embedded partially into the structure of the airbag-cover carrier or into a component connected to the carrier. A first part of the two-dimensional textile element may be embedded into the carrier, for example, by injection, back injection, back-compression molding, casting, or injecting foam. A second part of the two-dimensional textile element is not, or is only partially, embedded in this structure. During the swinging motion of the cover during airbag release, the two-dimensional textile element at least partially, and possibly also fully, loosens or detaches from the matrix, for example, of the airbag-cover carrier, and in so doing, absorbs forces pressing against the airbag cover. As the cover continues to swing open, remaining forces are absorbed over the surface of the two-dimensional textile element, due to its ability to expand or stretch.
Advantageous embodiments of the invention are explained in the dependent claims.
In an advantageous embodiment, the matrix is constructed as a single piece together with the airbag-cover carrier. The two-dimensional textile element, can, for example, be directly foamed, back-injected, injected, back-compression molded, or cast simultaneously with the carrier in such a way that a lower part of the two-dimensional textile element i.e., a portion of the two-dimensional textile element that is closer to the outer side of the cover, is fully embedded into the mass of material forming the carrier in the manufacturing process of the carrier, while another area, i.e., a portion of the two-dimensional textile element that faces away from the outer side of the cover, remains free. By coating the two-dimensional textile element, for example, one can intentionally prevent or control the depth of penetrating flow of the molten material forming the carrier through the two-dimensional textile element.
In an advantageous embodiment, the matrix that receives the two-dimensional textile element can also be constructed as a component separate from the airbag-cover carrier, so that this component can be manufactured first together with its matrix and then subsequently connected to the carrier in an additional processing step.
In an advantageous embodiment, the matrix may be made of a plastic that cures, for example, can be made from diverse thermoplastics such as, for example, polypropylene, ABS, or similar materials, so as to enable especially easy and cost-effective manufacturability of the airbag cover.
In an advantageous embodiment, the area of the two-dimensional textile element embedded in the matrix amounts to at least one-half the thickness of the two-dimensional textile element, and tests have shown that embedding 50% to 95% of the two-dimensional textile element produces excellent results.
In an advantageous embodiment, the two-dimensional textile element is constructed as a knitted fabric, which has the advantage of having a high degree of structural expansion or stretchability, over the entire textile surface. The ability to expand or stretch means that the two-dimensional textile element is well able to absorb the forces that are generated during airbag release and that are, for example, exerted on the hinge. The two-dimensional textile element can thus absorb the forces into the carrier matrix, particularly when a knitted fabric is used that has high multi-axial or multi-directional structural expansion.
An advantageous embodiment is also achieved then, when, instead of a knitted fabric, a woven fabric is used as the two-dimensional textile element, the entire surface of which, according to the independent claim, can be embedded into the corresponding matrix, although with only partial penetration of the carrier material through the two-dimensional textile element.
In an advantageous embodiment, the two-dimensional textile element can be a folded construction, such that, when looking at the folds in a cross-sectional view, the lower portion of the folds, i.e., that portion that is closer to the outer side of the airbag cover, are embedded in the respective matrix, for example, in the material for the airbag-cover carrier, and an upper portion of the folds, for example, the folds crests, are arranged outside of this embedded area.
The two-dimensional textile element can, for example, be made of polyester or polyamide material, which exhibits such a high resistance to heat that the area embedded in the matrix maintains sufficient temperature consistency, so that, for example, during the back-injection, injection, back-compression molding, casting, or foaming process, it will maintain its advantageous properties even after being embedded.
In an advantageous embodiment, the two-dimensional textile element is constructed as a multi-axial textile element, i.e., an element that stretches in multiple directions. This means that the two-dimensional textile element is able to absorb across its entire surface a great portion of the forces that are exerted when the hinge swings open.
A cost-effective way to manufacture the proposed hinge is possible by providing a barrier effect on the side of the two-dimensional textile element that faces the airbag-cover carrier, the barrier effect providing a higher resistance, for example, to flow-through or penetration of the molten material for the airbag-cover carrier, than the two-dimensional textile element itself.
This flow-through-altering layer or barrier of the two-dimensional textile element makes it possible to control the amount of the molten material that flows through the two-dimensional textile element. By not allowing the molten material to flow through the two-dimensional textile element completely, it is possible to achieve a configuration in which the lower portion or lower coating that is toward the matrix of the airbag cover is completely embedded in the matrix material, whereas a portion of the two-dimensional textile element that is facing away from the carrier is only partially or not at all embedded in the matrix material.
This flow-through-altering layer or barrier can, for example, be formed by applying a coating to one side of the two-dimensional textile element. It is also possible to define various areas having different flow resistances to the molten masses, for example, in the area of the two-dimensional textile element, whereby the area having a higher flow-through resistance faces the airbag-cover carrier.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are shown in the drawings.
FIG. 1 illustrates an airbag cover opened after airbag release.
FIG. 2 shows in a larger-scale cross-section a first embodiment of a coated two-dimensional textile element embedded in the area of the airbag-cover hinge.
FIG. 3 shows in a larger-scale illustration an additional embodiment of a two-dimensional textile element embedded in the area of the hinge for the airbag cover.
FIG. 4 shows a larger-scale cross-section of the hinge of an airbag cover, as it is opening during airbag release.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates an airbag cover 1 , which, in this drawing, is opened and connected by a hinge 2 to a surrounding area 3 of the airbag cover. The surrounding area 3 is part of, for example, a dashboard, a headrest, an armrest of a motor vehicle seat, a column, vehicle interior trim paneling, etc. An undeployed airbag is stored behind the airbag cover 1 . The airbag itself is not shown in the drawings.
When the airbag cover 1 opens, it swings about the hinge 2 into the interior space of the vehicle and opens up a path that allows the inflating airbag to expand into the interior of the vehicle. The hinge 2 absorbs a portion of the forces exerted on the airbag cover 1 , which prevents the cover from opening in an uncontrolled manner. This minimizes the risk that the airbag cover 1 will detach from the surrounding area 3 and put persons sitting in the vehicle at risk of injury from the cover 1 .
FIG. 2 is a cross-sectional view of the hinge portion of the airbag cover 1 . The airbag cover 1 in the area of the hinge 2 is constructed from a carrier 4 that may be made of a plastic material, particularly a thermoplastic material such as polypropylene. A coating of foam 5 is applied to the carrier 4 on the side facing the interior of the vehicle and a decorative covering 6 then applied to the surface of the foam, so as to fashion a visually attractive interior of the vehicle.
In this embodiment, the illustration of the carrier 4 is interrupted, because the depth or thickness of the carrier 4 , preferably 2-3 mm, depends upon the respective size of the airbag cover 1 . In this embodiment, a layer 7 is provided on the side of the carrier 4 facing away from the decorative covering 6 . The layer can be constructed, for example, as a coating side. A two-dimensional textile element 8 is arranged on the side of the layer 7 facing away from the carrier 4 . In this embodiment, the two-dimensional textile element 8 is constructed as a knitted fabric.
The layer 7 is provided as a flow- or penetration-inhibiting layer that limits the flow or penetration into the layer 7 of the molten thermoplastic material that forms the carrier 4 , i.e., the layer 7 has a higher level of flow resistance than the two-dimensional textile element 8 , so that the penetration depth “A” of the two-dimensional textile element 8 to the thermoplastic material forming the carrier 4 can be precisely adjusted.
In this embodiment, layer 7 is made of a fleece. After the thermoplastic material used in this embodiment is hardened, the two-dimensional textile element 8 is thus embedded across the area of the penetration depth A, that is, the penetration depth A characterizes the matrix 9 in which the two-dimensional textile element 8 is embedded. On the side of the matrix 9 facing away from the carrier 4 , there is a “free area” 10 of the two-dimensional textile element 8 . This free area 10 is not part of the embedded two-dimensional textile element 8 .
Instead of the fleece used in the embodiment according to FIG. 2 (which, for example, can be polyester), a perforated film or other similar flow-resistant materials can be used as the coating materials, which achieve a uniform penetration depth when a curable mass penetrates the two-dimensional textile element.
FIG. 3 illustrates a carrier 4 , which is, on the other hand, covered with foam 5 , as well as a finishing decorative skin 6 , on the side facing the interior of a motor vehicle. In this embodiment, an additional layer 7 or coating side is not used. Instead, the two-dimensional textile element 8 has an area 11 facing the carrier 4 that creates a higher flow resistance than a “looser” area 12 facing away from the carrier 4 , which has a lower flow resistance than area 11 . As shown in the embodiment according to FIG. 2 , a non-embedded, free area 10 of the two-dimensional textile element 8 is also provided here. The area of the coated two-dimensional textile element 8 that is embedded into the matrix of the carrier 4 is designated by 9 .
In an advantageous embodiment, due to the barrier effect of the coated two-dimensional textile element, for example, more than 50% (as shown in the vertical direction in the illustration) of the thickness of the two-dimensional textile element 8 is included in the embedded area, and less than 50% of the two-dimensional textile element 8 belongs to the “free”, non-embedded area 10 of the same. In an advantageous embodiment, approximately 70 to 80% of the two-dimensional textile element is embedded. Naturally, a corresponding variation of the ratio of embedded area to free area can be provided, depending upon the application, that is, upon the force that an expanding airbag exerts on the airbag cover, and, depending upon the weight and size of the airbag cover, as well as upon the length of the outward swing of the airbag cover.
If a large portion of the two-dimensional textile element is embedded in the matrix of the carrier 4 , then a greater portion of the occurring forces can be absorbed by this hinge.
In addition to the illustrated knitted fabrics, the two-dimensional textile element can also be constructed as woven fabric, whereby an advantageous adjustment of the free area that is not embedded can then be achieved, if the woven fabric has sufficient thickness, such as is customary, for example, for knitted fabrics. Naturally, as described above, the woven fabric can also be coated.
Likewise, a two-dimensional textile element, such as, for example, a woven fabric that has a folded construction can be used, so that, for example, the folded areas adjacent the carrier 4 are embedded and the “fold crests” facing away from the carrier are exposed, i.e., not embedded.
With reference to FIG. 4 , the hinge area of an airbag cover is illustrated in an oversize illustration, that is, the airbag cover is swung in the direction of the arrow toward the motor vehicle interior. The number 14 designates a predetermined breaking point that represents a weakening and which is used to define the site of the swinging motion of the airbag cover 1 . The swinging open of the airbag cover 1 causes the carrier material 4 to break. The cover 1 swinging open even farther causes the two-dimensional textile element to detach, loosen, or stretch in a pre-defined manner, up into the inside of the carrier matrix 4 . A great portion of the occurring forces is thereby absorbed over the entire surface by the structural expansion and by the component strength of the carrier matrix.
The area of the two-dimensional textile element in which the material for the carrier does not flow delaminates up into the inside of the adjacent carrier matrix. Thus, the structural expansion over the entire surface of the two-dimensional textile element and its embedding into the carrier serve to absorb the occurring forces into the carrier matrix, and this results in an outward swinging motion of the airbag cover 1 .
Residual forces cause an additional swinging open of the airbag cover 1 , and these residual forces are initially received and absorbed over the entire surface by the textile expandability of the two-dimensional textile element, i.e., particularly of a knitted fabric, so that, for one, the airbag cover opens in a controlled manner and is in no danger of being torn from its surrounding environment.
One advantage of the proposed hinge is that a particularly lightweight two-dimensional textile element 8 can be used, so that the weight of the hinge 2 can be kept very low. Because of this, it is not necessary that the hinge be a heavy metal hinge, for example, which is cost-intensive to produce. Because the weight of the hinge 2 can be kept low, the forces that occur are also lower than would be the case with a heavier cover for the airbag.
Furthermore, the proposed hinge 2 for the airbag cover also enables a cost-effective manufacturing process, because the hinge 2 can be manufactured together with the airbag cover 1 . In other words, the two-dimensional textile element 8 of the hinge 2 can be embedded into the carrier matrix (partially), at the time the carrier is manufactured.
|
The invention relates to a hinge for an airbag cover, having a planar textile element as a hinge between the cover of the airbag and an adjacent airbag cover region, for example in the interior of a motor vehicle, and to a region of the planar textile element which faces a carrier of the airbag cover and is embedded in a matrix which is connected to the cover, and a region of the planar textile element which is not embedded in the matrix.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a burner.
2. Discussion of Background
U.S. Pat. No. 4,932,861 to Keller et al. has disclosed a conical premix burner which consists Of several shells and produces a closed swirl flow in the cone head. The swirl flow becomes unstable along the cone tip on account of the increasing swirl and changes into an annular swirl flow. In combination with the sudden widening in the cross section provided at the cone tip, the annular flow causes a backflow zone on the burner axis. Gaseous fuels are injected here along the tangential ducts (also called air-inlet slots) formed by the individual shells and are mixed homogeneously with the combustion air flowing in. The combustion starts by ignition at the stagnation point of the backflow zone or backflow bubble, the backflow zone thus fulfills the function of a bodiless flame retention baffle. However, the last nozzles for this gaseous fuel in the direction of flow lie very close to the burner outlet and thus in proximity to the flame. Accordingly, the fuel introduced through these nozzles does not mix with the air in an optimum manner and tends to lead to higher NOx emissions. If the intention is to extend the premix section in order to keep the NOx emissions to a minimum, this requires a complicated transition piece between the burner body and the following part. The flow field produced downstream by the premix burner leads to problems in a following tube either at the margin or at the center on account of the low axial velocity. This then leads to backfiring and the premix burner cannot be operated at an optimum level in the transient regions in this manner. Liquid fuels are preferably introduced here via a central nozzle at the burner head. The liquid fuels vaporize in the conical hollow space. Under conditions specific to gas turbines, the ignition .of these liquid fuels takes place relatively early and consequently always near the fuel nozzle, which in turn inevitably leads to the threat of a potential increase in the NOx emissions precisely on account of this non-optimum mixing, which threat has to be counteracted, for example, by water injection. Further problems arising from the operation with a liquid fuel are connected with the relatively small cross section of flow and consequently with the small cone angle which might arise from that in the region of the atomization angle of the fuel nozzle. This factor may easily lead to wetting of the cone shells and thus to harmful cracking processes with regard to the pollutant emissions as soon as a pressure difference occurs for example. In addition, it should be realized that the attempt to fire hydrogenous gases (MBTU or LBTU gases) like natural gas has led to premature ignition at the nozzles for a gaseous fuel along the tangential ducts. Attempts to remedy this have involved the introduction of a special injection method for such gaseous fuels at the burner outlet, although the results of this injection method have not been entirely satisfactory.
SUMMARY OF THE INVENTION
Accordingly, one object of the invention is to propose novel measures in the case of a burner of the type mentioned at the beginning which are able to remove the abovementioned disadvantages.
The premix burner according to the invention consists of a conical swirl generator which is made with at least two tangentially arranged slots. The combustion air flows here axially into the swirl generator and then to the outside via the said tangential slots or ducts, this conical swirl generator being enclosed by a body preferably designed as a tube. Since the shape of this body exerts a great effect on the flow outside and downstream of the swirl generator, it may still be changed after the swirl generator by suitable measures. Thus the cross section of the body enclosing the swirl generator may decrease in the direction of flow, for example by means of a cone or venturi. A gaseous fuel may also be introduced here by nozzles which are located in the region of the slots. If the burner is operated with a liquid fuel, the fuel is fed into the cross section of the enclosing body in the region of the tip of the conical swirl generator. If an MBTU or LBTU gas is introduced, the relatively large quantity of this fuel can be introduced directly from outside into the cross section of the enclosing body, whereby the mixing with the swirl flow prevailing there is likewise ensured.
The essential advantages of the invention may be seen in the fact that the flow field after the swirl generator can be freely modulated. Furthermore, it should be emphasized that the injection of a liquid fuel does not lead to wetting of the flow wall of the enclosing body, because the cross section of flow is maximized precisely in this plane. Thus, thanks to the large spray angle which is thus possible, optimum mixing with the swirled combustion air is successfully achieved. The long premix section now possible downstream of the swirl generator minimizes the NOx emissions from the subsequent combustion. The good accessibility for MBTU and LBTU gases has already been dealt with above. Furthermore, it should be noted that the burner front of the burner according to the invention need no longer be cooled. Sealing problems between premix and head stage also no longer occur here.
Due to the simple geometry of the burner according to the invention, air can be directed into the tip of the swirl generator in an uncomplicated manner, which air may be utilized to make the mixture leaner or to produce an axial jet on the burner axis. If the burner is operated with a liquid fuel, this air may also be utilized to assist the atomization in a more simple manner compared with the premix burner belonging to the prior art. The inverse arrangement of the burner according to the invention compared with the said prior art, as far as the swirl generation is concerned, improves the atomization of the liquid fuel, in the course of which deposits in the region of the shells of the swirl generator are impossible. If the flow in the outer region is to be orientated purely axially or made leaner, this may be achieved by the swirl body not covering the entire cross section of the enclosing body.
Advantageous and expedient further developments of the achievement of the object according to the invention are defined in the further claims.
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 drawings, wherein:
FIG. 1 shows a side sectional view of a premix burner,
FIG. 2 shows a front view of the premix burner according to FIG. 1,
FIG. 3 shows a premix burner supplemented by a head nozzle for injecting a liquid fuel,
FIG. 4 shows a front view of the premix burner according to FIG. 3,
FIG. 5 shows a further schematically represented premix burner having an axial marginal flow, FIG. 6 shows a front view of the premix burner according to FIG. 5, likewise schematically represented,
FIG. 7 shows a further premix burner with measures for injecting hydrogenous gases,
FIG. 8 shows a front view of the premix burner according to FIG. 7,
FIG. 9 shows a further schematically represented premix burner, wherein the swirl generator does not cover the entire cross section of the enclosing body, and
FIG. 10 shows a front view of the premix burner according to FIG. 9, likewise schematically represented.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
To better understand the structure of the premix burners described below, the corresponding front view should be used at the same the as the individual figures in elevation.
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, FIG. 1 shows a premix burner 1 which consists of a tubular body 2 and a hollow, conical swirl generator 3 integrated therein. The swirl generator 3 is positioned to narrow in the direction of flow. The air 4 flowing into the swirl generator flows in axially into the interior 16 of the conical swirl generator and from there, flows tangentially or quasi-tangentially, as the arrows 5 are intended to symbolize, from the inside to the outside. Tangential ducts 6, 7 are provided here for this purpose. The tangential ducts 6, 7 are formed by nesting at least two hollow, conical sectional bodies 8, 9 to define a conical interior space 16 with the center axes of these sectional bodies 8, 9 mutually offset. In certain operating configurations, it is not out of the question for the swirl generator 3 to consist of a single spiral. As outlined briefly above, the mutual offset of the respective center axis or longitudinal symmetry axis of the conical sectional bodies 8, 9 in each case creates the tangential ducts 6, 7 at the adjacent wall. The tangential ducts 6, 7 provide gas through which the combustion air 5 flows from the interior space 16 of the swirl generator 3 into the tube 2.
The conical shape of the sectional bodies 8, 9 shown has a certain fixed angle in the direction of flow. Of course, depending on operational use, the sectional bodies 8, 9 may have increasing or decreasing curvature in the direction of flow, that is, they may be designed like a diffuser or confuser. The two last-mentioned shapes are not shown graphically, since they can readily be imagined by the person skilled in the art. The two conical sectional bodies 8, 9 each have a fuel line 10, 11, which fuel lines 10, 11 are arranged along the tangential ducts 6, 7 and are provided with injection openings 12, 13, through which preferably a gaseous fuel 14 is injected into the combustion air 5 flowing through there, as revealed by the arrows. These fuel lines 10, 11 are preferably arranged in the region of the tangential outflows, predetermined by the ducts 6, 7, from the swirl generator 3 and the inflow into the tube 2, this in order to obtain an optimum air/fuel mixture 15. If the combustion air 5 is additionally preheated or enriched, for example, with a recycled flue gas or exhaust gas, this generally provides lasting assistance for the vaporization of the fuel 14 used, especially if the fuel is a liquid fuel, the injection of which may also be carried out via the said. fuel lines 10, 11. Narrow limits per se are to be adhered to in the configuration of the conical sectional bodies 8, 9 with regard to the cone angle and the width of the tangential ducts 6, 7 so that the desired flow field of the combustion air 5 or the mixture 15 can arise at the outlet of the swirl generator 3. In general it may be said that a reduction in the width of the tangential ducts 6, 7 locally promotes the formation of the critical swirl number, which is jointly responsible for the formation of a backflow zone. It should be said at the same time that a correction in this respect is also possible by influencing the axial velocity in the region of the swirl generator 3. Further details of how this is carried out may be gathered from FIG. 5. The critical swirl number may also be influenced by the width of the tangential ducts 6, 7 being designed to be variable in the direction of flow. If the width of the ducts 6, 7 decreases in the direction of flow, the location of the formation of the backflow zone is displaced downstream. The following comments apply to the formation of the backflow zone: located on the outflow side of the tube 2 is the actual combustion chamber, which is not shown in more detail here. The tube 2 here performs the function of a mixing tube which provides a defined mixing section downstream of the swirl generator 3, in which mixing section perfect premixing is achieved irrespective of the fuel injected. Furthermore, this mixing section permits loss-free guidance of the flow so that for the time being no backflow zone can form even in interaction with the transition geometry appearing in this case, whereby the mixture quality for the respective fuel may be influenced over the length of the mixing tube 2. However, this mixing tube 2 has a further feature, which consists in the fact that, in the mixing tube 2 itself, the axial velocity profile has a pronounced maximum at the axis, so that a flashback of the flame from the combustion chamber is not possible. It is true though that the axial velocity in such a configuration potentially decreases toward the wall. In order to prevent a flashback in this region too, the mixing tube 2, in the direction of flow and in the peripheral direction, may be provided with a number of bores (not shown) of the most varied cross section and direction, through which an air quantity flows into the interior of the mixing tube 2, and can produce an increase in velocity along the wall. Another way of achieving the same effect is for the cross section of flow of the mixing tube 2 to be reduced (likewise not shown in more detail) on the outflow side of the swirl generator 3, as a result of which the overall velocity level within the mixing tube 2 is raised. If the measure selected for guiding the flow within the mixing tube 2 should produce an intolerable pressure loss, this may be remedied by a diffuser (not shown in the figure) being provided at the end of the mixing tube 2. As already mentioned above, the combustion chamber adjoins the end of the mixing tube 2, there being a jump in cross section between the two cross sections of flow. It is not until this point that the central backflow zone is formed, which has the properties of a flame retention baffle, which admittedly is bodiless here. As already indicated, the formation of a stable backflow zone also requires a sufficiently high swirl number in the mixing tube 2. If a fluidic marginal zone develops during operation inside the said jump in cross section, in which marginal zone vortex breakdowns occur due to the vacuum prevailing there, this leads to increased ring stabilization of the backflow zone itself. If a high swirl number is unwelcome to begin with, stable backflow zones may be produced by feeding small swirled air flows at the end of the mixing tube, for example through tangential openings. In this case it is assumed that the required air quantity is about 5-20% of the total air quantity. The design of the swirl generator 3 is especially suitable for designing the tangential ducts 6, 7 with a variable width, whereby a relatively large operational range can be covered without interfering with the overall length of the swirl generator 3. The conical sectional bodies 8, 9 are of course also displaceable relative to one another in another plane, as a result of which even overlapping of the same is possible. Furthermore, it is possible to nest the conical sectional bodies 8, 9 spiral-like one inside the other by a contra-rotating movement. Therefore the shape, size and configuration of the tangential ducts 6, 7 can be varied as desired, whereby the swirl generator 3 has wide operational availability without changing its overall length.
FIG. 2 shows the outflow of the combustion air 5 from the interior space 16 of the swirl generator 3 into the mixing tube 2, the injection of the fuel 14 into the combustion-air flow 5 taking place in the region of the tangential ducts 6, 7. A gaseous fuel is preferably injected in the region of the tangential ducts 6, 7.
FIGS. 3 and 4 differ from FIGS. 1 and 2 in that here a fuel lance 17 extends through the interior space of the swirl generator 3, from which fuel lance 17 the fuel injection 18 into the mixing tube 2 is effected in the region of the tip of the swirl generator 3. This nozzle 19 is preferably operated with a liquid fuel 20, though it is not out of the question to run the nozzle 19 on another fuel. During the injection of a liquid fuel, the free cross section in this plane proves to be an advantage in so far as the oil-spray cone 21, as the figure shows, may be of more generous proportions without running the risk of wetting the walls of the mixing tube 2. Otherwise the configuration of the premix burner 1 here corresponds to that in the preceding figures.
FIGS. 5 and 6 adopt the configuration in FIGS. 1 and 2 with the difference that the swirl generator 3 additionally permits an annular axial air flow 22. The ultimate purpose of such an air flow is apparent from the description relating to FIG. 1 where it is stated that the formation of the critical swirl number at the correct location may be adjusted by an axial injection of an air flow.
FIGS. 7 and 8 are based on FIGS. 3 and 4, means 23 for injecting an MBTU or LBTU gas 24 into the mixing tube 2 being provided here as a further development. This type of injection essentially depends on the fact that the introduction of the requisite large quantity of such a gas 24 can scarcely be brought about by the means of injection at the swirl generator 3.
The premix burner according to FIGS. 9 and 10 essentially refers to FIGS. 1 and 2, the axial inlet opening 25 of this swirl generator 3 being maximized, i.e. the inlet cross section 25 of the swirl generator 3 corresponds to the cross section of the mixing tube 2. The first possible point at which the air flow 5 passes through the tangential ducts 6, 7 lies downstream of the inlet cross section 25. This embodiment is especially useful where the flow in the outer region is to be orientated purely axially or is to be made leaner.
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.
|
In a burner (1) for heat generation, the inflowing air (4) is first of all directed into a hollow conical swirl generator (3) which is surrounded by a mixing tube (2). This swirl generator (3) tapers in the direction of flow in such a way that a hollow cone results therefrom. Furthermore, the swirl generator (3) has tangential openings (6, 7) in the direction of flow, which are preferably designed as ducts through which the combustion air (5) flows out of the hollow space (16) into the mixing tube (2). In the region of the tangential openings (6, 7), nozzles (12, 13) are provided through which a fuel (14) is injected into the combustion air (5) flowing past there. A fuel, whether liquid or gaseous, may be supplied by further means in operative connection with the burner (1).
| 5
|
CROSS-REFERENCE TO RELATED CASES
This application is a continuation of application Ser. No. 10/617,241, filed Jul. 9, 2003 (now U.S. Pat. No. 6,814,194), which is a division of application Ser. No. 10/022,050 filed Dec. 13, 2001 (now U.S. Pat. No. 6,615,962), both of which are hereby incorporated by reference in their entirety.
The disclosure of the commonly owned German priority application Ser. No. 100 62 499.5, filed Dec. 14, 2000, as well as of each U.S. and foreign patent and patent application identified in the specification of the present application, is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to improvements in torque transmitting apparatus, and more particularly to improvements in hydraulic torque converters which can be utilized with advantage in the power trains of motor vehicles, e.g., between the rotary output element of the prime mover (such as an internal combustion engine) and the input element (such as a shaft) of a change-speed transmission.
A conventional hydrokinetic torque converter in the power train of a motor vehicle normally comprises a housing which shares the angular movements of the output element (such as the crankshaft) of the engine, a pump which shares the angular movements of the housing, a turbine which can receive torque from the housing by way of a body of hydraulic fluid confined in the housing and being circulated by the vanes or blades of the pump, as well as an output member (e.g., a hub) which can receive torque from the turbine to transmit torque to a driven member such as the input shaft of the change-speed transmission. The torque converter can further comprise a bypass clutch or lockup clutch (hereinafter called bypass clutch) which, when necessary or desired, transmits torque directly between the pump or housing and the turbine. Still further, such conventional torque converter can also comprise at least one torsional vibration damper which operates in the power train between the housing and the output member.
In many conventional torque converters of the above outlined character, a portion of the bypass clutch is fixedly secured to the input of the torsional vibration damper. Reference may be had, for example, to published German patent application Ser. No. 199 63 236 A1. The piston of the bypass clutch is or can be riveted to the input of the torsional vibration damper and such input comprises two annular flanges. During actuation (engagement or disengagement) of the bypass clutch, the piston of the bypass clutch is caused to move axially and to thus frictionally engage or become disengaged from the housing of the torque converter. Such axial movement of the piston entails a movement of the output of the torsional vibration damper because the output is provided with gear teeth mating with complementary gear teeth on the hub of the torque converter.
It can happen that the mating gear teeth generate pronounced friction or that they jam. In fact, the tension between the input of the torsional vibration damper and the piston of the bypass clutch, and/or non-uniform engagement of the piston of the bypass clutch with the friction surface of the housing of the torque converter, can cause the development of excessive stresses, a cracking of cooperating parts and fatigue-induced breaks. Such undesirable phenomena are particularly likely to develop in the parts which are riveted to each other. Still further, excessive tension between the piston of the bypass clutch and the input of the torsional vibration damper is likely to develop when the piston is caused to frictionally engage the housing with attendant deformation (particularly in the axial direction of the bypass clutch) when the pressure of hydraulic fluid in the cylinder chamber for the piston increases, i.e., when the piston is called upon to transmit torque from the housing to the output of the torque converter by establishing a direct power transmitting path from the output element of the prime mover, through the housing of the torque converter and to the output of the latter, i.e., by bypassing the pump and the turbine of the torque converter.
The torsional vibration damper comprises coil springs or other suitable resilient elements which act in the circumferential direction of the input and output when the input turns relative to the output and/or vice versa. When the RPM of the torsional vibration damper is very high, the springs are held against radially outward movement under the action of centrifugal force. The means for preventing such radially outward movements of the springs are costly as well as bulky because they take up room as considered axially as well as radially of the damper. In order to achieve most satisfactory friction within the entire RPM range of the springs, it is necessary to establish an optimum relationship between the parts which can or should turn relative to each other, especially between the coil springs on the one hand and the input and/or output of the torsional vibration damper on the other hand.
It is often advisable to connect the torque converter to an axially elastic disc or wall which is attached to and receives torque from the output shaft of the prime mover (such as the crankshaft of the engine) in the power plant of a motor vehicle. The connection is normally established by resorting to threaded fasteners having shanks mating with internal threads provided in one of the torque converter and the disc. This normally involves individual application and tightening of each of a plurality of threaded fasteners. Such tightening is carried out by resorting to a suitable tool which can reach the fasteners through one or more access openings provided in the housing or bell of the change-speed transmission of the power train. The torque converter must be caused to turn, at least at intervals, in order to afford access to the fasteners. Such modes of affixing the torque converter to the torsional vibration damper and of mounting the damper in the torque converter are time-consuming and necessitate the hiring of highly skilled artisans. The situation is complicated because the installation of a torque converter in the power train of a vehicle also invariably necessitates the hiring of highly skilled artisans who are capable of carrying out the above outlined undertakings in addition to centering of cooperating moving (rotary) parts relative to the adjacent part or parts.
OBJECTS OF THE INVENTION
An object of the instant invention is to provide a hydraulic torque converter which is more reliable than heretofore known torque converters and whose useful life is much longer than those of the aforediscussed and other conventional apparatus of such character.
Another object of the invention is to provide a torque converter which can be assembled and installed in the power train of a motor vehicle or the like in a manner much simpler than conventional torque converters.
A further object of the present invention is to provide a torque converter which is constructed and assembled with a view to reduce the effects of fatigue upon its useful life and/or upon the reliability of its operation and which is more likely to withstand the effects of unanticipated stresses, hard-to-detect cracks and/or breaks as well as weakening of joints, connections and wear-induced problems than conventional torque converters.
An additional object of this invention is to provide a novel and improved method of assembling a torque converter and of installing such apparatus-in partly or fully assembled condition—in the power train of a motor vehicle.
Still another object of the invention is to provide one or more novel and improved torsional vibration dampers for use in the aforediscussed novel hydraulic torque converter.
A further object of the invention is to provide a novel and improved combination of a bypass clutch and one or more torsional vibration dampers for use in a hydraulic torque converter.
Another object of this invention is to provide a torque converter which embodies a bypass clutch and wherein the generation and/or application or utilization of friction and/or damping can be initiated and controlled in a manner more reliable and more predictable than in conventional torque converters.
An additional object of the invention is to provide a torque converter whose operation is more reliable and more predictable within the entire RPM range of the rotary output element or elements of the prime mover, such as the camshaft or the crankshaft of the internal combustion engine in the power train of a motor vehicle, than the operation of conventional torque converters.
Still another object of the invention is to provide a novel and improved method of operatively connecting the improved torque converter with a shaft, disc or another rotary output element of a prime mover.
A further object of our invention is to provide a torque converter wherein one or more rotary and/or otherwise movable parts of the bypass clutch, of one or more torsional vibration dampers and/or one or more other components can be centered in a manner simpler, more reliable and less time-consuming than that required for analogous manipulation(s) of components in conventional torque converters.
Another object of the invention is to simplify the assembly of the torque converter with a prime mover and/or with a driven unit (such as a variable-speed transmission) in the power train of a motor vehicle.
An additional object of the invention is to provide a torque converter which is constructed and assembled in such a way that its space requirements in a motor vehicle (such as between the engine and the transmission) are much less than in heretofore known power trains.
Still another object of the invention is to provide a power train which can be utilized in any one of a large number of different power trains to meet one or more specific or broad requirements pertaining to savings in space, material and/or number of parts, to reliability and/or useful life, to the possibility to occupy space which is avaiable under the hood of or elsewhere in a motor vehicle and/or to meet two or more of the above-enumerated and/or other prerequisites.
A further object of the instant invention is to provide a power train, particularly for use in a motor vehicle, which embodies a torque converter exhibiting at least some of the above-enumerated features and attributes.
SUMMARY OF THE INVENTION
One feature of the present invention resides in the provision of a hydraulic torque converter which comprises a housing arranged to rotate about a predetermined axis, to confine a supply of a suitable hydraulic fluid and to receive torque from an output element of a prime mover (e.g., from the crankshaft of an internal combustion engine in the power train of a motor vehicle). The improved torque converter further comprises a pump which is disposed in and is arranged to rotate with the housing about the predetermined axis, and an annular turbine which is coaxial with the pump, which is disposed in the housing and which is arranged to receive torque from the fluid in the housing in response to rotation of the pump. The improved torque converter also comprises a rotary input element (e.g., the input shaft of a change-speed transmission) which is coaxial with the housing, a rotary output member (such as a hub) which is arranged to transmit torque between the input element and at least one of the pump, turbine and housing, a bypass clutch which is engageable to transmit force between the pump and the turbine during predetermined stages of operation of the torque converter, and at least one torsional vibration damper in a power flow between the housing and the output member. The damper comprises an input, an output which is coaxial with the housing and with the input and is rotatable relative to the input, and energy storing means arranged to oppose rotation of the input and the output relative to each other.
The improved torque converter can further comprise a stator which, if used, is installed between the pump and the turbine.
The input element can include or constitute or form part of a shaft of an automatic change-speed transmission.
The bypass clutch can include a substantially disc-shaped member and the torque converter can further comprise means for resiliently connecting the disc-shaped member to the input of the damper with freedom of movement in the direction of the axis of the housing. The substantially disc-shaped member can include or constitute a piston of the bypass clutch, and such torque converter can further comprise a force-locking connection between the piston and the housing; such connection can include friction surfaces which contact each other in the engaged condition of the bypass clutch.
The aforementioned member (piston) of the bypass clutch can be connected with the input or with the output of the damper at a plurality of points which are spaced apart from each other in the circumferential direction of the turbine. The input or the output of the damper and/or the member (piston) of the bypass clutch can be provided with stiffness reducing means disposed at least partially radially inwardly of the aforementioned array of connection points, namely with means for reducing the stiffness of the input, output or piston in the direction of the predetermined axis.
The stiffness reducing means can include an annular array of recesses in the input, output or piston, and each such recess can be adjacent one of the aforementioned plurality of points. For example, each recess can include an arcuate slit which partially surrounds one of the points. The width of one end portion of each slit can exceed the width of the other end portion and/or the width of an intermediate portion of the respective slit. One end portion of each recess or slit in the input, output or piston can extend radially outwardly beyond at least one of the aforementioned points.
If the recesses are slits provided in the input of the torsional vibration damper, such slits can be provided in the radially outermost portion of the input and can have open ends at the periphery of the input.
An enlarged end of each slit can be spaced apart from the axis of the housing the same distance as the aforementioned points.
The slits, recesses or other suitable stiffness reducing means can be provided in the input or output of the damper and/or in the piston of the bypass clutch during a first stage of assembly of the damper with the housing and the output member, and the input can undergo a shaping treatment (such as the imparting of the final shape) during a second stage which follows the first stage of assembly of the damper with the housing and with the output member.
The damper can be installed in a power flow between the bypass clutch and the output member or in a power flow between the turbine and the output member.
The input of the damper can include at least two walls or panels, and such torque converter can further comprise means (such as rivets) for connecting at least one wall of the input with a member (such as a piston) of the bypass clutch.
A portion of the bypass clutch can be placed next to a portion of the torsional vibration damper, and such torque converter can further comprise an annular array of fasteners (such as rivets) which spacedly surround the axis of the housing and connect the two portions to each other. Such torque converter can further comprise means (such as the aforementioned slots) for reducing the stiffness of at least one of the interconnected portions in the axial direction of the housing. The slots, recesses or analogous stiffness reducing means are or can be adjacent the fasteners. Each such recess or slot can be open as seen radially outwardly away from the axis of the housing and closed radially inwardly of neighboring fasteners. The recesses can alternate with the fasteners, and the widths of at least some of the recesses—as seen in the circumferential direction of the portions of the damper and bypass clutch—can increase in a direction toward the axis of the housing.
It is also possible to provide the input or the output of the damper and/or the piston of the bypass clutch with recesses having closed radially inner end portions nearest to the axis of the housing and bounded by at least substantially circular surfaces of the input, output and/or piston; each such recess can resemble a keyhole.
The widths of at least some of the recesses—as seen in the circumferential direction of the housing—can decrease in a direction toward the axis of the housing. For example, such recesses can be bounded by an undulate peripheral surface of the input, output and/or piston.
A portion (such as the aforementioned piston) of the bypass clutch can be connected to apportion (such as the input) of the damper by suitable springs with limited freedom of movement in the direction of the axis of the housing of the improved torque converter. The springs can include an annuar array of leaf springs which spacedly surround the axis of the housing. Such torque converter can further comprise means for non-rotatably connecting the input of the damper with the turbine. The piston of the bypass clutch and the housing include annular portions which frictionally engage each other in the engaged condition of the bypass clutch, and the aforementioned leaf springs can connect the input of the damper with a radially outermost part of the aforementioned portion (piston) of the bypass clutch.
The energy storing means of the at least one damper can include an annulus of coil springs and means for limiting the movability of such springs at least radially of the axis of the housing. The means for limiting can include a ring which is surrounded by the convolutions of the coil springs with limited freedom of movement of the springs and ring relative to each other radially of the axis of the housing. Such torque converter can further comprise means for connecting the ring to the damper, namely to the input or the output of the damper. The ring can be made of any suitable material, especially a metallic or a plastic material.
The means for limiting can include a preshaped annular member and the convolutions of the coil springs forming part of the damper spacedly surround the preshaped annular member. The end portions of the latter can be affixed to each other by bonding (such as welding), by hooking (i.e., by resorting to one or more hooks at one end of the annular member and to one or more eyelets for such hook or hooks at the other end of the annular member) or by nesting (e.g., by fitting a male member at one end into a complementary female member at the other end of the annular member).
The input and/or the output of the damper can include means for locating the annular member relative to the input and the output in at least one of the directions including radially of the axis of the housing and in the direction of such axis. The locating means can include an annular array of discrete projections provided on the input and/or on the output of the damper. The projections can further serve as a means for tensioning the annular member. Each such projection can include a deformed portion of the input and/or the output of the damper.
The ratio of the diameter d of the wire of the ring to the inner diameters D of convolutions of the coil springs is or can be determined by the relationship 0.8*D>d>0.2*D, preferably by the relationship 0.6*D>d>0.3*D.
The springs of the energy storing means can be received in recesses provided therefor in the input of the damper, and such input can be further provided with at least substantially radial arms alternating with the recesses, as seen in the circumferential direction of the damper. The output of such damper can include entraining portions which cooperate with the arms to stress the springs in response to rotation of the input relative to the output and/or vice versa.
The arms and/or the entraining means can be provided with surfaces which at least substantially conform to the surfaces of adjacent portions of the springs forming part of the energy storing means.
One or more springs of the energy storing means can be installed in prestressed condition, i.e., such springs are caused by the adjacent arms to store energy even in neutral angular positions of the input and output of the damper relative to each other. Alternatively or in addition to the just mentioned feature, the springs can be maintained in prestressed condition by the entraining portion of the output of the damper. The recesses of the input of the damper can be bounded by surfaces making right angles with each other.
Another feature of the present invention resides in the provision of a hydraulic torque converter which comprises a housing including a mass and being arranged to rotate about a predetermined axis, to confine a supply of hydraulic fluid and to receive torque from an output element of a prime mover. The improved torque converter further comprises a pump which is disposed in and is arranged to rotate with the housing about the latter's axis, an annular turbine which is coaxial with the pump, which is disposed in the housing and which is arranged to receive torque from the fluid in the housing in response to rotation of the pump, a rotary input element which is coaxial with the housing, a rotary output member which is arranged to transmit torque between the input element and the pump, housing and/or turbine, and a bypass clutch which is engageable to transmit force between the pump and the turbine during predetermined stages of operation of the torque converter. The latter further comprises at least one torsional vibration damper including an input, an output coaxial with the housing and with the input and rotatable relative to the input, energy storing means arranged to oppose rotation of the input and output relative to each other, and a torque transmitting member between the output element and the input. Still further, the torque converter comprises an annular array of retaining members provided on the mass and received in openings provided therefor in the torque transmitting member, and means for holding the retaining members in the respective openings.
The retaining members can include pins having axes at least substantially parallel to the axis of the housing and including end portions which extend or can extend through and beyond the respective openings; the holding means can engage such end portions of the pins. Such holding means can extend at least substantially circumferentially of the torque transmitting member.
In accordance with one presently preferred embodiment, the holding means includes a ring-shaped support and discrete holding members provided on the ring-shaped support and each engaging one of the retaining members.
The torque transmitting member can be disposed between the prime mover and the mass of the housing, as seen in the axial direction of the housing.
At least one of the retaining members can have an at least substantially conical shape and the corresponding opening has a complementary shape to snugly receive the conical retaining member.
The openings are or can be provided in a reinforced portion of the torque transmitting member; the latter can include a substantially disc-shaped body having a folded over radially outermost part which constitutes the reinforced portion of the torque transmitting member.
The mass of the housing can constitute an annular body, and the holding means can include forks each of which has prongs extending at least substantially circumferentially of the annular mass and engaging free end portions of the respective retaining members. The prongs can be received in grooves provided therefor in the free end portions of the respective retaining members. It is advisable to ensure that the forks are maintained in frictional engagement with the torque transmitting member and with the respective retaining members.
As already mentioned hereinbefore, the holding means can include a discrete holding member for each of the retaining members and a ring-shaped support for the holding members. Such torque converter can further comprise means for securing the ring-shaped support to the torque transmitting member against accidental separation from the latter.
The retaining members can include or constitute forks which extend circumferentially of the ring-shaped support. Each fork engages one of the retaining members and is separable from the respective retaining member in response to rotation of the ring-shaped support relative to the mass and/or vice versa. The forks cooperate with the retaining members to hold the ring-shaped support against movement relative to the mass in the axial direction of the housing.
The torque converter can further comprise means for preventing undesired rotation of the ring-shaped support relative to the mass when the retaining members are held in the respective openings. The rotation preventing means can comprise at least one snap fastener; such snap fastener can include a detent which is provided on the holder or on the torque transmitting member of the damper and an opening for the detent in the torque transmitting member or in the holder.
The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The improved torque converter itself, however, both as to its construction and the modes of assembling, installing and utilizing the same, together with numerous additional important and advantageous features and attributes thereof, will be best understood upon perusal of the following detailed description of certain presently preferred specific embodiments with reference to the acccompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an axial sectional view of a hydraulic torque converter which embodies one form of the present invention and is installed between the rotary output shaft of an engine and the input element of a change-speed transmission in the power train of a motor vehicle;
FIG. 2 is an elevational view of the input and of the energy storing means of the torsional vibration damper in the torque converter as seen from the left-hand side of FIG. 1 ;
FIG. 3 is an enlarged view of a detail within the phantom-line circle III shown in FIG. 1 ;
FIG. 4 is a fragmentary elevational view of the input in a modified torsional vibration damper and of an assembly which connects the input to a disc borne by the output shaft of the engine;
FIG. 5 is a sectional view substantially as seen in the direction of arrows from the arcuate phantom line V—V in FIG. 4 ;
FIG. 6 is a substantially axial sectional view as seen in the direction of arrows from the line VI—VI in FIG. 7 and shows a modified torsional vibration damper which can be utilized in the hydraulic torque converter of the present invention;
FIG. 7 is a fragmentary elevational view of the input and of the energy storing means in the damper, as seen from the left-hand side of FIG. 6 , and further shows the means for fastening the damper to the piston of the bypass clutch forming part of a torque converter embodying the damper shown in FIG. 6 ;
FIG. 8 is a view similar to that of FIG. 7 but shows a portion of a modified input;
FIG. 9 is a view similar to that illustrated in FIG. 7 but showing certain constituents of an additional torsional vibration damper and of the means for affixing it to the piston of the bypass clutch;
FIG. 10 is a fragmentary elevational view of the input in an additional torsional vibration damper and of an array of fasteners which secure the input to the piston of a bypass clutch, e.g., a clutch of the type shown in FIG. 1 ;
FIG. 11 is a fragmentary elevational view of an input forming part of still another torsional vibration damper and constituting a modification of the input shown in FIG. 10 ;
FIG. 12 is a fragmentary axial sectional view of a hydraulic torque converter constituting a further modification of the torque converter shown in FIG. 1 including a different non-rotatable but axially yieldable connection between the piston of the bypass clutch and the input of the torsional vibration damper;
FIG. 13 is an enlarged view of a detail as seen in the direction of arrow XIII which is shown in FIG. 12 ;
FIG. 14 is an enlarged view of a detail as seen in the direction of arrow XIV which is shown in FIG. 12 ; and
FIG. 15 is a fragmentary axial sectional view of a hydraulic torque converter constituting a further modification of the torque converter which is illustrated in FIG. 1 , and more specifically of a different connection between the bypass clutch and the torsional vibration damper.
DESCRIPTION OF PREFERRED EMBODIMENTS
The hydraulic torque converter 1 which is shown in FIG. 1 comprises a housing 13 which is affixed to the output element 2 of a prime mover, not shown. The output element 2 can constitute the crankshaft of an internal combustion engine in the power train of a motor vehicle; such power train further includes a rotary input element 3 of a change-speed transmission (not shown) which can drive the wheels or certain wheels of the motor vehicle by way of a differential in a manner well known in the art. The torque converter 1 is a fluid-operated clutch which can be utilized in lieu of a dry friction clutch to uncouple the engine in order to stop the motor vehicle in gear or to couple the engine for acceleration. Reference may be had, for example, to pages 691-693 of “Modern Automotive Technology” by James E. Duffy (1994 Edition published by The Goodheart-Willcox Company, Inc., Tinley Park, Ill.). As concerns the operation of a power train which employs a friction clutch, in lieu of a torque converter, reference may be had, for example, to commonly owned U.S. Pat. No. 4,901,596 granted Feb. 20, 1990 to Reik et al. for “ASSEMBLY FOR TAKING UP AND COMPENSATING FOR TORQUE-INDUCED SHOCKS”.
The input element 3 preferably constitutes the input shaft of an automatic or automated change-speed transmission. The housing 13 comprises coaxial shells 4 and 5 which are sealingly secured (such as welded) to each other. It is also possible to connect the shells 4 , 5 to each other by resorting to threaded fasteners, to caulking, to a bayonet lock, to a snap-in connection or the like. It is advisable to employ one or more washers and/or other metallic, plastic or other elastic sealing elements and/or to resort to a press fit in order to ensure adequate sealing of the interior of the housing 13 from the surrounding atmosphere.
The means for non-rotatably securing the shell 4 of the housing 13 to the output shaft 2 of the prime mover comprises an axially yieldable elastic torque-transmitting disc 6 having a radially inner portion affixed to the shaft 2 by an annular array of threaded fasteners 2 a (two can be seen in FIG. 1 ). These fasteners further serve as a means for ensuring that the axis X—X of the housing 13 coincides with the axis of the output shaft 2 as well as with the common axis of rotary components of the torque converter 1 .
The annular radially outermost portion 6 a of the torque transmitting disc 6 is reinforced in that it is folded over itself, e.g., in a suitable cold forming machine. This outermost portion 6 a is affixed to a ring-shaped portion or flywheel or mass 8 of the housing 13 in a novel manner, namely by a fastener assembly 10 . The latter comprises an annular array of preferably equidistant conical retaining members or projections 7 in the form of short pins borne by the mass 8 and snugly received in complementary conical openings 6 b provided in the reinforced portion 6 a of the disc 6 . The axes of the projections or pins 7 are parallel to the axis X—X of the housing 13 , and these pins extend in a direction from the shell 4 of the housing 13 toward the engine including the output shaft 2 . The mass 8 is centered on and is welded or otherwise affixed to the shell 4 ; this mass is a circumferentially complete body but it can be replaced with a set of discrete segments each of which can carry one or more abutments or pins 7 .
The radially outermost portion of the shell 4 is recessed in a direction axially of and away from the disc 6 in order to provide room for the mass 8 , i.e., to thus contribute to a reduction of axial length of the housing 13 and hence of the entire torque converter 1 . The arrangement can be such that the left-hand side of the mass 8 need not even extend to the plane of the leftmost portion of the shell 4 . The illustrated mass 8 is at least substantially coplanar with and spacedly surrounds the heads of the threaded fasteners 2 a . This is made possible because the central portion of the shell 4 is also recessed in a direction away from the torque transmitting member or disc 6 .
Each projection 7 has a stud-shaped extension 7 a which is recessed into the mass 8 ; for example, each stud 7 a can be provided with an external thread mating with a complementary internal thread in the respective tapped bore or hole of the mass 8 . Alternatively, and if the projections 7 are to serve solely as a means for centering (or as a means for assisting the centering) of the mass 8 on the disc 6 , these projections can be welded or otherwise more or less permanently affixed to the mass.
The means for holding the torque converter against axial movement relative to the disc 6 includes a ring-shaped support here shown as a bayonet lock 9 having openings 9 a for entry of tips (free end portions) of the projections 7 in one (non-locking) angular position of the bayonet lock. The latter is thereupon turned so that its fork-shaped or stud-shaped holding members 9 c enter complementary openings 7 b of the projections 7 . Blocking devices 9 d in the form of snap fasteners on the bayonet lock 9 then enter complementary openings 6 c by snap action. In order to prevent accidental separation of the bayonet lock 9 from the disc 6 , the peripheral portion of the member 9 is provided with an annular array of axially extending resilient tongues 9 c which engage adjacent portions of the peripheral surface of the disc 6 .
It is within the purview of the present invention to employ a starter gear (not shown) which is affixed to the disc 6 or to the mass 8 , or which forms part of the member 6 or 8 . Furthermore, the mass 8 and/or the disc 6 can be provided with a customary arrangement of indicia (e.g., in the form of notches) which can be monitored by means serving to control the operation of the combustion engine including the shaft 2 . Alternatively, such indicia can be provided on a discrete part (not shown) which is affixed to the disc 6 or to the mass 8 .
The fastener assembly 10 is shown in greater detail in FIGS. 4 and 5 . As already mentioned hereinbefore, this assembly serves to separably connect the torque transmitting disc 6 with the torque converter 1 . FIG. 4 is a fragmentary front elevational view of the fastening assembly 10 as seen in the direction of the arrow IV in FIG. 1 , and FIG. 5 is a sectional view as seen in the direction of arrows from the arcuate line V—V shown in FIG. 4 . As can be seen in FIG. 4 , the bayonet lock 9 is affixed to the axially elastic torque transmitting disc 6 (e.g., a body made of a suitable metallic sheet material). The tensioning or holding forks 9 c (only one shown in each of FIGS. 4 and 5 ) extend circumferentially of the bayonet lock 9 ; for example, this bayonet lock can be provided with at least three forks 9 c with pairs of prongs 9 c ′, 9 c ″ bent out of the plane of the major part or body of the bayonet lock so that the prongs are spaced apart from and parallel to one side of the major part. The prongs 9 c ′, 9 c ″ flank the tip 7 c of the respective projection 7 and extend into the respective opening 7 b.
FIG. 4 shows one of the forks 9 c of the bayonet lock 9 in full engagement with the tip 7 c of the respective projection 7 , i.e., the tip 7 c prevents any further angular movement of the bayonet lock relative to the torque transmitting disc 6 . The projection 7 is urged into the respective complementary opening 6 b of the disc 6 so that the peripheral surface of this projection is in frictional engagement with the surface bounding the opening. A detent including a snap fastener tongue 9 d extends into the opening 6 c of the disc 6 so that the parts 6 and 8 are releasably locked against angular movement relative to each other. It will be noted that proper assembly of the disc 6 with the housing 13 merely necessitates a slight turning of the parts 6 , 8 relative to each other as soon as the projections 7 are received in the complementary openings 6 b ; this is much simpler and less time-consuming than the conventional procedures which normally involve the utilization of a set of screws or bolts and nuts which are individually applied to secure the disc 6 or an equivalent thereof to the housing of the torque converter.
The mode of utilizing the fastening assembly 10 is as follows: The torque converter 1 is assumed to be properly assembled with the change-speed transmission including the input shaft 3 . In order to mount the transmission on the output shaft 2 of the engine, the projections 7 are inserted into their respective complementary openings 6 b . An auxiliary tool 11 (shown in FIG. 4 by phantom lines and preferably constituting a suitably configurated piece of metallic sheet material) is employed to thereupon turn the bayonet lock 9 relative to the disc 6 until the extension 9 d terminates such turning in that it enters the opening 6 c . A similar tool can be employed to initiate a disengagement of the disc 6 from the projections 7 of the mass 8 and housing 13 ; such tool is utilized to lift the snap fastener 9 d out of the opening 6 c and to thus release the housing 13 for angular movement relative to the disc 6 , i.e., the bayonet lock 9 is disengaged from the tips of the projections 7 .
An advantage of the just described undertakings involving a connection of the housing 13 (i.e., of the torque converter 1 ) to the disc 6 (i.e., to the output shaft 2 ) and a disengagement of the housing from the disc is that such procedures can be carried out without necessitating the provision of any additional space in the direction of the axis X—X. Another advantage of such mounting of the housing 13 on the disc 6 and shaft 2 is that rotation of the bayonet lock 9 relative to the reinforced radially outermost portion 6 a of disc 6 results in simultaneous locking of all projections 7 in the respective openings 6 b of the disc without necessitating any repeated turning of the shaft 2 . This is in contrast with conventional procedures which involve the utilization of several screws, bolts and nuts or like threaded fasteners. Thus, in order to remove all of the threaded fasteners, it is necessary to repeatedly index a conventional torque converter in order to move successive threaded fasteners to a position in which they can be reached by a wrench or another suitable tool.
A single turning of the bayonet lock 9 relative to the disc 6 and housing 13 releases all of the fasteners 7 for withdrawal from the respective openings 6 b of the disc 6 , or such single turning effects a retention of all fasteners in their respective openings; this feature alone contributes to substantial savings in time during mounting of the torque converter 1 on or during its separation from the disc 6 and shaft 2 . Though it is possible to remove all of the threaded fasteners of a conventional connection between the torque converter and the output shaft of an engine without repeatedly turning the shaft and/or the housing of the torque converter, this is possible only if the fully installed conventionally mounted torque converter provides access to several nuts or screws without any changes in its angular position; this can be achieved only by resorting to a pronounced increase of the combined axial length of the engine and the torque converter.
The bayonet lock 9 can be made of a metallic or plastic sheet material, e.g., of a plastic material which is reinforcd with carbon filaments and/or with other suitable reinforcing or stabilizing materials.
As can be seen in FIG. 5 , the forks 9 c (only one shown) of the bayonet lock 9 can also serve to accurately center the housing 13 of the torque converter 1 (such housing is rigid with the fasteners 7 and the mass 8 ) on the disc 6 in that the prongs 9 c ′, 9 c ″ (see FIG. 4 ) of the forks can engage the neck of the respective fastener without any play when the detent 9 d snaps into the adjacent recess 6 c of the disc 6 . As also shown in FIG. 5 , the extension 7 a of the fastener 7 shown therein is received in the mass 8 without play. The bayonet lock 9 cooperates with the fastener 7 to properly center the mass 8 relative to the disc 6 .
It is clear that the fastener assembly 10 or an equivalent thereof can be utilized with advantage in many conventional power trains to non-rotatably but releasably secure two or more parts to each other. For example, such assembly can be utilized in many conventional power trains to secure a torque converter or a friction clutch to the output element of an engine or another prime mover; such conventional power train need not embody any other features of the torque converter which is disclosed in the present application. Furthermore, the improved fastener assembly 10 can be utilized to mount and center a friction clutch on the input shaft of a change-speed transmission in a power train wherein the clutch is employed in lieu of a torque converter. Still further, the disc 6 can be replaced with a rigid disc which does not permit any or any appreciable axial movements of the housing 13 relative to the output shaft 2 . The illustrated axially yieldable resilient disc 6 is preferred in many instances because it is capable of damping at least some stray movements of the shaft 2 and housing 13 relative to each other in the direction of the axis X—X as well as at least some wobbling movements relative to such axis.
The torque converter 1 further comprises a pump or impeller 12 which is coaxial with and shares the angular movements of the shell 5 , a turbine 14 which is disposed in and is rotatable with as well as relative to the housing 13 , and preferably also a stator 16 which is installed between the pump 12 and the turbine 14 (as seen in the direction of the axis X—X). The turbine 14 is rotated by the body of oil or other suitable hydraulic fluid in the housing 13 when the latter rotates with the pump 12 in response to rotation of the output shaft 2 . The turbine 14 is non-rotatably connected with a rotary output member 15 (hereinafter also called hub) which is non-rotatably connected to the input element 3 by an internal gear 3 a.
The stator 16 can influence the transmitted torque and is mounted on a freewheel 16 a which surrounds the input shaft 3 of the transmission. An important function of the stator 16 is to improve the circulation of fluid in the housing 13 . FIG. 1 shows that the stator 16 is flanked by two distancing members 16 b , 16 c ; the member 16 b is mounted on a suitable bearing 16 d (e.g., a friction bearing which is adjacent and can rotate relative to the radially innermost portion of the shell 5 ), and the member 16 c is adjacent an annular arrangement of lobes 16 e at the right-hand axial end of the hub 15 . This hub has an axial extension 15 a separated from the radially innermost portion of the shell 4 by a friction bearing 15 d.
The torque converter 1 further comprises a bypass clutch 17 which can be engaged to transmit torque directly between the shell 4 of the housing 13 (i.e., directly from the output shaft 2 ) and the hub or output member 15 . To this end, the bypass clutch 17 employs a member 19 which acts as a piston in that it can be moved axially of the housing 13 in order to place its annular friction surface 19 a into or away from engagement with the confronting annular friction surface 4 a of the shell 4 . A friction lining 20 can be affixed to the radially outermost portion of the piston 19 or to the shell 4 to define the friction surface 19 a or 4 a and to constitute or establish a force-locking connection between the piston 19 and the housing 13 .
A torsional vibration damper 18 is installed in the power flow between the housing 13 and the hub 15 downstream of the bypass clutch 17 . The piston 19 of the clutch 17 is movable axially of the housing 13 along the axial extension 15 a of the hub 15 into and away from abutment with a radially extending axial stop 15 b.
The friction lining 20 is optional; it can be utilized in order to enhance the friction coefficient of the bypass clutch 17 and can be glued, riveted or otherwise affixed to the piston 19 or to the shell 4 of the housing 13 . It is also possible to employ two friction linings, one on the piston and the other on the shell 4 . That side or surface of the friction lining 20 which constitutes the friction surface 4 a or 19 a can be profiled (such as ribbed) to promote the cooling of the bypass clutch 17 in actual use. The profiling can be such that it allows for a controlled flow of coolant between two chambers 21 and 22 ; such coolant is or can be the hydraulic fluid which causes the turbine 14 to rotate in response to rotation of the pump 12 during certain stages of operation of the torque converter 1 . Cooling of the bypass clutch 17 is particularly important when the clutch operates with slip, i.e., when the surfaces 4 a , 19 a bear against and slide relative to each other. The arrangement is preferably such that the chambers 21 , 22 are at least substantially sealed from each other when the clutch 17 is fully engaged, i.e., when the piston 19 is driven by and at the speed of the shell 4 ; at such time, the only flow of fluid between the chambers 21 , 22 is that permitted by the profiling of the friction surface 4 a and/or 19 a.
The collar constituting the radially innermost portion of the piston 19 is sealed against the peripheral surface of axial extension 15 a of the hub 15 by an annular sealing element 15 c , e.g., a split ring or the like.
In order to engage the bypass clutch 17 , the chamber 21 receives hydraulic fluid from a suitable pump or another fluid source (not shown) through a channel 21 a provided in the input shaft 3 of the change-speed transmission and in the non-illustrated transmission case within the tubular neck 5 a (radially innermost portion) of the shell 5 ; such neck 5 a is in sealing engagement with the transmission case in a manner not shown in FIG. 1 because it forms no part of the present invention. The shell 5 receives the pump or impeller 12 and at least a portion of the non-rotatable stator 16 . The distancing member 16 c is provided with one or more axially parallel openings 21 b in the form of bores which can convey pressurized fluid in order to establish a pressure differential between the interiors of the chambers 21 and 22 ; such pressure differential causes the piston 19 to move axially into selected or desired or required frictional engagement with the shell 4 (i.e., with the housing 13 ). The frictional engagement entails an operation of the bypass clutch 17 without slip or with a required slip.
The pressure of fluid in the chamber 22 is caused to increase when the bypass clutch 17 is to be disengaged or to operate with a reduced slip. This is achieved by causing the chamber 22 to receive pressurized fluid along a path defined, for example, in part by a channel or bore in the input shaft 3 and at least one channel or bore in the profiled friction bearing 15 d between the radially innermost portion of the shell 4 and the axial extension 15 a of the hub 15 . The pressure of fluid in the just mentioned path is established by a pump (not shown) or another suitable source of pressurized fluid and must suffice to ensure that the pressure in the chamber 22 rises above that in the chamber 21 so that the piston 19 is shifted axially toward the turbine 14 , i.e., that the friction surface 19 is at least partially disengaged from the friction surface 4 a.
The piston 19 of the bypass clutch 17 can be permanently biased in one of the two axial directions (toward or away from the turbine 14 ); this ensures that, when the pressure of fluid in the chamber 21 or 22 matches or closely approximates that of fluid in the chamber 22 or 21 , the clutch 17 is automatically engaged or fully disengaged, depending upon the direction of uninterrupted axial stressing of the piston 19 .
The torsional vibration damper 18 is installed in the power flow between the output shaft 2 and the hub 15 (by way of the fastener assembly 10 and housing 13 ) and is active in the engaged condition of the bypass clutch 17 . The damper 18 comprises an input 24 which is connected with the piston 19 of the bypass clutch 17 , an output 25 which is connected with the hub 15 (in some instances with a certain freedom of angular movement), and energy storing means including (in the embodiment of FIGS. 1 to 5 ) an annular array of eight equidistant coil springs 26 serving to oppose angular movements of the input 24 and output 25 relative to each other. The number of coil springs 26 (or of other suitable energy storing elements) can be reduced to one, two, three and so on, or increased to nine or more.
Each spring 26 is received in a radial recess or window 27 (see FIG. 2 ) at the periphery of the input 24 , and each such recess is flanked by two radially outwardly extending arms 36 of the input. The springs 26 can be prestressed, i.e., the arms 36 can cause these springs to store energy even when the input 24 and the output 25 are permitted or caused to assume neutral positions in which the output does not influence the stressing of such springs. The output 25 has entraining portions 28 which can engage the end convolutions 26 a of the adjacent coil springs 26 to cause the springs to store additional energy in response to angular movement of at least one of the input 24 and output 25 from its starting or neutral position in which the springs 26 are or can be only prestressed, namely caused to store only that energy which is imparted thereto by the respective pairs of arms 36 .
The entraining portions 28 are disposed at the periphery of the output 25 and are obtained by removing material from the output at a radial distance from the axis X—X corresponding to that between the axis and the recesses 27 of the input 24 . In order to increase the areas of contact between the entraining portions 28 and the adjacent end convolutions 26 a of the respective coil springs 26 , such entraining portions can be bent in a manner best shown at 28 a in the upper half of FIG. 1 and in FIG. 3 , i.e., the radii of curvature of the bent ends 28 a can match or approximate the radii of the convolutions 26 a . The same applies for the radially outermost portions of the arms 36 of the input 24 , i.e., such radially outermost portions can be bent in the same way as the parts 28 a so as to establish a larger-area contact with the adjacent end convolutions of the respective coil springs 26 .
In order to hold the coil springs 26 against excessive movements radially outwardly under the action of centrifugal force while the input 24 and the output 25 rotate about the axis X—X, the damper 18 preferably includes at least one wire ring 29 which is surrounded by the convolutions 26 a of all eight coil springs 26 (see FIG. 2 ). The position of the ring 29 is determined by locating projections 36 a (see FIGS. 2 and 3 ) which constitute suitably bent portions of the input 24 and engage the ring 29 from within to thus select and determine the extent to which the coil springs 26 can move radially outwardly under the action of centrifugal force when the input 24 rotates. Thus, once the torque converter 1 is assembled and installed between the shafts 2 and 3 , the position of the ring 29 is fixed by the locating projections 36 a of the input 24 . It is preferred, that the locating projections 36 a further serve to fix the position of the ring 29 in the axial direction of the housing 3 .
FIG. 3 shows that the inner diameters D of the convolutions 26 a (i.e., the diameter of the compartment or space 26 b surrounded by the convolutions 26 a of a coil spring 26 ) can equal or approximate 2 d wherein d is the diameter of the wire of which the ring 29 is made. It is presently preferred to employ a wire having a diameter d which is slightly greater than one half of the inner diameter of a convolution 26 a . The ends of this wire can be welded (at 29 a ) to each other. Alternatively, one of these ends can be provided with a hook (not shown) and the other end can be provided with an eyelet for the hook; such solution is preferred if it is anticipated that the ring 29 will necessitate replacement or temporary removal during the useful life of the torque converter 1 . The wire of the ring 29 can be bent to resemble its utimate shape (shown in FIG. 2 ) prior to causing it to pass through the internal spaces 26 b of the coil springs 26 .
The locating projections 36 a of the input 24 can be provided with slits 36 c (shown in each of FIGS. 2 and 3 ) which reduce the stiffness of the arms 36 as seen in the axial direction of the input 24 . The ratio of d to D is or can be determined by the relationship or equation 0.8*D>d>0.2*D, preferably 0.6*D>d>0.3*D. The arrangement can be such that the wire of the ring 29 contacts the convolutions 26 a of the coil springs 26 at its radially innermost as well as at its radially outermost portions. In all instances D> d and preferably D>d>0.25 D, most preferably 0.66D>d>0.25D. As concerns the diameter of the ring 29 , it is preferably selected in such a way that this ring contacts the radially innermost portions of the convolutions 26 a of all coil springs 26 when the ends of the wire of the ring 29 are secured to each other at 29 a . In other words, and as shown in FIGS. 2 and 3 the ring 29 can be dimensioned to ensure that the springs 26 have a minimal radial clearance or play s (see FIG. 3 ) relative to the surfaces 27 a surrounding the radially outermost portions of the recesses 27 . Such dimensioning of the ring 29 reduces the likelihood of excessive wear upon the coil springs 26 due to engagement with the input 24 during compression of the springs as a result of turning of the input relative to the output 25 and/or vice versa.
The input 24 of the damper 18 is affixed to the piston 19 of the bypass clutch 17 at points established by a circular array of rivets 30 . The shanks of such rivets extend through openings 36 b which are provided in the arms 36 of the input 24 radially outwardly of the coil springs 26 . The output 25 has an internal gear 31 mating with an external gear (spur gear) on the extension 15 a of the hub 15 . These mating internal and external gears preferably mesh with a certain play to ensure that the output 25 is mounted on the axial extension 15 a with a certain angular play. In other words, the mating gears of the output 25 and extension 15 a ensure that the damper 18 becomes effective with a certain delay.
The extent of angular movability of the input 24 and output 25 of the damper 18 is determined by the rivets 32 ( FIG. 1 ) each of which is rigidly affixed to the input 24 and each of which extends into an arcuate circumferentially extending slot 33 of the output 25 . The lengths of the slots 33 (as seen circumferentially of the radially inner portions of the input 24 and output 25 ) determine the extent to which the input and the input can turn relative to each other about the axis X—X of the housing 13 .
The slots 33 and the rivets 32 can be omitted if the torsional vibration damper 18 is set up to limit the extent of angular movability of the input 24 and output 25 relative to each other solely under the action of coil springs 36 . Thus, the angular movability of the input 24 and output 25 relative to each other from their neutral positions can be terminated when the convolutions of at least one of the coil springs 26 come into actual abutment with each other, i.e., when the at least one coil spring 26 begins to act as a solid block. In such instance, the convolutions 26 a of the coil springs 26 can be provided with jackets or coats of a suitable elastomeric material.
FIG. 1 further shows a safety ring 34 which is disposed between the left-hand heads of the rivets 32 and the adjacent side of the output 25 ; the purpose of the safety ring 34 (the illustrated safety ring is a flat annular disc resembling a washer) is to prevent penetration of the left-hand heads of the rivets 32 into the respective arcuate slots 33 of the output 25 .
The input 24 and the output 25 of the damper 18 are urged apart in the axial direction of the housing 13 by additional resilient means 35 shown in FIG. 1 in the form of a membrane- or diaphragm (Belleville) spring which urges the output against the safety ring 34 . This resilient means 35 opposes angular movements of the input 24 and output 25 relative to each other while the parts 24 , 25 move in directions to stress the coil springs 26 as well as while the springs 26 are permitted to dissipate some energy.
The illustrated torsional vibration damper 18 can be utilized with advantage in many types of torque converters, i.e., not only in those shown in the drawing and described in the specification of the present application. Furthermore, the torque converter 1 can employ several torsional vibration dampers, for example, the damper 18 and a second damper between the turbine 14 and the hub 15 .
The rivets 30 connect the piston 19 of the bypass clutch 17 with the arms 36 radially outwardly of the plate-like central portion or body 24 a of the input 24 . The arms 36 can be pivoted relative to the body 24 a , i.e., the rivets 30 can move (within limits) relative to the body 24 a in the axial direction of the housing 13 . FIG. 2 shows that the surfaces bounding each recess 27 can be disposed at least substantially at right angles to each other. Each arm 36 of the input 24 shown in FIG. 2 has a trapezoidal shape and tapers radially inwardly toward the center of the input body 24 a . This ensures that the rigidity of each arm 36 decreases radially inwardly toward the junction with the body 24 a . In other words, the flexibility of each arm 36 decreases in a direction toward the axis X—X. Such arrangement is desirable because it reduces the likelihood of breakage of the arms in the regions of the rivets 30 , especially due to fatigue in response to axial and/or other stressing during repeated engagement and disengagement of the bypass clutch 17 as well as while the bypass clutch is at least partly engaged. Still further, such configurations of the arms 36 exert a positive influence upon the piston 19 of the bypass clutch 17 , especially in the regions of the rivets 30 .
It is also within the purview of the present invention to provide the arms 36 with slots extending from the respective openings 36 b toward or to the body 24 a of the input 24 to thus enhance the elasticity of the input. Analogously, the piston 19 can be provided with slots extending radially outwardly to the rivets 30 to thus enhance its elasticity and to prolong its useful life. The provision of locating projections 36 a which constitute bent portions of the arms 36 also contributes to flexibility of the respective (radially inner or inner-most) portions of such arms.
The piston 19 need not be directly connected with the input 24 ; for example, the bypass clutch 17 or an equivalent thereof can comprise a washer or an analogous part which is rigid with the input and is connected to the piston 19 with limited freedom of axial movement, e.g., due to elasticity of the piston and/or washer.
Furthermore, the torque converter 1 can comprise two or even more dampers, e.g., the damper 18 and a second damper between the turbine 14 and the hub 15 of the torque converter. The arrangement is or can be such that, when the bypass clutch 17 is engaged, torque can be transmitted directly from the housing 13 to the hub 15 so that the pump 12 and the turbine 14 are bypassed. On the other hand, when the bypass clutch 17 is disengaged, torque is transmitted from the housing 13 , through the pump 12 , body of hydraulic fluid in the housing 13 and turbine 14 on to the hub 15 . The transmission of torque from the housing 13 to the hub 15 can take place along two paths if the bypass clutch is only partly engaged, i.e., when the piston 19 frictionally engages but is free to slide relative to the shell 4 of the housing 13 . An advantage of the torque converter 1 is that a single torsional vibration damper 18 suffices to damp vibrations of torque regardless of whether such torque is being transmitted only via pump 12 , only via bypass clutch 17 , or along each such path.
The ring 29 exhibits the advantage that it renders it possible to achieve substantial savings in space in the axial and radial directions of the torque converter 1 . This will be readily appreciated by taking into consideration that the ring 29 occupies space (within the coil springs 26 ) which would otherwise remain unoccupied. Moreover, the ring 29 does not interfere with confinement of springs 26 in discrete recesses 27 between the radially outwardly extending arms 36 of the input 24 . The properly installed ring 29 can be held against undesirable stray movements in any desired direction such as radially outwardly, radially inwardly and/or axially of the input 24 . The locating projections 36 a constitute but one of several means which can be utilized to prevent stray movements of the ring 29 . The provision of projections 36 a and of their slits 36 c exhibits the advantage that they contribute to axial flexibility or yieldability of the input 24 (i.e., more than separately produced projections which are welded to the input 24 radially inwardly of the ring; such separately produced projections would actually increase the rigidity of the input 24 ).
The arms 36 are or can be configurated to ensure that they can cooperate with the portions 28 a of the output 25 to properly engage and stress commercially available coil springs. Thus, the confronting edge faces of neighboring arms 36 are or can be parallel to each other.
It is within the purview of the present invention to provide the projections 7 on the disc 6 and to provide the openings 6 b in the mass 8 or in another part of or borne by the housing 13 . The same holds true for the interchangeability of positions of the snap fastener 9 d and the opening or openings 6 c . Such snap fastener permits, if and when necessary, for convenient detachment of the torque converter 1 from the shaft 2 . It is also possible to employ snap fasteners in the form of splints which can enter openings in the projections 7 by snap action and/or otherwise.
FIGS. 6 and 7 illustrate the torsional vibration damper 118 and the piston 119 of a modified torque converter. The piston 119 is secured to the input 124 of the damper 118 by an annular array of rivets 130 . The input 124 comprises two walls 124 b , 124 c which flank the output 125 of the damper 118 and the marginal portion of each of which is secured to the piston 119 by the rivets 130 . Such rivets are located radially outwardly of the friction surface 119 a of the piston 119 .
The marginal portions of the walls 124 b , 124 c of the input 124 are not profiled, i.e., they are not provided with radial extensions corresponding to the arms 36 of the input 24 . However, and in order to ensure adequate elasticity (axial flexibility) of such walls, their plate-like central bodies 124 a ′, 124 a ″ are partially separated from the rivet-receiving marginal portions 136 a by suitably configurated stiffness-reducing windows or slits 137 and 138 , respectively. Additional cutouts or slits can be provided to enhance the flexibility of certain other portions of the plate-like body 124 a ′ and/or 124 a ″. Each of the illustrated stiffness-reducing slits 137 , 138 is substantially U-shaped and partially surrounds the respective rivet 130 . The central portions of the slits 137 , 138 are narrower than their end portions, and such end portions are or can be located at the same radial distance from the axis of the damper 118 as the rivets 130 .
The walls 124 b , 124 c of the composite input 124 (as well as the plate-like body or wall 24 a of the input 24 of the damper 18 ) are preferably made by resorting to a deep drawing, stamping of pressing (molding) technique. It is often advisable to provide the slits 137 , 138 in the blanks which are to be converted into the walls 124 b , 124 c prior to the final shaping procedure, i.e., prior to imparting to these walls configurations (curvatures) corresponding to those shown in FIG. 6 , e.g., by resorting to a potting or an analogous technique. This simplifies the formation of slits 137 , 138 because these slits can be formed in the blanks for the walls 124 b , 124 c while the blanks are still flat.
FIG. 7 shows that the slits 137 are closed at their ends, i.e., that they do not extend all the way to the peripheral surface of the wall 124 b . The same applies for the windows or slits 138 in the wall 124 c . On the other hand, FIG. 8 illustrates a modification wherein one end portion of the slit or recess or window 137 is open, i.e., such open end portion extends radially outwardly beyond the rivet 130 and all the way into the peripheral surface of the illustrated input wall 224 b . This results in the making of a tongue 236 which extends circumferentially of the wall 224 b and is secured to the piston 119 of the associated bypass clutch by the illustrated rivet 130 . An advantage of the structure which is shown in FIG. 8 is that the wall 224 b and the tongue 236 are movable relative to each other axially (i.e., at right angles to the plane of FIG. 8 ) and that the tongue 236 can also have a certain freedom of radial movement relative to the common axis of the wall 224 b and piston 119 .
Referring again to FIGS. 6 and 7 , the composite input 124 a + 124 b and the output 125 of the damper 118 can turn relative to each other about their common axis under the bias or against the opposition of energy storing means including an annular assembly of coil springs 126 . Each coil spring 126 is a composite coil spring in that it includes an outer spring 126 a and an inner spring 126 b confined in the respective outer spring. The springs 126 a are received in windows 127 a , 127 b of the walls 124 b , 124 c and in windows 128 provided in the output 125 . When the input 124 a , 124 b and the output 125 are caused to turn relative to each other, the radially extending surfaces flanking the windows 127 a , 127 b , 128 bear upon the end convolutions of and stress the respective composite coil springs 126 .
The reference characters 129 a , 129 b denote flaps or extensions respectively provided on the walls 124 b , 124 c of the composite input to limit the extent of movability of the composite coil springs 126 radially outwardly, e.g., under the action of centrifugal force. The shapes of the radially inwardly facing surfaces of the flaps 129 a , 129 b preferably conform or substantially conform to the adjacent portions of external surfaces of convolutions forming part of the larger-diameter coil springs 126 a.
The extent of angular movability of the input 124 b , 124 c and the output 125 of the damper 118 relative to each other is determined by a projection 139 constituting a substantially axially depressed portion of the wall 124 c and received in a recess 133 of the output 125 . The length of the recess 133 (as seen in the circumferential direction of the damper 118 ) determines the extent of angular movability of the input 124 b , 124 c and output 125 relative to each other; this recess is longer than the projection 139 (again as seen in the circumferential direction of the damper).
The damper 118 can be provided with two or more circumferentially spaced apart projections 139 and with an equal nuber of recesses 133 , one for each projection 139 . Furthermore, similar or analogous means for limiting the angular movements of the input and output of the torsional vibration damper relative to each other can be employed in the torque converter 1 of FIGS. 1 to 5 as well as in other torque converters which are described and shown in the specification and drawing of the present application. Still further, similar means for limiting angular movements of two or more parts which are turnable relative to each other about a common axis and whose turnability must be limited with a high degree of accuracy and reliability can be employed in conventional torque converters or in numerous other apparatus.
The projection 139 of the wall 124 c can be replaced with a part (such as a tongue or pin or the like) which is a separately produced element and is welded or otherwise affixed to the wall 124 c.
FIG. 6 further shows a resilient energy storing element or device 135 which is a diaphragm spring or a membrane and serves to bias the wall 124 b axially and away from the output 125 , i.e., away from the wall 124 c . The means for ensuring that the diaphragm spring 135 shares the angular movements of one of the input 124 b , 124 c and output 125 relative to the other of these components of the damper 118 comprises a tongue 135 a provided on the diaphragm spring 135 and extending into one of the recesses 133 or into a discrete recess or window 133 a of the output 125 . Thus, the diaphragm spring 135 is compelled to share all angular movements of the output 125 relative to the input 124 b , 124 c.
The diaphragm spring 135 further serves as a means for yieldably opposing turning of the input 124 b , 124 c and output 125 relative to each other. If the damper 118 is to permit a certain amount of angular movement of the input 124 b , 124 c and output 125 relative to each other, the opening 133 a is dimensioned to receive the tongue 135 a of the diaphragm spring 135 with a preselected amount of play in the circumferential direction of the damper 118 . Such arrangement ensures that the friction between the diaphragm spring 135 and the input 124 b , 124 c and/or output 125 becomes effective with a preselected delay following initial angular displacement of the input and output relative to each other. Such delayed friction can be resorted to in the damper 118 as well as in the damper 18 and in other dampers which can be utilized in torque converters embodying the present invention.
The slots 137 and/or 237 can be formed in the blanks which are thereupon converted into the input wall 124 b or 224 b by resorting to a stamping procedure. However, it is also possible to provide such slots in a partly finished (shaped) wall 124 b or 224 b . Still further, it is possible to provide the blanks which are to be converted into the walls 124 b and/or 224 b with simple slits and to thereupon deform (such as selectively widen) these slits during certain stages of conversion (shaping) of blanks into finished walls 124 b and/or 224 b . This can be readily achieved by providing the slits in those portions of a blank for the wall 124 b or 224 b which are thereupon flexed, upset and/or otherwise curved as can be seen, for example, in the region of the slot 137 in the upper portion of FIG. 6 .
FIG. 9 shows a damper 318 which is similar to the damper 118 of FIGS. 6 and 7 . The wall 324 b of the input 324 of the damper 318 is non-rotatably affixed to the piston 119 of a bypass clutch by rivets 130 occupying an annular array of points or locations as seen in the circumferential direction of the radially outermost (marginal) portion of the piston. The wall 324 b of the input 324 is provided with slots or windows 337 a which are not identical with the slots or windows 337 b provided in the other wall (not shown in FIG. 9 ) of such composite input. The other wall of the input 324 is located behind the wall 324 b . The reason for differences between the slots 327 a and 327 b is that, under certain circumstances, axial flexibility of one wall of the input should deviate from that of the other wall, especially if the two walls are not identical. It has been found that the flexibility of the walls forming part of an input should depend or preferably depends upon their dimensions and/or other parameters.
In FIG. 9 , the slots 337 a are longer (as seen circumferentially of the piston 119 ) than the slots 337 b . In other words, axial flexibility of the flaps 336 a forming part of the wall 324 b exceeds that of the flaps on the other wall of the input 324 .
FIG. 10 illustrates a portion of an input 424 forming part of a damper resembling the damper 118 of FIGS. 6 and 7 . In order to enhance axial flexibility in the regions between the central portion of the disc or wall 424 a and the radial arms 436 which are flanked by the slots 437 , the radially outer ends of these slots are open, i.e., they extend all the way to the peripheral surface of the disc 424 a . In addition, each slot 437 a extends substantially exactly radially inwardly and has an enlarged radially innermost portion bounded by a circular surface. The openings 130 a are provided in the arms 436 and serve to receive rivets (not shown) which secure the disc 424 a to the other disc or wall (not shown) of the input 424 . The openings 130 a are or can be provided midway or substantially midway between the neighboring keyhole-shaped slots 437 .
An advantage of the input 424 of FIG. 10 is that it permits often desirable and necessary wobbling vibratory movements of the disc 424 a relative to the output (not shown) of the damper in the torque converter embodying the structure of FIG. 10 . Thus, neighboring arms 436 of the wall 424 a have a limited freedom of movement in a direction at right angles to the plane of FIG. 10 . This reduces the likelihood of development of excessive stresses in the torque converter embodying the structure of FIG. 10 . Excessive stresses could cause cracking of the disc or wall 424 a in the regions of the openings 130 a.
An advantage of keyhole-shaped recesses or slots 437 is that one avoids the formation of pronounced severed or stamped edges. Moreover, the likelihood of fatigue in regions where the arms 436 are repeatedly flexed relative to the central portion or wall 424 a of the input 424 is remote, and the same holds true as concerns the development of cracks at the radially inner ends of the keyhole-shaped recesses 437 . Similar results can be obtained if the sharply defined corners 36 f of the recesses 36 shown in FIG. 2 are replaced with much less or at least somewhat less pronounced corners bounded by concave edge faces of the central portion 24 a and the arms 36 of the input 24 .
FIG. 11 illustrates a portion of an input 524 having a disc or wall 524 a with an undulate peripheral surface bounding an annular array of recesses 537 the length of each of which decreases gradually toward the axis of the damper including the input 524 . The arms 537 a alternate with the recesses 537 and each such arm has an opening 130 a for a rivet (not shown in FIG. 11 ) which secures the disc or wall 524 a to the other disc or wall (not shown) of the input 524 . The radially innermost portions 537 b of the recesses 537 are bounded by concave portions of the peripheral surface of the wall 524 a.
An advantage of the input 524 is that the lengths of the recesses 537 (as measured in the circumferential direction of the input) can equal or even exceed the lengths of the arms 537 a . This even further reduces the likelihood of premature cracking of and/or other damage to the input 524 in response to repeated axial flexing of the arms 537 a and the central portion 524 a relative to each other.
An advantage of arms of the type shown at 36 in FIG. 2 over arms 537 a is that the radially outwardly extending edge faces of the arms 36 can lie flush against the adjacent end convolutions 26 a of the coil springs 26 . Regardless of their exact shapes, the arms of all inputs can be slotted and/or otherwise influenced to increase their flexibility in the axial direction of the respective torsional vibration damper.
FIGS. 12 to 14 illustrate certain features of a further hydraulic torque converter 601 having a housing 613 composed of two partially interfitted shells or walls 604 and 605 . A pump or impeller 612 is installed in and rotates with the shell 605 ; this pump can circulate a body of hydraulic fluid which, in turn, can rotate a turbine 614 extending in part into the interior of the shell 604 . The latter is connected to the output shaft 602 of the prime mover in the power train of a motor vehicle, e.g., without the interposition of a disc corresponding to the disc 2 in the torque converter 1 of FIG. 1 . The housing 613 constitutes the input of the torque converter 601 .
The output element of the torque converter 601 is constituted by or includes a hub 615 having an internal gear 603 a mating with an external gear on the input shaft of the change-speed transmission (not shown in FIGS. 12 to 14 ). The torque converter 601 further comprises a bypass clutch 617 which, when engaged, transmits torque directly between the housing 613 and the hub 615 . When the clutch 617 is disengaged, the transmission of torque takes place from the housing 613 to the hub 615 by way of a torsional vibration damper 618 ; this mode of operation departs from that of the torque converter 1 shown in FIG. 1 .
In order to connect the damper 618 to the turbine 614 , the latter is rotatably mounted on the hub 615 and, to this end, the turbine carries a discrete hub 615 a which is non-rotatably connected with the turbine. The hub 615 a is rotatable on the hub 615 and is sealingly secured thereto by a sealing ring 615 b . A radially extending collar 615 c constitutes an axial stop for the hub 615 a and its radially outermost portion non-rotatably carries the output 625 of the torsional vibration damper 618 . That side of the stop 615 c which faces away from the hub 615 a for the turbine 614 is surrounded by a sleeve constituting the radially outermost portion of the piston 619 which forms part of the bypass clutch 617 . The sleeve of the piston 617 is rotatable on and is movable axially of the hub 615 and surrounds a sealing ring 615 d which is recessed in this hub.
The input 624 of the damper 618 has an internal gear 624 a which mates with a complementary (spur) gear on an axial projection 615 a ′ of the discrete hub 615 a for the turbine 614 . The energy storing means 626 of the damper 618 opposes rotation of the input 624 and output 625 relative to each other, and the input 624 is axially movably connected with the piston 614 of the bypass clutch 617 . It will be noted that the axial projection 615 a ′ is located radially outwardly of the collar 615 c for the output 625 . In accordance with a feature of the invention embodied in the torque converter 601 , the axial rigidity of the input 624 of the damper 618 is pronounced, i.e., an axially yieldable input is replaced with the axially rigid or stiff input 624 and the torque converter 601 further comprises discrete resilient means 637 installed between the input 624 and the piston 619 .
FIG. 13 shows one of the resilient means 637 ; it constitutes a leaf spring which is riveted to the piston at 630 and to the input 624 at 630 a . This leaf spring 630 is but one of an annular array or assembly of such leaf springs which permit limited axial movements of the piston 619 relative to the axially rigid input 624 . Discrete rivets 630 and/or 630 a can be replaced with rivet-shaped formations (displaced portions) of the input 624 and/or piston 619 . The heads of such formations resemble and act as rivet heads; they are anchored in the end portions of the leaf springs 637 .
FIG. 14 shows that the torque converter 601 further comprises at least one axial stop 624 c which serves to maintain the piston 619 at a selected axial distance from the input 624 of the damper 618 ; the illustrated stop 624 c of FIG. 14 is an integral part of the input 624 . It is normally preferred to employ an annular arrangement of several discrete axial stops 624 a . The character 624 d denotes in FIG. 14 a window which is provided in the input 624 and affords access to the rivet 613 . The input 624 is provided with several windows 624 d , one for each of the rivets 630 .
Referring again to FIG. 12 , the output 625 of the damper 618 separates the input 624 from a washer 640 . The radially outer portions of the input 624 and the washer 640 are welded and/or riveted to each other between neighboring springs 626 or radially outwardly of such springs. Each spring 626 is a composite resilient element including an outer coil spring and an inner coil spring which is confined in the outer coil spring. Each such composite coil spring 626 is received in part in one of the windows 627 a provided in the input 624 , in one of the windows 627 b provided in the output 625 , and in one of the windows 628 provided in the washer 640 . Such mounting compels the springs 626 to store energy when the input 624 and the washer 640 are caused to turn relative to the output 625 and/or vice versa.
Friction generating devices 633 anchored in the input 624 and bearing upon the output 625 generate friction when the parts 624 , 625 are caused to turn relative to each other. Each device 633 (only one shown in FIG. 12 ) is or can constitute a leaf spring which is installed to bias the output 625 axially and away from the input 624 and/or vice versa.
The packages 626 of coil springs are held against excessive movement radially outwardly (e.g., under the action of centrifugal force) by abutments 629 a and 629 b respectively provided on the washer 640 or output 625 and input 624 . Each abutment 629 b is shown as an integral part of the input 624 . On the other hand, each abutment 629 a is or can constitute a separately produced part which is affixed to the output 625 or to the washer 640 .
The rivets 630 and/or 630 a can be replaced with screws, bolts and nuts and/or other types of fasteners without departing from the spirit of our invention. The utilization of rivets which are of one piece with the piston 619 or with the input 624 is preferred in many instances because this entails a substantial reduction of the overall number of parts in the torque converter 601 .
The leaf springs 637 can be installed radially inwardly of the springs 626 or at the same radial distance from the axis X—X; in the latter case, the leaf springs 637 can alternate with the springs 636 as seen in the circumferential direction of the damper 618 .
It is also possible to install the damper 618 axially between the housing 613 and the piston 619 or axially between the piston and the turbine 614 (this is actually shown in FIG. 12 ).
The springs of the damper can constitute expansion or compression springs.
FIG. 15 shows a further improved hydraulic torque converter 700 which includes an impeller or pump (not visible in that portion of the torque converter which is shown in FIG. 15 ), a turbine 701 in a housing 703 , and a stator 702 between the pump and the turbine. A torsional vibration damper 704 and a bypass clutch 705 are also provided in the housing 703 . The damper 704 comprises essentially an input composed of two disc-shaped members or walls 706 , 707 having radially outermost portions which are riveted or otherwise affixed to each other and are provided with windows for energy storing elements. A flange-like output 750 of the damper 704 is disposed between the disc-shaped members 706 , 707 of the input and its radially innermost portion is of one piece with an output element or hub 751 ; however, it is equally possible to employ separately produced parts 750 , 751 which are welded or otherwise reliably affixed to each other.
The member 706 of the input of the damper 704 is installed between the turbine 701 and the output 750 and is connected with (such as riveted to) an adapter 752 having an internal gear 708 mating with a spur gear 755 of the hub 751 with a certain play at least matching the maximum required angular movability of the input 706 , 707 and output 750 of the damper 704 relative to each other.
A hub 760 is connected with a casing 701 a of the turbine 701 , e.g., by welding, by rivets or by resorting to a friction fit. That side of the hub 760 which confronts the damper 704 is provided with axially parallel extensions 761 (e.g., with an annular arrangement of equidistant extensions) which are received in complementary recesses 762 of the adapter 752 , preferably at least substantially without play. The adapter 752 serves to connect the turbine 701 with the disc or wall 706 of the input of the damper 704 , i.e., the latter is mounted to damp vibrations of the turbine as well as vibrations of the bypass clutch 705 . It is to be noted that the turbine hub 760 is turnable relative to the hub 751 .
The adapter 752 is connected to the part 706 of the input of the damper 704 by two annuli of rivets. The outer annulus includes rivets 770 , and the inner annulus includes rivets 771 . The arrangement can be such that the rivets 770 are offset relative to the rivets 771 in the circumferential direction of the adapter 752 ; this reduces the tensional stresses between the adapter and the input 706 , 707 of the damper 704 .
An advantage of the adapter 752 is that it can be utilized to connect any one of several types of dampers with any one of several types of turbines, i.e., it is possible to select (for use in the torque converter 700 or in another torque converter) any one of several types of torsional vibration dampers and any one of several types of turbines by resorting to the building block construction principle of FIG. 15 .
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 and specific aspects of the above outlined contribution to the art of torque converters and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the appended claims.
|
A hydraulic torque converter, particularly for use in a motor vehicle between the prime mover and the transmission of the power train, employs a combination of a bypass clutch with one or more torsional vibration dampers which brings about savings in space and/or in the number of parts. In addition, the torque converter can stand long periods of use and is less prone to wear, adverse influences of abruptly developing stresses and/or other undesirable influences than conventional torque converters. Furthermore, the improved torque converter employs or can employ a bypass clutch and/or one or more torsional vibration dampers simpler and less expensive than but superior to those in conventional torque converters.
| 5
|
RELATED APPLICATION
The present invention is related to co-pending design Application Ser. No. (Attorney Docket No. 1025.1.002), entitled "CONTAINER FOR BARBEQUE GRILL CLEANING DEVICE," filed herewith, which has the same inventorship as the present invention.
FIELD OF THE INVENTION
The present invention is related to barbeque grill cleaning devices, and more particularly to such devices which are handheld.
BACKGROUND OF THE INVENTION
Preparing food by barbequing has become increasingly popular over the years. As is well known, the grill of a barbeque is formed of spaced parallel metal rods that support the food being cooked over a source of heat. Over a period of time sufficient residue from the food becomes baked onto the rods to require cleaning that is often difficult.
A number of devices for cleaning the rods of a grill have been made available. Some of them provide a scraping action, such as by a wire brush, but according to manufacturers of grills they can damage the rods. Other devices use a brush with bristles of plastic that do not damage the rods but which cannot be used when the rods are hot thus making the cleaning difficult. Furthermore, a bristle of any kind can be retained on a rod so as to contaminate the next batch of food that is cooked. Alternatively, the rods of the grill can be sprayed with a cleaning agent, but this is expensive, messy, and possibly unsafe for the environment.
SUMMARY OF THE INVENTION
In accordance with this invention, a piece of ice is formed and rubbed along the rods of a grill while they are hot. The hot rods form grooves in the ice that scrape foreign particles from them. It has been found that the steam formed in this process contributes significantly to the cleaning.
The ice is formed at one end of a suitably shaped mold, and a tear line is provided in the mold whereby that end of the mold can be easily removed so as to expose the ice. The other end of the mold, which is not removed, provides a convenient and comfortable means for holding the ice when it is being used for cleaning.
Although the molds made of cardboard or the like could be sold with water in them and frozen by a user well in advance of their use, it is more convenient to provide them in folded form so as to be flat and equipped with closeable openings so that a user can fill them with water when needed.
In another embodiment of the invention, the mold is suitable for reuse.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the invention are described in detail below with reference to the drawings, in which like items are identified by the same reference designation, wherein:
FIG. 1A shows a grill cleaner of this invention;
FIG. 1B shows the grill cleaner of FIG. 1A ready for use;
FIG. 2 illustrates how a grill cleaner of this invention is to be used;
FIG. 3 is a side view of a second embodiment of a grill cleaner of this invention;
FIG. 4A is a pictorial view of a third embodiment of the invention;
FIGS. 4B, 4C, and 4D are top, bottom, and side views, respectively, of the embodiment of FIG. 4A.
FIG. 5 shows a number of embodiments like that of FIG. 4A joined together;
FIG. 6 shows a fourth embodiment of the invention using non-disposable components; and
FIG. 7 shows a number of embodiments like FIG. 6 joined together.
DESCRIPTION OF THE INVENTION
FIG. 1A shows a container made of inexpensive waterproof material, such as cardboard with a waxed inner surface, that has a rectangular end 2 and a wedge-shaped end 4 having a tear line 6 between them. A tab 7 may be provided to aid in the tearing. In one form of the invention, the container 2, 4, is filled with water when it is made available to a customer, and the customer freezes it before use. After freezing, the wedge-shaped section 4 of the container 2, 4 is uncovered by tearing along the tear line 6 so as to leave a wedge of ice 4' as shown in FIG. 1B. The portion of the container in the rectangular portion 4 serves as a handle with the container material 2 insulating the user's hand from the ice.
The user then forces the wedge 4' of ice against rods 8 of a grill as shown in FIG. 2 and pushes it back and forth. When the rods 8 are hot, they melt grooves 8' in the wedge of ice 4' that scrape food particles from the rods. At the same time steam is formed that aids in the cleaning.
Because shipping a container 2, 4 filled with water might be awkward and expensive, it can be shipped in an empty condition and filled with water by the user via a hole 10. If the container 2, 4 remains upright during the freezing process, nothing more is needed, but a stopper 12 for the hole 10 is provided that is attached to the container 2, 4 by a thread 14 so that the container 2, 4 can be placed in any position during freezing.
FIG. 3 is a side view of a container having a slightly different shape. It has a rectangular end 16 that is joined by a wedge section 18 to a thinner rectangular section 20. The sections 18 and 20 meet at a tear line 22. It is only necessary that the end of the ice that is in contact with the rods 8 be thick enough to withstand the forces involved. At the same time, it is desirable that this end of the ice be thin enough to permit the grooves such as 8' to be quickly formed to their full depth in order to provide a scraping action. Other shapes for the end of the ice that is to be in contact with the rods 8 that meet the above criteria will occur to one skilled in the art.
FIGS. 4A, 4B, 4C, and 4D illustrate another embodiment of the invention. The cross-section of the entire container is in the shape of a wedge between a large end 26 and a small end 28. A top 30 and a bottom 32 of the container are joined together at the small end 28 as by gluing or by folding them over and gluing as shown at 34. A side 36, and the opposite side, not shown, are foldable along center lines such as the line 38 in the side 36. A cover 40 that is joined to the large end 26, the bottom 30, the side 36 and the other side, not shown, is foldable along a center line 42 extending between the side 36 and the other side so that the entire container can be made flat and therefore more suitable for shipment. In this case, however, a hole 44 is provided in the cover 40 so that a user may fill it with water. Unless the container is to be retained upright while the water is frozen, a stopper 46 and line 48 fastening the stopper 46 to the cover 40 are provided. After water has been frozen in the container of FIGS. 4, 4B, 4C, and 4D a bottom portion 50 is removed after tearing along a tear line 52 with the aid of a tab 54 so as to leave a section 56 to serve as a handle.
FIG. 5 shows a number of containers like that of FIGS. 4A, 4B, 4C, and 4D with adjacent sides joined by tear lines 57.
Instead of using a container that is entirely disposable after use, the ice grill cleaner of this invention can be formed in a permanent mold 58, as shown in FIG. 6, to which water frozen therein will not adhere such as metal coated with Teflon®, as in some ice trays. In order to provide an insulating handle for a user to grasp, a hollow insert 60 is provided that fits snugly into the top of the mold 58. Because the cross-section of the mold 58 is tapered, a portion 62 of the insert 60 remains above the mold 58 so that it can be grasped by a user. In use, the mold 58 and the member 60 are filled with water and frozen. The outside of the insert 60 is such as not to adhere to the mold 58, but the inside must be such as to adhere firmly to ice so as not to come loose in use. Alternatively, inward extending tabs 64 could be provided that would be frozen in the ice. The insert 60 is preferably made of reusable material such as plastic, but it could be made of disposable material such as cardboard.
FIG. 7 shows a tray formed by joining molds such as shown in FIG. 6 together.
Although various embodiments of the invention have been shown and described in detail, they are not meant to be limiting. Those of skill in the art may recognize certain modifications to these embodiments, which modifications are meant to be covered by the spirit and scope of the appended claims. For example, in the embodiments of the invention shown in FIGS. 6 and 7, as an alternative to using the tab 64, a user could insert a stick vertically into the mold 58 through the insert 60.
|
A device for cleaning a barbeque grill is described comprising a block of ice having a wedge-shaped cross-section at one end and handle of temperature insulating material at the other.
| 1
|
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of U.S. provisional application Ser. No. 61/326,629 filed on Apr. 21, 2010 by Michael Taylor entitled Grout Removal Tool the disclosure of which is incorporated herein by reference.
BACKGROUND INFORMATION
[0002] 1. Field
[0003] Embodiments of the disclosure relate generally to the field of removal of grout between ceramic or other tile and more particularly to embodiments for a reciprocating tool for removal of grout with enhanced durability and ergonomic design.
BACKGROUND
[0004] The current art available for tile grout removal tools includes hand tools and electrically powered devices. Electrically powered devices include tools that work using a reciprocating motion or a rotary motion. Hand tools are very labor intensive and slow in removing tile grout. They are only practical for small areas of grout removal. Powered tools are typically limited to rotary and reciprocating saw tools.
[0005] Powered rotary tools use abrasive disks that rotate at a high RPM to remove grout. These tools create large amounts of dust and are difficult to control. During the grout removal process the abrasive disk can slip from the grout groove and damage the tile. Many tiles are set with small spaces between the tile. Tiles set with such small spacing between the tiles very often have misaligned grout lines. The rotary tools cannot be used to remove the grout in the areas where the two corners of the tiles meet without damaging the tile edges. Abrasive disks are typically ⅛″ wide, so grout removal is limited to grout widths of more than ⅛′.
[0006] The available reciprocating tools use an existing reciprocating saw with a grout removal attachment. The attachment uses a metal grout removal blade with a row of teeth held parallel to the grout groove and removes the grout with a row of teeth held parallel to the grout groove and removes the grout with a sawing motion. Due to the heavy weight of the reciprocating saw the device is difficult to control which can cause the grout removal blade to slip from the grout groove and damage the tile surface. These devices have the same limitations as the rotary devices in that they cannot remove grout from narrow grout grooves at the corner intersections of slightly misaligned tiles. In addition, the wear on the grout removal blades is severe and requires frequent replacement. Replacement of the blades is time consuming, and costly. Because of the grinding motion of the grout removal blade much dust is created during the grout removal process. This device is generally limited to removing grout from grout lines that are ⅛″ wide or greater.
[0007] The current grout removal tools, both reciprocating and rotary, require the use of a vacuum during use to manage the dust created. Use of the vacuum requires a second operator for the vacuum or the tool operator must manage both the vacuum and the grout removal tool which increases the difficulty of controlling the grout removal device and increases the possibility of tile damage.
[0008] It is therefore desirable to provide a powered grout removal tool which is durable, light weight and adapted for use with small or uneven grout lines.
SUMMARY
[0009] Embodiments described herein provide a grout removal tool that incorporates a case carrying a reciprocating motor and having an external contoured finger grip. A drive shaft extends from the motor to engage a chuck drive rod. A cooling piston is concentrically carried by the drive shaft for reciprocating motion. A chuck is attached to the chuck drive rod for removably constraining a carbide tipped bit.
[0010] The features, functions, and advantages that have been discussed can be achieved independently in various embodiments of the present invention or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A is a right side view of an embodiment of the grout removal tool;
[0012] FIG. 1B is a top view of the embodiment of FIG. 1A ;
[0013] FIG. 1C is a left side view of the embodiment of FIG. 1A ;
[0014] FIG. 1D is a bottom view of the embodiment of FIG. 1A ;
[0015] FIG. 1E is a rear view of the embodiment of FIG. 1A ;
[0016] FIG. 1F is a front view of the embodiment of FIG. 1A
[0017] FIG. 2 is an isometric view of the embodiment shown in FIGS. 1A-1F with a chisel bit;
[0018] FIG. 3 is a side section view of the embodiment;
[0019] FIG. 4 is a side section view with the motor removed for clarity of other components;
[0020] FIG. 5 is a side view of a pointed tip carbide bit for use with the grout removal tool;
[0021] FIG. 6A is a side view of a chisel tip carbide bit; and,
[0022] FIG. 6B is a bottom view of the chisel tip carbide bit of FIG. 6A .
DETAILED DESCRIPTION
[0023] The embodiment disclosed herein provides a smaller handheld, electrically powered reciprocating device with carbide tips secured to a chuck in the reciprocating device. As shown in FIGS. 1A-1E and 2 , a grout removal tool 10 is provided with a contoured case 12 having a finger grip 14 to be held and manipulated by a user. The finger grip 14 is covered with a pliable material such as rubber or soft polyethylene to provide greater friction for gripping and to reduce imparted vibration to the fingers. Embossed chevrons 15 also enhance the surface of the grip. A removable carbide tip 16 is inserted in a chuck 18 in the grout removal tool 10 , the operation of which will be described in greater detail subsequently.
[0024] The combination of the grout removal tool 10 and the carbide tip 16 allows tile grout to be chiseled loose rather than ground out as existing grout removal devices function. The carbide tip 16 is removable and various carbide tips can be configured to work with various sizes of grout widths and will effectively remove grout in areas where the grout lines are narrow and the tiles are misaligned. The shape of the carbide tip can be symmetrically pointed (as seen in FIGS. 1A-1E , 4 and 5 ) to precisely remove small amounts of grout or can be chisel shaped (as seen in FIGS. 2 , 3 , 6 A and 6 B) to remove larger amounts of grout.
[0025] FIGS. 3 and 4 show the internal components of the grout removal tool 10 . A reciprocating motor 20 is carried in the case 12 . A power switch 22 provides electrical power from a conventional 110 V power cord 24 to the motor through a control potentiometer 26 . As seen in FIG. 1E , the switch is mounted on an external flat 27 on the rear of the case thereby avoiding unintentional operation of the switch when grasping the finger grip. Returning to FIG. 3 , the travel of the reciprocating motor 20 is controllable by a dial 29 on the potentiometer 26 positionable at various settings as best seen in FIG. 1A (shown at intermediate setting II) which can be varied to increase or decrease the amount of grout being removed and change the precision of the tool. The power of the drive motor is increased over currently available similar devices to insure long motor life and adequate power to work more efficiently to remove large amounts of grout.
[0026] A drive shaft 28 extends from the motor for connection to a chuck drive rod 30 terminating in the chuck 18 . As shown in FIG. 3 a spring 32 engages the drive rod for resilient reaction to the reciprocation of the motor enhancing the drive characteristics of the chuck and attached tip. Spring base 34 engages a shoulder 35 on the circumference of aperture 36 in case 12 through which drive rod 30 and chuck 18 protrude.
[0027] A cooling piston 40 is carried on the drive shaft 28 and/or chuck drive rod 30 . For the embodiment shown, the center boss 42 of the piston provides the interengagement between the drive shaft and chuck drive rod. The cooling piston reciprocates with the drive shaft as driven by the reciprocating motor. Motion of the piston creates air flow within chamber 44 in the case 12 to provide cooling for the motor. Air flow is enhanced by apertures in the case including air vent holes 46 in sides 48 a and 48 b of the case (as best seen in FIGS. 1A and 1C as well as vent slots 50 in bottom 52 of the case (as best seen in FIG. 1D ). In an original embodiment, the cooling piston 40 is a rigid plastic disc. For an exemplary embodiment shown, the cooling piston 40 is a flexible diaphragm having an outer ring 54 and an inner ring 56 joined by a reduced thickness membrane 58 . In certain embodiments, the outer ring may be constrained in grooves in the inner wall of the case. In alternative embodiments, the outer ring is unconstrained and resonance between the outer ring and inner ring induced by the reciprocation of the drive shaft may enhance the motion of the membrane. Cooling of the motor with the cooling piston significantly enhances the durability and life of the motor. The simplified form of the piston avoids costly fabrication and operation of alternative cooling devices such as a fan.
[0028] The carbide tips 16 shown in FIGS. 5 , 6 A and 6 B have virtually no wear during the life of the tips and thereby reduce the time to replace tips and replacement tip costs. The angle 60 of the chisel tips for the grout removal tool is optimized to provide the desired precision and grout removal speed.
[0029] Being of a smaller size than similar reciprocating devices used for grout removal makes the tool easy to control and reduces significantly the possibility of damage to the tile. The combination of size, cooling and efficient carbide tips with a motor size enlarged for heavy duty use allows the motor and grout removal tool to be operated continuously as opposed to prior art devices which required repeated shut down for cooling purposes. The chiseling motion for grout removal also increases the operation control over the tool which also reduces significantly any tile damage. The features of this new grout removal tool allow large areas of grout to be removed with reduced labor and tile damage.
[0030] The grout removal tool can be used to remove all sizes of grout from between tiles and allow the old grout to be replaced extending the life of the tile. The grout removal tool can be used to remove grout for tile floors, counter tops, shower and tub enclosures, and any other application using grouted tiles. Due to the ease of use and control the grout removal tool can be used to remove grout from large areas such as complete counter tops and shower and tub enclosures.
[0031] The grout removal tool can be used with narrow grout lines and in situations where the tiles are misaligned without damaging the tile surface. Removing grout on misaligned, narrow grout lines cannot be accomplished effectively with existing tools.
[0032] Various size and configurations of tips can be used depending on the precision necessary for different grout removal applications. Pointed tips can be used when precision is required or chisel shaped tips can be used when large amounts of grout need to be removed more rapidly.
[0033] Grout removal is accomplished by selecting the correct tip for the grout removal application. A pointed tip is selected where precision is required, or the grout line is narrow. A wider chisel tip is used when the grout line is wide and it is appropriate to remove large amounts of grout at a time. The pointed tip can also be used effectively when removing grout at corners where tiles are perpendicular to each other.
[0034] The grout removal tip is mounted into the chuck affixed to the front of the grout removal tool. The tip is held in the chuck by a set screw or frictionally engaged by segregated collate lips with a threaded cap which holds the tip in place during operation.
[0035] The proper tip travel is selected with the rotary dial of the adjustment potentiometer on the side of the tool. Shorter travels are selected for situations requiring precise control of the tip and longer travels are selected for situations where large amounts of grout are to be removed. The power switch is activated and the tip is held at an angle to the grout. The angle is determined by the amount of grout being removed, and the style of tip being used. The tool is moved forward along the grout line removing grout from the grout line.
[0036] Having now described various embodiments of the invention in detail as required by the patent statutes, those skilled in the art will recognize modifications and substitutions to the specific embodiments disclosed herein. Such modifications are within the scope and intent of the present invention as defined in the following claims.
|
A grout removal tool incorporates a case ( 12 ) carrying a reciprocating motor ( 20 ) and having an external contoured finger grip ( 14 ). A drive shaft ( 28 ) extends from the motor to engage a chuck drive rod ( 30 ). A cooling piston ( 40 ) is concentrically carried by the drive shaft for reciprocating motion. A chuck ( 18 ) is attached to the chuck drive rod for removably constraining a carbide tipped bit ( 16 ).
| 4
|
This application is a continuation-in-part, of application Ser. No. 07/243,064, filed Sep. 9, 1988, now abandoned.
BACKGROUND
Encapsulation of particulate solids and of liquid droplets is commonly done for purposes of controlled release, environmental protection or rendering inert reactive, toxic or hazardous materials. Coating of pharmaceuticals, pesticides, catalysts and discrete electronic elements are some specific examples of applications involving microencapsulation techniques.
There are many different reasons to coat active pharmaceutical agents. First if the active substance is coated it can mask the taste of unpleasant tasting substances. In other cases, the medicament is encapsulated in forms called enteric formulations to prevent the active substance from being exposed to stomach acids. Erythromycin base is readily destroyed in the presence of stomach acid. Attempts to enterically coat erythromycin base is a common subject of the pharmaceutical literature. Enteric formulations are designed to allow the drug to pass through the acidic environment of the stomach without disintegration and yet disintegrate in the duodeneum. Aspirin is often formulated in enteric forms to prevent it from irritating the lining of the stomach. Commonly used coatings for enteric substances are those of the phthalate family especially cellulose acetate phthalate.
Other reasons that drugs are often encapsulated or formulated in delayed release or sustained release form is to prolong the active lifetime of drugs with a short half life. A drug such as nitrofuradantoin is quickly absorbed by the gut and is quickly eliminated by the kidney. However, it is desirable that the nitrofuradantoin be at a high constant plasma level. Microencapsulation can avoid the requirement that a patient take it more times during the day and thus the problems with patient compliance.
In other instances, the drugs are formulated in delayed release form to lessen toxic effects. If it is released all at once in the gut excessively high levels of drugs may be reached. Whereas if the drug is a sustained release form, a therapeutic level but not a toxic level may be achieved. The literature has many examples of formulations of theophylline to allow a therapeutic dose without toxic symptoms.
There are several different types of microencapsulation techniques employed for encapsulation and microencapsulation of pharmaceuticals.
One such method is pan coating. This is an older method developed in the 1880's. This method is used to coat pharmaceutical tablets as well as candies and the like. The disadvantage with this is that it requires rather large particles on the order of several millimeters to several centimeters in size.
Another method is the Wurster coating method. The Wurster coating is an extremely powerful and versatile method for microencapsulation that was developed by Dale Wurster at the University of Wisconsin in the 1960's. It is often called fluid bed coating. The smallest size that the Wurster coater can use is about 100 microns and more realistically about 150 microns. This requires a solid core and utilizes a fluidized bed of air. This means that any material sensitive to oxygen or moisture would be very difficult to process.
A third method of microencapsulation is spray drying. Spray drying is an older method of microencapsulation than the Wurster coating method. Its actual usage is primarily more in the area of foods such as solid drink mixes. Spray drying requires an excessively large amount of capsule wall on the order of 80% on a volume basis. Spray drying is done at elevated temperatures to remove moisture which means that there is a possibility of degrading temperature sensitive pharmaceuticals.
In employing any of these methods coating uniformity is a constant concern. In the case of the pan coating and Wurster coating the capsule walls are applied as droplets on the order of 40 microns in size and above. The droplet size is more likely to be 100-200 microns. The uniformity of the coating then relies upon the uniformity of depositing these relatively large droplets of wall material. This causes some non-uniformity in the coating when these droplets are large compared to the core material. In the case of spray drying the wall is actually a matrix and the small droplets of core material are embedded in it much as a peanut cluster. Some droplets are close to the surface of the particle and some are very deep within. Further, a wall applied as a liquid must flow on wet. This presents problems around sharp surfaces of the core material. Thus in all of these processes coating uniformity varies substantially.
One form of microencapsulation which has not been utilized for pharmaceuticals is vapor deposition of polymeric films. This technology relates both to the vacuum vapor deposition of polymers such as poly-p-xylylene (Parylene) and also to glow discharge polymerized films such as polyolefins including ethylene and methylene, styrene, chlorotrifluoroethylene, tetrafluoroethylene, tetramethyldisuloxane and the like. These methods are generally disclosed in the "Biocompatability of Glow Discharge Polymerized Films and Vacuum Deposited Parylene" in the Journal of Applied Polymer Science: Applied Polymer Symposium 38, 55-64 (1984).
Vapor deposited Parylene is used to coat many different substrates including particulate substrates. The method of coating particulate material with Parylene is disclosed for example in Gorham et al U.S. Pat. No. 3,300,332. Primarily the Parylene is used in applications where absolute protection of the coated substrate is required. Examples of these would be coating of reactive metals such as lithium and sodium, coating of catalysts to prevent reaction and coating of electronic components to prevent environmental degradation of the component. In biological applications the Parylene coatings are used to protect implanted materials and prevent rejection of the materials by the body's defenses. Exemplary applications are disclosed for example in Synthetic Biomedical Polymers Concepts and Applications Copyright 1980 Technomic Publishing Co. pp 117-131. Coating of integrated circuits to be implanted in the body is disclosed in Blood Compatability of Components and Materials in Silicone Integrated Circuits, Electronic Letters Aug. 6, 1981, 17 (16). The use of Parylene generally in orthopedic uses is also discussed in Parylene Biomedical Data a 1975 publication of the Union Carbide Co. Parylene because of its strength, biological compatability and general inertness in physiological environments has made it generally suitable as an orthopedic coating for implant devices and the like. This same durability would suggest that it is unsuitable for pharmaceutical application.
SUMMARY OF HE INVENTION
The present invention is premised on the realization that active pharmaceutical agents can be microencapsulated by vapor deposition of polymeric compositions about the pharmaceutical agent. Even though inert polymeric compositions such as poly-p-xylylenes are deposited on pharmaceutical agents the film thickness can be controlled to provide effective controlled release of the pharmaceutical in a variety of circumstances.
In a preferred embodiment, the present invention encompasses a poly-p-xylylene coated pharmaceutical agent which is orally ingestible. The film thickness is controlled to provide effective time release of the active pharmaceutical, inspite of the extreme inertness of the poly-p-xylylene. Other objects and advantages of the present invention will be further appreciated in light of the following detailed description and drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section diagrammatic representation of the apparatus used in the present invention;
FIG. 2 is a cross-sectional diagrammatic depiction of an active pharmaceutical agent coated with a vapor deposited polymeric film;
FIG. 3 is a perspective view partially broken away of a dermatological pharmaceutical applicator;
FIG. 4 is a cross-sectional view of a tablet incorporating the coated pharmaceuticals of the present invention;
FIG. 5 is a cross-sectional view of an alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention includes a reactive pharmaceutical agent coated with a vapor deposited polymeric film produced by chemical vapor deposition. Chemical vapor deposition in accordance with this invention is used in a broad sense and includes vacuum deposited polymeric films, plasma polymerization deposited polymeric films, glow discharge deposited polymeric films and ultraviolet surface-polymerization deposited polymeric films. Glow discharge films would in turn include both films generated from plasma maintained by radio frequency as well as audio frequency. These polymeric films can include polyethylene, polymethylene, polymethylmethacrylate, silicones such as polydimethylsiloxane, polyfluorinated hydrocarbons such as chlorotrifluoroethylene, tetrafluoroethylene, and also polymers formed from unsaturated monomers such as styrene. The films generated from the method referred to as ultraviolet surface-polymerization are derived from, for instance, hexachlorobutadiene, such as described in Kunz et al: J. Chem. Soc., Faraday Trans. 68(1):140-149, (1972), which is incorporated herein by reference in its entirety.
In a preferred embodiment the vapor deposited film is a vacuum deposited polymeric film and more particularly a poly-p-xylylene. A poly-p-xylylene has the following repeating units: ##STR1## wherein n is 10-10,000 and X is a number from 0 to 3 inclusive and R would represent an aromatic nuclear substituent. Each substituent group R can be the same or different and can be any inert organic or inorganic group which can normally be substituted on aromatic nuclei. Illustrations of such substituent groups are alkyl, aryl, alkenyl, amino, cyano, carboxyl, alkoxy, hydroxylalkyl, carbalkoxy and like radicals as well as inorganic radicals such as hydroxyl, nitro, halogen and other similar groups which are normally substitutable on aromatic nuclei.
Particularly preferred of the substituted groups are those simple hydrocarbon groups such as the lower alkyl such as methyl, ethyl, propyl, butyl, hexyl and halogen groups particularly chlorine, bromine, iodine and fluorine as well as the cyano group and hydrogen, i.e., where X is 0.
These polymers are formed by the pyrolysis and vapor deposition of a di-p-xylylene having the following general formula: ##STR2## wherein R and X represent the same as the above Formula 1. These materials are the subject of several United States patents such as U.S. Pat. No. 3,117,168 entitled Alkylated Di-p-Xylylenes and U.S. Pat. No. 3,155,712 entitled Cyanated Di-p-Xylylenes and U.S. Pat. No. 3,300,332 entitled Coated Particulate Material and Method for Producing Same all of which are incorporated herein by reference.
The pyrolysis of the vaporous di-p-xylylene occurs upon heating the dimer from about 450° C. to about 700° C. and preferably about 550° C. to about 700° C. Regardless of the pressure employed pyrolysis of the starting di-p-xylylene begins at about 450° C. At temperatures above 700° C. cleavage o the constituent groups can occur resulting in a tri- or polyfunctional species causing cross linking or highly branched polymers. It is preferred that reduced or subatmosphere pressures be employed for pyrolysis to avoid localized hot spots. For most operations pressures within the range of 0.0001 to 10 millimeters Hg are practical. However desired greater pressures can be employed. Likewise inert inorganic vapor diluents such as nitrogen, argon, carbon dioxide and the like can be employed to vary the optimum temperature of operation or to change the total effective pressure of the system.
The diradicals formed in the manner described above are made to impinge upon the surface of the particulate material having surface temperatures below 200° C. and below the condensation temperature of the diradicals present thereby condensing thereon and thus spontaneously polymerizing the having the structure shown in formula 1.
The pharmaceutical for use in the present invention can be any solid, particulate pharmaceutical which requires a timed release application. Suitable pharmaceuticals for use in the present invention include, for instance, ammonium bisphosphate, ammonium chloride, aspirin, colchicine, theophylline, diethylstilbestrol, digestive enzymes such as pancreatin and pepsin, erythromycin, ferrogylcine sulphate, methenamine maleate, oxbile extract, paraminosalicylic acid, phenazopyridiene, proteolitic enzymes such as bromelains, trypsin, and chymotrypsin, potassium chloride, potassium iodide, potassium salicylate, sodium acid pyrophosphate, sodium amino benzoate, sodium biphosphate, sodium chloride U.S.P. or N.F., sodium salicylate, sulfasalzine, sulfoxone sodium, Thyroid USP, ascorbic acid as well as others.
The preferred polymeric coating agent is formed from a commercially available di-p-xylylene composition sold by the Union Carbide Co under the trademark Parylene. The compositions available are Parylene N wherein the above formula both Xs equal 0, Parylene C wherein the one R represents chlorine and the second R represents hydrogen (X=0) and a third composition Parylene D wherein both Rs represent chlorine.
The microencapsulation by vapor deposition can be accomplished in the apparatus shown in FIG. 1 which is similar to an apparatus disclosed in U.S. Pat. No. 3,300,332 previously incorporated by reference.
The apparatus 11 includes an access door which opens to an insulated pyrolysis tube 14. Pyrolysis tube 14 leads to an evacuated chamber 15. Inside the insulated tube 14 is a dish or boat 16 adapted to hold the di-p-xylylene composition. The boat 16 rests on a first heater 17. A second heater 18 encircles a portion of the insulated tube 14 acting as a pyrolysis zone. The tube 14 includes a restricted opening 19 which leads into a rotatable chamber 21 which lies within the evacuated chamber 15. The rotatable chamber 21 is turned by a motor 22 rotating a shaft 23 extending through a vacuum seal 24 into the evacuated chamber 15.
A plurality of baffles or screens 25 are fixed to the walls of the rotating chamber 21 to break up aggregates of core particles. A vacuum pump 26 acts to evacuate the chamber 15 and thus the rotatable chamber 21. A suitable gauge 27 is incorporated to measure the pressure within the evacuated chamber 15.
In operation, the pharmaceutical core particles are placed in chamber 21 and this is rotated while being evacuated. The dimer paraxylylene is placed in boat 16. The heat generated by heater 17 as well as the reduced pressure within the tube 14 causes the di-p-xylylene to evaporate. As it evaporates it is drawn towards the restricted opening 19 and through the portion of the tube 14 which is heated by heater 18. The temperature of the xylylene in boat 16 should be above 170° C. While passing through the portion heated by heater 18, the dimer xylylene is heated to about 700° C. Thus, the dimer is cleaved into its monomeric radicals. The radicals pass through the restricted opening 19 into the interior of the rotated chamber 21. The interior of this chamber is maintained at a lower pressure about 0.14 torn by the vacuum pump 26. The interior of the rotating drum 21 is maintained at room temperature approximately 20° C. The reactive monomer enters the drum 21 through restricted opening 19 and impinges upon the core materials being rotated within the drum. The reduced temperature of the core materials causes the radical to condense on the surface of the core material and polymerize. This creates a very thin coating generally 0.1 to about 10 microns. The baffles or screens 25 act to sift and disperse the pharmaceutical core material to prevent agglomeration.
After the pharmaceutical particles are coated with the Parylene they are removed and processed. They can be compressed with appropriate excipients into tablets or into capsules. With appropriate sterilization they can be processed into an injection form for veterinary uses.
In order to ensure uniformity of coating the coating chamber is advantageously rotated at about 10 to 500 rpms thus continuously tumbling the particles and exposing fresh surface to the condensing diradicals.
The coating thickness must be controlled for controlling the release properties of the pharmaceutical after application or ingestion. The wall thickness of the polymer coating is a function of both the surface area of the particles being coated as well as the amount of pyrolyzed paraxylylene introduced into the reaction chamber 21.
For purposes of evaluation, the wall thickness of a coating is equal to 1/3 of the radius of the core particle multiplied by the volume of the wall material divided by the volume of the core material. Thus where the core has an average diameter of 150 microns and the radius of the core is 75 microns one can calculate the thickness of the coating. Presuming for example that the ratio of the volume of the walled material divided by the volume of the core material is 0.15 the thickness would be equal to 1/3×75 microns ×0.15=3.75 microns. For purposes of the present invention, the wall thickness should be from about 0.1 micron to about 10 microns and preferably about 0.3 to about 3.0 microns, and the pharmaceutical agent core has a particle size of from about 5 microns to about 2,000 microns and preferably from about 50 microns to about 300 microns and more preferably from about 75 microns to about 150 microns.
Agglomeration of the particles can be controlled by increasing agitation within the reaction chamber, adding large inert particles to bounce around within the reaction chamber or inserting narrow rods within the reaction chamber. If the pharmaceutical powder appears to be initially tacky this can be controlled by adding a small amount of the paraxylylene dimer. An apparently tacky and agglomerated mass of particles actually becomes a free flowing mass of particles upon the application of the paraxylylene dimer.
To evaluate the release properties of pharmaceuticals coated by the parylene polymers the following examples were carried out.
EXAMPLE 1
Potassium chloride (700 g) sieved through a This amount of potassium chloride was placed in the reaction chamber and 28 g of Parylene C dimer placed in the boat 16. The vapor heating temperature was 171° C. The pyrolysis furnace temperature was 690° C. The rotation speed of the reaction chamber was 50 turns per minute. After the chamber pressure reached 20 microns of mercury Parylene C was vaporized and deposited over a 3 hour period. This was repeated five times. After each coating, the potassium chloride plus coating was removed, sieved and replaced with some loss of the material. The amount of material lost was compensated with proportionately less Parylene C dimer placed in the boat. According to the amounts of Parylene evaporated the final amount of parylene plated is shown in Table I. In one run of potassium chloride the Parylene C was replaced with parylene N. In this embodiment 700 g of potassium chloride were placed in the chamber and 14 g of parylene N was placed in the boat. The vapor heating temperature was 171° C. The post heater temperature was 242° C. The paralysis furnace temperature was 690° C. and the rotation speed was 50 rpm.
As shown in FIG. 2, this produces a microencapsulated pharmaceutical 31 having a core 32 (in this case potassium chloride) coated with a Parylene derived polymeric coating 3. The average wall thickness was about 1 micron.
TABLE I______________________________________Grams Core Grams Wall % Core/Wall Parylene______________________________________PHARMACEUTICAL 1:POTASSIUM CHLORIDE BATCH ONE700 28 4 C700 14 2 C461 9.3 2 C388 7.75 2 C700 14 2 NPOTASSIUM CHLORIDE BATCH TWO684 14 2 C684 14 2 C474 9.5 2 C408 8.2 2 C343 7 2 C______________________________________
EXAMPLE 2
theophylline was coated with parylene C. In this embodiment 500 g of theophylline was placed in the rotatable chamber and 5 g of parylene C was placed in the boat. The vapor heating temperature was 165° C., the pyrolysis furnace was 690° C. and the rotation speed of the chamber was 40 revolutions per minute. After the chamber pressure reached 6 microns H 2 the Parylene C was vaporized and deposited over a three hour period. This was repeated five times. The results of this are shown in Table II. The average wall thickness was about 0.2 microns.
TABLE II______________________________________Run Grams Core Grams Wall % Core/Wall Parylene______________________________________1 500 5 1 C2 500 5 1 C3 500 5 1 C4 500 5 l C5 500 5 1 C______________________________________
EXAMPLE 3
Erythromycin was also encapsulated with parylene C. The erythromycin encapsulation provided an unexpected problem in that the pressure as measured by the pressure gauge could not be reduced below about 90 microns. It was presumed that the erythromycin was outgassing. However, after the first coat was placed on the erythromycin the pressure was able to be dropped between 30 and 50 microns. Thus, the 500 g of starting material was coated with parylene C dimer with a vapor heating temperature of 170° C., paralysis temperature of 690° C. and a rotation of the reaction chamber of 40 rpm. The pressure was between 30 and 90 microns for the run. The results again are shown in Table III. The average wall thickness was about 0.5 microns.
TABLE III______________________________________Run Grams Core Grams Wall % Core/Wall Parylene______________________________________1 500 7 1.4 C2 500 7 1.4 C3 500 7 1.4 C4 500 7 1.4 C5 500 7 1.4 C______________________________________
To test the dissolution rate of pharmaceuticals coated according to the present invention, theophylline coated with Parylene C according to Example 2 was tested according to the method set out in United States Pharmacopeia 21st Revision 1985 Test 711 utilizing the apparatus No. 2. In this test the medium was 900 milliliters of water, the temperature was maintained at 37° C. and the test apparatus was rotated at 100 rpm. The theophylline 50 milligrams was weighed accurately and added to the dissolution vessel. Five milliliters of sample was withdrawn at 15, 30, 60, 120, 240, 360 and 1440 minutes and filtered through Wattman No. 1 filter. The samples were then analyzed for theophylline using UV spectrophotometer at 27 nm wave length. The particle size represented below in Table IV is the average particle size in microns of the sample passing through the respective sieves.
TABLE IV______________________________________TIME % RELEASE(MIN) MEAN S.D. R.S.D.______________________________________BATCH I: 362.5 um.15 12.94 0.321 2.48 30 21.69 4.950 22.80 60 35.94 2.610 7.27120 46.78 1.410 3.02240 59.38 1.224 2.06360 65.53 0.694 1.061440 90.17 1.568 1.739BATCH I: 275.0 um. 15 11.693 0.386 3.301 30 16.548 0.817 4.937 60 23.025 1.065 4.624120 27.706 2.438 8.800240 38.113 2.765 7.254360 48.593 4.181 8.603720 61.629 5.712 8.229840 65.629 4.457 6.819960 70.667 4.445 6.2891440 80.593 5.838 7.244BATCH I: 215.0 um. 15 10.77 2.415 22.42 30 30.70 2.838 9.24 60 43.23 4.231 9.79120 60.435 2.997 4.96240 68.55 2.057 3.00360 76.66 1.995 3.001320 92.25 2.644 2.85BATCH I: 180.0/ um. 15 14.441 2.345 14.898 30 27.625 4.573 16.557 60 43.568 5.658 12.988120 58.396 3.870 6.628240 72.676 2.151 2.960360 81.030 1.769 2.183480 85.856 1.331 1.551720 91.621 0.569 0.6211440 97.665 1.134 1.161BATCH II: 362.5 um. 15 9.648 0.658 6.827 30 13.990 0.462 3.304 60 19.020 0.720 3.785120 23.435 0.734 3.133240 33.965 1.273 3.748360 40.118 1.872 4.667720 53.745 2.806 5.2211200 65.39 3.394 5.1901440 69.38 3.227 4.419BATCH II: 275.0 um. 15 14.740 1.333 9.049 30 21.451 1.807 8.426 60 29.490 2.076 7.041120 36.258 2.112 5.827240 47.889 2.589 5.407360 56.693 2.699 4.761480 62.954 3.323 5.278720 72.086 2.838 3.9361440 82.061 3.309 4.033BATCH II: 215.0 um. 15 11.340 2.780 24.520 30 27.610 1.770 6.400 60 39.230 3.330 8.500120 50.340 3.690 7.330240 61.610 4.750 7.710360 72.860 5.970 7.520480 79.320 5.970 7.520780 91.580 5.880 6.400BATCH II: 180.0/ um. 15 8.105 2.078 25.648 30 12.155 3.396 27.943 60 19.717 5.599 28.398120 24.373 5.361 21.199240 33.395 5.465 16.366360 39.827 6.111 15.344480 42.722 5.546 12.981720 50.630 5.124 10.1201440 60.426 5.562 9.205______________________________________
In an alternate embodiment as shown in FIG. 3, the vapor deposited polymer film can be used to coat a layer of a medicament. For example, a thin layer of a dermatological medicament 41 such as antibiotic or steroid can be placed on a first lamina 42 such as a polyethylene sheet or other inert flexible material. A layer 43 of Parylene is then vapor deposited on the dispersed medicament. After deposition the sheet can be placed on the surface of a pathological skin such as burns and the like and various dermatosis. This will provide for sustained release of the antibiotic or medicament.
In another embodiment shown in FIG. 4 the vapor deposited polymer can enhance the effects of medicaments that can be compressed into loosely packed blocks or pellets. In this embodiment pellets 51 of compressed particles 52 (excipients and active pharmaceutical) are coated in the same manner described above by placing the compressed pellets in the reaction chamber and coating with parylene. The Parylene radical monomers by their nature penetrate into tiny cracks and crevices coating the individual particles which form the pellets as well as the pellets themselves as represented by layer 53. This provides a sustained release form of the medicaments.
Generally the present invention functions with small core particle materials to very large core particle materials. However, when the core particle materials are less than 10 microns say for example 1-10 microns agglomeration is more likely to occur. Accordingly as shown in FIG. 5, with smaller particles an inert core material 61 can be employed. The small pharmaceutical particles 62 are embedded into the surface of the inert core material as it is being coated with a first layer of Parylene. In this embodiment, the core material is simply rotated within the reaction chamber in combination with the pharmaceutical agent. The Parylene radicals are then deposited onto the core materials coating the core materials and permitting the pharmaceutical particles to fix to the surface of the core material. The core material coated with Parylene and having pharmaceutical particles embedded in the Parylene is then coated with a second layer 64 of Parylene further to provide a complete coating of the pharmaceutical agent as well as the core material. This provides a simple method to dilute the pharmaceutical.
Thus, according to the present invention the vapor deposited film coated pharmaceuticals have a large number of potential uses either in forming an orally ingestible pharmaceutical, an injectible pharmaceutical or a dermatological medicament. The surprising ability of the vapor deposited polymeric film to provide a controlled release of the pharmaceutical makes it particularly useful in many different applications. Further, the general inertness of the polymeric film protects the medicament from environmental conditions. This ability to protect the medicament and provide for controlled release of the medicament is a very surprising combination of characteristics.
The vapor deposited films provide for a very controlled application of a very uniform wall thickness about the pharmaceutical agent core. Since the coating is applied molecule by molecule it provides an extremely uniform coating which can be readily controlled.
The preceding description has intended to provide both a description of the invention as well as the preferred mode of practicing the invention known to the inventor at this time.
|
A microencapsulated pharmaceutical is formed by vapor depositing a polymeric film about an active pharmaceutical agent. The film thickness of the vapor deposited film is controlled to provide effective controlled release of said pharmaceutical agent subsequent to application. In a preferred embodiment the pharmaceutical is an orally ingestible pharmaceutical formed by vapor deposition of a poly-p-xylylene polymer about a core comprising an active pharmaceutical agent. The pharmaceutical agent exhibits surprising controlled release activity inspite of the extreme inertness of vapor deposited films such as Parylene films.
| 0
|
FIELD OF THE INVENTION
This invention is related to centrifugal water pumps and consists of a union of lateral covers with the water pump housing by means of non-screwing pressure elements and of an external gasket adjustment mechanism.
BACKGROUND OF THE INVENTION
All water pumps have covers providing access to the same in such a way that these covers are joined with a housing by means of screws. Water pumps working in different natural conditions, in remote areas, for example used in mining, require frequent disassembly of the covers to eliminate jams or for internal cleaning which is time consuming, especially when covers are joined with the housing by means of screws. After prolonged periods of use, the water pump gaskets suffer wear, causing leaks and requiring an interruption of use for replacement.
The present invention provides for the elements which eliminate these inconveniences. The first element allows rapid and easy assembly and disassembly of the lateral covers by eliminating the use of screws to join said covers. The second element allows external adjustment of the gasket and so avoiding leaks.
The objective of the present invention is to prolong the smooth functioning of the water pumps and facilitate rapid repair and maintenance in difficult working conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective drawing of the housing and the suction cover which closes the access opening, showing the holding pins of said cover;
FIG. 2 is a lateral view of the housing cross-section and the holding pins;
FIG. 3 is a front view of the housing with the holding pins, shown as constituent parts;
FIG. 4 is a view of the breakdown of a part of the pump external gasket adjustment mechanism; and
FIG. 5 is a partial view in a longitudinal section of the part of the external gasket adjustment mechanism and an enlarged detail of this section showing the operation of the mechanism for adjusting the gasket.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 to 4 show a water pump housing which comprises, on its external face opposite the motor connecting shaft (not shown), a circular access opening 2 which is plugged with a suction cover 3 with a bevelled edge 4, which fits into the opening 2. A unit with three L shaped projections 5 with openings 7 and located in the external adjacent surface around the opening 2 and along both opposite faces of the pump, each of which forms a unit containing pins 6 which may be inserted in the said openings 7 of the projections 5. The support cover 3a with a diameter equal to the opposite suction cover 3 has internal hexagonal cavities 21 for the insertion of each screw head which fasten the support of the pump by external nuts. Each of the L shaped projections 5 has a small rear inclination upwards which impedes the backward movement of the respective pin 6 and pressures the cover in the upper region. According to FIG. 5, along the motor connecting side, the pump has a conical body 8 integrally connected with the support cover 3a (see FIG. 2), with a tow guard 10 and with two vertical pins 10a, gaskets 11 and 13 on a coupling 12, and a support ring 14. A moving coupling plate 9 (see FIG. 4) is housed in the central cavity of the coupling 12 by means of a motor connecting shaft. The conical body 8 is comprised, in the surface around the opening for the motor connecting shaft 8a (see FIG. 4), of two opposite equidistant guide arcs 18 and at 90 degrees from these guide arcs 18 there is a threaded pin 17 with nuts 19, parallel to the said surface and extending from it, along which there is an external displaceable bushing 15, with bevelled ends 16, which move in turn with the guide arcs 18. Below these guide arcs 18 are openings 20 to provide access to the pins 10a of the tow guard 10. The functioning of the elements of the invention can be explained as follows: the suction and support covers 3 and 3a with their opposite lateral locations, have bevelled edges 4 which fit with the edges of the openings 2, and when in place allow the passing of the pins 6 along the openings 7 provided in the projections 5 of each lateral region. The insertion of these pins 6 whose ends rest on the external surface of the cover 3, will force bevelled edge 4 to make tight contact with the walls of the opening 2, forming a hermetic seal. The projections 5 in their rear part present a small upward sloping region which force the pin 6 to pressure forward against the cover 3 avoiding a loosening due to vibration of the pump.
It will be observed that due to the configuration of the pins 6, for their insertion or removal a tool such as a hammer will be sufficient and their handling will therefore be rapid and simple.
The adjustment of the gasket according to this invention is determined by the position of the tow guard 10 with its pins 10a, which project through the openings 20 (see FIG. 5) below the guide arcs 18. Since the bevelled end 16 of the bushing 15 rests on the projection pins 10a, in the guide arcs 18 and that this bushing 15 is movable along the threaded pin 17 by means of the nut 19, upon the tightening of this nut the bevelled ends 16 of the bushing 15 will force, in a cam effect and in a change of direction of the movement, the pins 10a to move along the shaft pressing the gaskets 11 and 13 and making them expand laterally, forming a gasket on the coupling 12 and the walls of the conical body 8.
As can be appreciated from what has been shown and due to the fact that the movement of the bushing 15 is uniform throughout and limited to straight movement due to the effect of the guides that the guide arcs 18 and the threaded pin 17 provide on which it moves, the movement transmitted to the pins 10a of the tow guard 10 will also be equally uniform and balanced also exerting uniform pressure on the group of internal gaskets in the conical body 8.
|
The disclosure is related to centrifugal water pumps and consists of a union of lateral suction and support covers with the water pump housing by a plurality of non-screwing pressure elements and of an external gasket adjustment mechanism.
| 5
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation in part of application Ser. No. 11/246,687 filed 11 Oct. 2005 the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of printing. In particular, the invention concerns an inkjet printhead for high resolution printing.
CROSS REFERENCE TO OTHER RELATED APPLICATIONS
[0003] The following applications have been filed by the Applicant simultaneously with this application.
MNN022US MNN023US MNN024US MNN026US MNN027US MNN028US MNN029US MNN030US
[0004] The disclosures of these co-pending applications are incorporated herein by reference. The above applications have been identified by their filing docket number, which will be substituted with the corresponding application number, once assigned.
[0005] The following applications were filed by the Applicant simultaneously with the parent application, application Ser. No. 11/246,687:
11/246676 11/246677 11/246678 11/246679 11/246680 11/246681 11/246714 11/246713 11/246689 11/246671 11/246670 11/246669 11/246704 11/246710 11/246688 11/246688 11/246715 11/246718 11/246685 11/246686 11/246703 11/240691 11/246711 11/246690 11/246712 11/246717 11/246769 11/246700 11/246701 11/246702 11/246668 11/246697 11/246698 11/246699 11/246675 11/246684 11/246672 11/246673 11/246683 11/246682 11/246707 11/246706 11/246705 11/246708 11/246693 11/246692 11/246696 11/246695 11/246694 11/246674 11/246667
[0006] The disclosures of these applications are incorporated herein by reference.
[0007] The following patents or patent applications filed by the applicant or assignee of the present invention are hereby incorporated by cross-reference.
6405055 6628430 7136186 10/920372 7145689 7130075 7081974 7177055 7209257 7161715 7154632 7158258 7148993 7075684 11/635526 11/650545 11/653241 11/653240 11758648 7241005 7108437 6915140 6999206 7136198 7092130 09/517539 6566858 6331946 6246970 6442525 09/517384 09/505951 6374354 7246098 6816968 6757832 6334190 6745331 09/517541 10/203559 7197642 7093139 10/636263 10/636283 10/866608 7210038 10/902833 10/940653 10/942858 11/706329 11/757385 11/758642 7170652 6967750 6995876 7099051 11/107942 7193734 11/209711 11/599336 7095533 6914686 7161709 7099033 11/003786 11/003616 11/003418 11/003334 11/003600 11/003404 11/003419 11/003700 11/003601 11/003618 7229148 11/003337 11/003698 11/003420 6984017 11/003699 11/071473 11748482 11778563 11779851 11778574 11/003463 11/003701 11/003683 11/003614 11/003702 11/003684 11/003619 11/003617 11/764760 11/293800 11/293802 11/293801 11/293808 11/293809 11/482975 11/482970 11/482968 11/482972 11/482971 11/482969 11/097266 11/097267 11/685084 11/685086 11/685090 11/740925 11/763444 11/763443 11/518238 11/518280 11/518244 11/518243 11/518242 11/084237 11/084240 11/084238 11/357296 11/357298 11/357297 11/246676 11/246677 11/246678 11/246679 11/246680 11/246681 11/246714 11/246713 11/246689 11/246671 11/246670 11/246669 11/246704 11/246710 11/246688 11/246716 11/246715 11/246707 11/246716 11/246705 11/246708 11/246693 11/246692 11/246696 11/246695 11/246694 11/482958 11/482955 11/482962 11/482963 11/482956 11/482954 11/482974 11/482957 11/482987 11/482959 11/482960 11/482961 11/482964 11/482965 11/482976 11/482973 11/495815 11/495816 11/495817 6227652 6213588 6213589 6231163 6247795 6394581 6244691 6257704 6416168 6220694 6257705 6247794 6234610 6247793 6264306 6241342 6247792 6264307 6254220 6234611 6302528 6283582 6239821 6338547 6247796 6557977 6390603 6362843 6293653 6312107 6227653 6234609 6238040 6188415 6227654 6209989 6247791 6336710 6217153 6416167 6243113 6283581 6247790 6260953 6267469 6588882 6742873 6918655 6547371 6938989 6598964 6923526 6273544 6309048 6420196 6443558 6439689 6378989 6848181 6634735 6299289 6299290 6425654 6902255 6623101 6406129 6505916 6457809 6550895 6457812 7152962 6428133 7216956 7080895 11/144844 7182437 11/599341 11/635533 11/607976 11/607975 11/607999 11/607980 11/607979 11/607978 11/735961 11/685074 11/696126 11/696144 11/696650 11/763446 10/407212 10/407207 10/683064 10/683041 11766713 11/482980 11/563684 11/482967 11/482966 11/482988 11/482989 11/293832 11/293838 11/293825 11/293841 11/293799 11/293796 11/293797 11/293798 11/124158 11/124196 11/124199 11/124162 11/124202 11/124197 11/124154 11/124198 11/124153 11/124151 11/124160 11/124192 11/124175 11/124163 11/124149 11/124152 11/124173 11/124155 7236271 11/124174 11/124194 11/124164 11/124200 11/124195 11/124166 11/124150 11/124172 11/124165 11/124186 11/124185 11/124184 11/124182 11/124201 11/124171 11/124181 11/124161 11/124156 11/124191 11/124159 11/124176 11/124188 11/124170 11/124187 11/124189 11/124190 11/124180 11/124193 11/124183 11/124178 11/124177 11/124148 11/124168 11/124167 11/124179 11/124169 11/187976 11/188011 11/188014 11/482979 11/735490 11/228540 11/228500 11/228501 11/228530 11/228490 11/228531 11/228504 11/228533 11/228502 11/228507 11/228482 11/228505 11/228497 11/228487 11/228529 11/228484 11/228489 11/228518 11/228536 11/228496 11/228488 11/228506 11/228516 11/228526 11/228539 11/228538 11/228524 11/228523 11/228519 11/228528 11/228527 11/228525 11/228520 11/228498 11/228511 11/228522 111/228515 11/228537 11/228534 11/228491 11/228499 11/228509 11/228492 11/228493 11/228510 11/228508 11/228512 11/228514 11/228494 11/228495 11/228486 11/228481 11/228477 11/228485 11/228483 11/228521 11/228517 11/228532 11/228513 11/228503 11/228480 11/228535 11/228478 11/228479 6087638 6340222 6041600 6299300 6067797 6286935 6044646 6382769 10/868866 6787051 6938990 11/242916 11/242917 11/144799 11/198235 11/766052 7152972 11/592996 6746105 11/763440 11/763442 11/246687 11/246718 11/246685 11/246686 11/246703 11/246691 11/246711 11/246690 11/246712 11/246717 11/246709 11/246700 11/246701 11/246702 11/246668 11/246697 11/246698 11/246699 11/246675 11/246674 11/246667 7156508 7159972 7083271 7165834 7080894 7201469 7090336 7156489 10/760233 10/760246 7083257 10/760243 10/760201 7219980 10/760253 10/760255 10/760209 7118192 10/760194 10/706238 7077505 7198354 7077504 10/760189 7198355 10/760232 10/760231 7152959 7213906 7178901 7222938 7108353 7104629 11/446227 11/454904 11/472345 11/474273 11/478594 11/474279 11/482939 11/482950 11/499709 11/592984 11/601668 11/603824 11/601756 11/601672 11/650546 11/653253 11/706328 11/706299 11/706965 11/737080 11/737041 11/778062 11778566 11782593 11/246684 11/246672 11/246673 11/246683 11/246682 60/939086 10/728804 7128400 7108355 6991322 10/728790 7118197 10/728970 10/728784 10/728783 7077493 6962402 10/728803 7147308 10/728779 7118198 7168790 7172270 7229155 6830318 7195342 7175261 10/773183 7108356 7118202 10/773186 7134744 10/773185 7134743 7182439 7210768 10/773187 7134745 7156484 7118201 7111926 10/773184 7018021 11/060751 11/060805 11/188017 7128402 11/298774 11/329157 11/490041 11/501767 11/499736 11/505935 7229156 11/505846 11/505857 11/505856 11/524908 11/524938 11/524900 11/524912 11/592999 11/592995 11/603825 11/649773 11/650549 11/653237 11/706378 11/706962 11749118 11/754937 11749120 11/744885 11779850 11765439 11/097308 11/097309 11/097335 11/097299 11/097310 11/097213 11/210687 11/097212 7147306 11/545509 11764806 11782595 11/482953 11/482977 11/544778 11/544779 11/764808 11/066161 11/066160 11/066159 11/066158 11/066165 10/727181 10/727162 10/727163 10/727245 7121639 7165824 7152942 10/727157 7181572 7096137 10/727257 10/727238 7188282 10/727159 10/727180 10/727179 10/727192 10/727274 10/727164 10/727161 10/727198 10/727158 10/754536 10/754938 10/727227 10/727160 10/934720 7171323 11/272491 11/474278 11/488853 11/488841 11749750 11749749 10/296522 6795215 7070098 7154638 6805419 6859289 6977751 6398332 6394573 6622923 6747760 6921144 10/884881 7092112 7192106 11/039866 7173739 6986560 7008033 11/148237 7222780 11/248426 11/478599 11/499749 11/738518 11/482981 11/743661 11/743659 11/752900 7195328 7182422 11/650537 11/712540 10/854521 10/854522 10/854488 10/854487 10/854503 10/854504 10/854509 7188928 7093989 10/854497 10/854495 10/854498 10/854511 10/854512 10/854525 10/854526 10/854516 10/854508 10/854507 10/854515 10/854506 10/854505 10/854493 10/854494 10/854489 10/854490 10/854492 10/854491 10/854528 10/854523 10/854527 10/854524 10/854520 10/854514 10/854519 10/854513 10/854499 10/854501 10/854500 7243193 10/854518 10/854517 10/934628 7163345 11/499803 11/601757 11/706295 11/735881 11748483 11749123 11766061 11775135 11772235 11778569 11/014731 11/544764 11/544765 11/544772 11/544773 11/544774 11/544775 11/544776 11/544766 11/544767 11/544771 11/544770 11/544769 11/544777 11/544768 11/544763 11/293804 11/293840 11/293803 11/293833 11/293834 11/293835 11/293836 11/293837 11/293792 11/293794 11/293839 11/293826 11/293829 11/293830 11/293827 11/293828 11/293795 11/293823 11/293824 11/293831 11/293815 11/293819 11/293818 11/293817 11/293816 11/482978 11/640356 11/640357 11/640358 11/640359 11/640360 11/640355 11/679786 10/760254 10/760210 10/760202 7201468 10/760198 10/760249 7234802 10/760196 10/760247 7156511 10/760264 10/760244 7097291 10/760222 10/760248 7083273 10/760192 10/760203 10/760204 10/760205 10/760206 10/760267 10/760270 7198352 10/760271 10/760275 7201470 7121655 10/760184 7232208 10/760186 10/760261 7083272 11/501771 11/583874 11/650554 11/706322 11/706968 11/749119 11779848 11/014764 11/014763 11/014748 11/014747 11/014761 11/014760 11/014757 11/014714 11/014713 11/014762 11/014724 11/014723 11/014756 11/014736 11/014759 11/014758 11/014725 11/014739 11/014738 11/014737 11/014726 11/014745 11/014712 11/014715 11/014751 11/014735 11/014734 11/014719 11/014750 11/014749 11/014746 11/758640 11775143 11/014769 11/014729 11/014743 11/014733 11/014754 11/014755 11014765 11/014766 11/014740 11/014720 11/014753 11/014752 11/014744 11/014741 11/014768 11014767 11/014718 11/014717 11/014716 11/014732 11/014742 11/097268 11/097185 11/097184 11778567 11/293820 11/293813 11/293822 11/293812 11/293821 11/293814 11/293793 11/293842 11/293811 11/293807 11/293806 11/293805 11/293810 11/688863 11/688864 11/688865 11/688866 11/688867 11/688868 11/688869 11/688871 11/688872 11/688873 11/741766 11/482982 11/482983 11/482984 11/495818 11/495819 11/677049 11/677050 11/677051 11/014722 10/760180 7111935 10/760213 10/760219 10/760237 10/760221 10/760220 7002664 10/760252 10/760265 7088420 11/446233 11/503083 11/503081 11/516487 11/599312 11/014728 11/014727 7237888 7168654 7201272 6991098 7217051 6944970 10/760215 7108434 10/760257 7210407 7186042 10/760266 6920704 7217049 10/760214 10/760260 7147102 10/760269 10/760199 10/760241 10/962413 10/962427 10/962418 7225739 10/962402 10/962425 10/962428 7191978 10/962426 10/962409 10/962417 10/962403 7163287 10/962522 10/962523 10/962524 10/962410 7195412 7207670 11/282768 7220072 11/474267 11/544547 11/585925 11/593000 11/706298 11/706296 11/706327 11/730760 11/730407 11/730787 11/735977 11/736527 11/753566 11/754359 11/778061 11/765398 11778556 11780470 11/223262 11/223018 11/223114 11/223022 11/223021 11/223020 11/223019 11/014730 7079292 09/575197 7079712 09/575123 6825945 09/575165 6813039 6987506 7038797 6980318 6816274 7102772 09/575186 6681045 6728000 7173722 7088459 09/575181 7068382 7062651 6789194 6789191 6644642 6502614 6622999 6669385 6549935 6987573 6727996 6591884 6439706 6740119 09/575198 6290349 6428155 6785016 6870966 6822639 6737591 7055739 7233320 6830196 6832717 6957768 09/575172 7170499 7106888 7123239
BACKGROUND OF THE INVENTION
[0008] The quality of a printed image depends largely on the resolution of the printer. Accordingly, there are ongoing efforts to improve the print resolution of printers. The print resolution strictly depends on the spacing of the printer addressable locations on the media substrate and the drop volume. The spacing between nozzles on the printhead need not be as small as the spacing between addressable locations on the media substrate. The nozzle that prints a dot at one addressable location can be spaced any distance away from the nozzle that prints the dot at the adjacent addressable location. Movement of the printhead relative to the media, or vice versa, or both, will allow the printhead to eject drops at every addressable location regardless of the spacing between the nozzles on the printhead. In the extreme case, the same nozzle can print adjacent drops with the appropriate relative movement between the printhead and the media.
[0009] Excess movement of the media with respect to the printhead will reduce print speeds. Multiple passes of a scanning printhead over a single swathe of the media, or multiple passes of the media past the printhead in the case of pagewidth printhead reduces the page per minute print rate.
[0010] Alternatively, the nozzles can be spaced along the media feed path or in the scan direction so that the addressable locations on the media are smaller than the physical spacing of adjacent nozzles. It will be appreciated that the spacing the nozzles over a large section of the paper path or scan direction is counter to compact design. More importantly, it requires the paper feed to carefully control the media position and precise printer control of nozzle firing times.
[0011] For pagewidth printheads, the large nozzle array emphasizes the problem. Spacing the nozzles over a large section of the paper path requires the nozzle array to have a relatively large area. The nozzle array must, by definition, extend the width of the media. But its dimension in the direction of media feed should be as small as possible. Arrays that extend a relatively long distance in the media feed direction require complex print platens that maintain the spacing between the nozzles and the media surface across the entire array. Some printer designs use a broad vacuum platen opposite the printhead to get the necessary control of the media. In light of these issues, there is a strong motivation to increase the density of nozzles on the printhead (that is, the number of nozzles per unit area) in order to increase the addressable locations of the printer and therefore the print resolution while keeping the width of the array (in the direction of media feed) small.
SUMMARY OF THE INVENTION
[0012] Accordingly, the present invention provides a printhead for an inkjet printer, the printhead comprising:
[0013] an array of nozzles arranged in adjacent rows, each nozzle having an ejection aperture and a corresponding actuator for ejecting printing fluid through the ejection aperture, each actuator having electrodes spaced from each other in a direction transverse to the rows; and,
[0014] drive circuitry for transmitting electrical power to the electrodes; wherein,
[0015] the electrodes of the actuators in adjacent rows have opposing polarities such that the actuators in adjacent rows have opposing current flow directions.
[0016] By reversing the polarity of the electrodes in adjacent rows, the punctuations in the power plane of the CMOS can be kept to the outside edges of the adjacent rows. This moves one line of narrow resistive bridges between the punctuations to a position where the electrical current does not flow through them. This eliminates their resistance from the actuators drive circuit. By reducing the resistive losses for actuators remote from the power supply side of the printhead IC, the drop ejection characteristics are consistent across the entire array of nozzles.
[0017] Preferably, the electrodes in each row are offset from its adjacent actuators in a direction transverse to the row such that the electrodes of every second actuator are collinear. In a further preferred form, the offset is less than 40 microns. In a particularly preferred form, the offset is less than 30 microns. Preferably the array of nozzles is fabricated on an elongate wafer substrate extending parallel to the rows of the array, and the drive circuitry is CMOS layers on one surface of the wafer substrate, the CMOS layers being supplied with power and data along a long edge of the wafer substrate. In a further preferred form, the CMOS layers have a top metal layer forming a power plane that carries a positive voltage such that the electrodes having a negative voltage connect to vias formed in holes within the power plane. In another preferred form, the CMOS layers have a drive FET (field effect transistor) for each actuator in a bottom metal layer. Preferably, the CMOS layers have layers of metal less than 0.3 microns thick.
[0018] In some embodiments, the actuators are heater elements for generating a vapor bubble in the printing fluid such that a drop of the printing fluid is ejected from the ejection aperture. Preferably, the heater elements are beams suspended between their respective electrodes such that they are immersed in the printing fluid. Preferably, the ejection apertures are elliptical with the major axis of the ejection aperture parallel to the longitudinal axis of the beam. In another preferred form, the major axes of the ejection apertures in one of the rows are respectively collinear with the major axes of the ejection apertures in the adjacent row such that each of the nozzles in one of the rows is aligned with one of the nozzles in the adjacent row. Preferably, the major axes of adjacent ejection apertures are spaced apart less than 50 microns. In a further preferred form, the major axes of adjacent ejection apertures are spaced apart less than 25 microns. In a particularly preferred form, the major axes of adjacent ejection apertures are spaced apart less than 16 microns.
[0019] In particular embodiments, the printhead has a nozzle pitch greater than 1600 nozzle per inch (npi) in a direction transverse to a media feed direction. In preferred embodiments, the nozzle pitch is greater than 3000 npi. In a particularly preferred embodiment, the printhead has a print resolution in dots per inch (dpi) that equals the nozzle pitch. In specific embodiments, the printhead is a pagewidth printhead configured for printing A4 sized media. Preferably, the printhead has more than 100,000 of the nozzles.
[0000] Accordingly, the present invention provides an inkjet printhead for a printer that can print onto a substrate at different print resolutions, the inkjet printhead comprising:
[0020] an array of nozzles, each nozzle having an ejection aperture and a corresponding actuator for ejecting printing fluid through the ejection aperture; and,
[0021] a print engine controller for sending print data to the array of nozzles; wherein,
[0022] during use the print engine controller can selectively reduce the print resolution by apportioning print data for a single nozzle between at least two nozzles of the array.
[0023] The invention recognizes that some print jobs do not require the printhead's best resolution—a lower resolution is completely adequate for the purposes of the document being printed. This is particularly true if the printhead is capable of very high resolutions, say greater than 1200 dpi. By selecting a lower resolution, the print engine controller (PEC) can treat two or more transversely adjacent (but not necessarily contiguous) nozzles as a single virtual nozzle in a printhead with less nozzles. The print data is then shared between the adjacent nozzles—dots required from the virtual nozzle are printed by each the actual nozzles in turn. This serves to extend the operational life of all the nozzles.
[0024] Preferably, the two nozzles are positioned in the array such that they are nearest neighbours in a direction transverse to the movement of the printhead relative to the substrate. Preferably, the PEC shares the print data equally between the two nozzles in the array. In a further preferred form, the two nozzles are spaced at less than 20 micron centres. In a particularly preferred form, the printhead is a pagewidth printhead and the two nozzles are spaced in a direction transverse to the media feed direction at less than 16 micron centres. In a specific embodiments, the two nozzles are spaced in a direction transverse to the media feed direction at less than 8 micron centres. In particular embodiments, the printhead has a nozzle pitch greater than 1600 nozzle per inch (npi) in a direction transverse to a media feed direction. In preferred embodiments, the nozzle pitch is greater than 3000 npi. In a particularly preferred embodiment, the printhead has a print resolution in dots per inch (dpi) that equals the nozzle pitch. In specific embodiments, the printhead is configured for printing A4 sized media and the printhead has more than 100,000 of the nozzles.
[0025] In some embodiments, the printer operates at an increased print speed when printing at the reduced print resolution. Preferably, the increased print speed is greater than 60 pages per minute. In preferred forms, the PEC halftones the color plane printed by the adjacent nozzles with a dither matrix optimized for the transverse shift of every drop ejected.
[0000] Accordingly, the present invention provides an inkjet printhead comprising:
[0026] an array of nozzles arranged in adjacent rows, each nozzle having an ejection aperture, a chamber for containing printing fluid and a corresponding actuator for ejecting the printing fluid through the ejection aperture, each of the chambers having a respective inlet to refill the printing fluid ejected by the actuator; and,
[0027] a printing fluid supply channel extending parallel to the adjacent rows for supplying printing fluid to the actuator of each nozzle in the array via the respective inlets; wherein,
[0028] the inlets of nozzles in one of the adjacent rows configured for a refill flowrate that differs from the refill flowrate through the inlets of nozzles in another of the adjacent rows.
[0029] The invention configures the nozzle array so that several rows are filled from one side of an ink supply channel. This allows a greater density of nozzles on the printhead surface because the supply channel is not supplying just one row of nozzles along each side. However, the flowrate through the inlets is different for each row so that rows further from the supply channel do not have significantly longer refill times.
[0030] Preferably, the inlets of nozzles in one of the adjacent rows configured for a refill flowrate that differs from the refill flowrate through the inlets of nozzles in another of the adjacent rows such that the chamber refill time is substantially uniform for all the nozzles in the array. In a further preferred form, the inlets of the row closest the supply channel are narrower than the rows further from the supply channel. In some embodiments, there are two adjacent rows of nozzles on either side of the supply channel.
[0031] Preferably, the inlets have flow damping formations. In a particularly preferred form, the flow damping formation is a column positioned such that it creates a flow obstruction, the columns in the inlets of one row creating a different degree of obstruction to the columns is the inlets of the other row. Preferably, the columns create a bubble trap between the column sides and the inlet sidewalls. Preferably, the columns diffuse pressure pulses in the printing fluid to reduce cross talk between the nozzles.
[0032] In some embodiments, the actuators are heater elements for generating a vapor bubble in the printing fluid such that a drop of the printing fluid is ejected from the ejection aperture. Preferably, the heater elements are beams suspended between their respective electrodes such that they are immersed in the printing fluid. Preferably, the ejection apertures are elliptical with the major axis of the ejection aperture parallel to the longitudinal axis of the beam. Preferably, the major axes of adjacent ejection apertures are spaced apart less than 50 microns. In a further preferred form, the major axes of adjacent ejection apertures are spaced apart less than 25 microns. In a particularly preferred form, the major axes of adjacent ejection apertures are spaced apart less than 16 microns.
[0033] In particular embodiments, the printhead has a nozzle pitch greater than 1600 nozzle per inch (npi) in a direction transverse to a media feed direction. In preferred embodiments, the nozzle pitch is greater than 3000 npi. In a particularly preferred embodiment, the printhead has a print resolution in dots per inch (dpi) that equals the nozzle pitch. In specific embodiments, the printhead is a pagewidth printhead configured for printing A4 sized media. Preferably, the printhead has more than 100,000 of the nozzles.
[0000] Accordingly, the present invention provides an inkjet printhead comprising:
[0034] an array of nozzles arranged in a series of rows, each nozzle having an ejection aperture, a chamber for holding printing fluid and a heater element for generating a vapor bubble in the printing fluid contained by the chamber to eject a drop of the printing fluid through the ejection aperture; wherein,
[0035] the nozzle, the heater element and the chamber are all elongate structures that have a long dimension that exceeds their other dimensions respectively; and,
[0036] the respective long dimensions of the nozzle, the heater element and the chambers are parallel and extend normal to the row direction.
[0037] To increase the nozzle density of the array, each of the nozzle components—the chamber, the ejection aperture and the heater element are configured as elongate structures that are all aligned transverse to the direction of the row. This raises the nozzle pitch, or nozzle per inch (npi), of the row while allowing the chamber volume and therefore drop volume to stay large enough for a suitable color density. It also avoids the need to spread the over a large distance in the paper feed direction (in the case of pagewidth printers) or in the scanning direction (in the case of scanning printheads).
[0038] Preferably each of the rows in the array is offset with respect to it adjacent row such that none of the long dimensions of the nozzles in one row are not collinear with any of the long dimensions of the adjacent row. In a further preferred form the printhead is a pagewidth printhead for printing to a media substrate fed past the printhead in a media feed direction such that the long dimensions of the nozzles are parallel with the media feed direction.
[0039] Preferably the long dimensions of the nozzles in every second are in registration. In a particularly preferred form the ejection apertures for all the nozzles is formed in a planar roof layer that partially defines the chamber, the roof layer having an exterior surface that is flat with the exception of the ejection apertures. In a particularly preferred form, the array of nozzles is formed on an underlying substrate extending parallel to the roof layer and the chamber is partially defined by a sidewall extending between the roof layer and the substrate, the side wall being shaped such that its interior surface is at least partially elliptical. Preferably, the sidewall is elliptical except for an inlet opening for the printing fluid. In a particularly preferred form, the minor axes of the nozzles in one of the rows partially overlaps with the minor axes of the nozzles in the adjacent row with respect to the media feed direction. In a further preferred form, the ejection apertures are elliptical.
[0040] Preferably, the heater elements are beams suspended between their respective electrodes such that, during use, they are immersed in the printing fluid. Preferably, the vapor bubble generated by the heater element is approximately elliptical in a cross section parallel to the ejection aperture.
[0041] In some embodiments, the printhead further comprises a supply channel adjacent the array extending parallel to the rows. In a preferred form, the array of nozzles is a first array of nozzles and a second array of nozzles is formed on the other side of the supply channel, the second array being a mirror image of the first array but offset with respect to the first array such that none of the major axes of the ejection apertures in the first array are collinear with any of the major axes of the second array. Preferably, the major axes of ejection apertures in the first array are offset from the major axes of the ejection apertures in the second array in a direction transverse to the media feed direction by less than 20 microns. In a particularly preferred form, the offset is approximately 8 microns. In some embodiments, the printhead has a nozzle pitch in the direction transverse to the direction of media feed greater than 1600 npi. In a particularly preferred form, the substrate is less than 3 mm wide in the direction of media feed.
[0000] Accordingly, the present invention provides an inkjet printhead comprising:
[0042] an array of nozzles for ejecting drops of printing fluid onto print media when the print media and moved in a print direction relative to the printhead; wherein,
[0043] the nozzles in the array are spaced apart from each other by less than 10 microns in the direction perpendicular to the print direction.
[0044] With nozzles spaced less than 10 microns apart in the direction perpendicular to the print direction, the printhead has a very high ‘true’ print resolution—i.e. the high number of dots per inch is achieved by a high number of nozzles per inch.
[0045] Preferably, the nozzles in the array that are spaced apart from each other by less than 10 microns in the direction perpendicular to the print direction, are also spaced apart from each other in the print direction by less than 150 microns.
[0046] In a further preferred form, the array has more than 700 of the nozzles per square millimeter.
[0047] Preferably, the array of nozzles is supported on a plurality of monolithic wafer substrates, each monolithic wafer substrate supporting more than 10000 of the nozzles. In a further preferred form, each monolithic wafer substrate supports more than 12000 of the nozzles. In a particularly preferred form, the plurality of monolithic wafer substrates are mounted end to end to form a pagewidth printhead for mounting is a printer configured to feed media past the printhead is a media feed direction, the printhead having more than 100000 of the nozzles and extends in a direction transverse to the media feed direction between 200 mm and 330 mm. In some embodiments, the array has more than 140000 of the nozzles.
[0048] Optionally, the printhead further comprises a plurality of actuators for each of the nozzles respectively, the actuators being arranged in adjacent rows, each having electrodes spaced from each other in a direction transverse to the rows for connection to respective drive transistors and a power supply; wherein,
[0049] the electrodes of the actuators in adjacent rows have opposing polarities such that the actuators in adjacent rows have opposing current flow directions. Preferably the electrodes in each row are offset from its adjacent actuators in a direction transverse to the row such that the electrodes of every second actuator are collinear. In particularly preferred embodiments, the droplet ejectors are fabricated on an elongate wafer substrate extending parallel to the rows of the actuators, and power and data supplied along a long edge of the wafer substrate.
[0050] In some embodiments, the printhead has a print engine controller (PEC) for sending print data to the array of nozzles; wherein,
[0051] during use the print engine controller can selectively reduce the print resolution by apportioning print data for a single nozzle between at least two nozzles of the array. Preferably, the two nozzles are positioned in the array such that they are nearest neighbours in a direction transverse to the movement of the printhead relative to a print media substrate. In a particularly preferred form, the PEC shares the print data equally between the two nozzles in the array. Preferably, the two nozzles are spaced at less than 40 micron centers.
[0052] In a particularly preferred form, the printhead is a pagewidth printhead and the two nozzles are spaced in a direction transverse to the media feed direction at less than 16 micron centers. Preferably, the adjacent nozzles are spaced in a direction transverse to the media feed direction at less than 8 micron centers. Preferably, the printhead has a nozzle pitch greater than 1600 nozzle per inch (npi) in a direction transverse to a media feed direction. In a further preferred form, the nozzle pitch is greater than 3000 npi.
[0000] Accordingly, the present invention provides a printhead integrated circuit for an inkjet printhead, the printhead integrated circuit comprising:
[0053] a monolithic wafer substrate supporting an array of droplet ejectors for ejecting drops of printing fluid onto print media, each drop ejector having a nozzle and an actuator for ejecting a drop of printing fluid through the nozzle; wherein,
[0054] the array has more than 10000 of the droplet ejectors.
[0055] With a large number of droplet ejectors fabricated on a single wafer, the nozzle array has a high nozzle pitch and the printhead has a very high ‘true’ print resolution—i.e. the high number of dots per inch is achieved by a high number of nozzles per inch.
[0056] Preferably, the array has more than 12000 of the droplet ejectors. In a further preferred form, the print media moves in a print direction relative to the printhead and the nozzles in the array are spaced apart from each other by less than 10 microns in the direction perpendicular to the print direction. In a particularly preferred form, the nozzles in the array that are spaced apart from each other by less than 10 microns in the direction perpendicular to the print direction, are also spaced apart from each other in the print direction by less than 150 microns.
[0057] In a preferred embodiment, the array has more than 700 of the droplet ejectors per square millimeter. In a particularly preferred form, the actuators are arranged in adjacent rows, each having electrodes spaced from each other in a direction transverse to the rows for connection to respective drive transistors and a power supply, the electrodes of the actuators in adjacent rows having opposing polarities such that the actuators in adjacent rows have opposing current flow directions. In a still further preferred form, the electrodes in each row are offset from their adjacent actuators in a direction transverse to the row such that the electrodes of every second actuator are collinear.
[0058] In specific embodiments, the monolithic wafer substrate is elongate and extends parallel to the rows of the actuators, such that in use power and data is supplied along a long edge of the wafer substrate. In some forms, the inkjet printhead comprises a plurality of the printhead integrated circuits, and further comprises a print engine controller (PEC) for sending print data to the array of droplet ejectors wherein during use the print engine controller can selectively reduce the print resolution by apportioning print data for a single droplet ejector between at least two droplet ejectors of the array. Preferably, the two nozzles are positioned in the array such that they are nearest neighbours in a direction transverse to the movement of the printhead relative to a print media substrate. In a particularly preferred form, the PEC shares the print data equally between the two nozzles in the array. Optionally, the two nozzles are spaced at less than 40 micron centers. In particularly preferred embodiments, the printhead is a pagewidth printhead and the two nozzles are spaced in a direction transverse to the media feed direction at less than 16 micron centers. In a still further preferred form, the adjacent nozzles are spaced in a direction transverse to the media feed direction at less than 8 micron centers.
[0059] In some embodiments, the inkjet printhead comprises a plurality of the printhead integrated circuits mounted end to end to form a pagewidth printhead for a printer configured to feed media past the printhead is a media feed direction, the printhead having more than 100000 of the nozzles and extends in a direction transverse to the media feed direction between 200 mm and 330 mm. In a further preferred form the array has more than 140000 of the nozzles.
[0060] Preferably, the array of droplet ejectors has a nozzle pitch greater than 1600 nozzle per inch (npi) in a direction transverse to a media feed direction, and preferably the nozzle pitch is greater than 3000 npi.
[0000] Accordingly, the present invention provides a printhead integrated circuit (IC) for an inkjet printhead, the printhead IC comprising:
[0061] a planar array of droplet ejectors, each having data distribution circuitry, a drive transistor, a printing fluid inlet, an actuator, a chamber and a nozzle, the chamber being configured to hold printing fluid adjacent the nozzle such that during use, the drive transistor activates the actuator to eject a droplet of the printing fluid through the nozzle; wherein,
[0062] the array has more than 700 of the droplet ejectors per square millimeter.
[0063] With a high density of droplet ejectors fabricated on a wafer substrate, the nozzle array has a high nozzle pitch and the printhead has a very high ‘true’ print resolution—i.e. the high number of dots per inch is achieved by a high number of nozzles per inch.
[0064] Preferably, the array ejects drops of printing fluid onto print media when the print media and moved in a print direction relative to the printhead, and the nozzles in the array are spaced apart from each other by less than 10 microns in the direction perpendicular to the print direction. In a further preferred form, the nozzles that are spaced apart from each other by less than 10 microns in the direction perpendicular to the print direction, are also spaced apart from each other in the print direction by less than 150 microns.
[0065] In specific embodiments of the invention, a plurality of the printhead ICs are used in an inkjet printhead, each printhead IC having more than 10000 of the droplet ejectors, and preferably more than 12000 of the nozzle and cells.
[0066] In some embodiments, the printhead ICs are elongate and mounted end to end such that the printhead has more than 100000 of the droplet ejectors and extend in a direction transverse to the media feed direction between 200 mm and 330 mm. In a further preferred form, the printhead has more than 140000 of the droplet ejectors.
[0067] In some preferred forms, the actuators are arranged in adjacent rows, each having electrodes spaced from each other in a direction transverse to the rows for connection to the corresponding drive transistor and a power supply; wherein,
[0068] the electrodes of the actuators in adjacent rows have opposing polarities such that the actuators in adjacent rows have opposing current flow directions.
[0069] Preferably, in these embodiments, the electrodes in each row are offset from its adjacent actuators in a direction transverse to the row such that the electrodes of every second actuator are collinear. In further preferred forms, the elongate wafer substrate extends parallel to the rows of the actuators, and power and data supplied along a long edge of the wafer substrate.
[0070] In specific embodiments, the printhead has a print engine controller (PEC) for sending print data to the array of nozzles; wherein,
[0071] during use the print engine controller can selectively reduce the print resolution by apportioning print data for a single nozzle between at least two nozzles of the array.
[0072] Preferably, the two nozzles are positioned in the array such that they are nearest neighbours in a direction transverse to the movement of the printhead relative to a print media substrate. In a further preferred form, the PEC shares the print data equally between the two nozzles in the array. Preferably, the two nozzles are spaced at less than 40 micron centers. In a particularly preferred form, the printhead is a pagewidth printhead and the two nozzles are spaced in a direction transverse to the media feed direction at less than 16 micron centers. In a still further preferred form, the adjacent nozzles are spaced in a direction transverse to the media feed direction at less than 8 micron centers.
[0073] In some forms, the printhead has a nozzle pitch greater than 1600 nozzle per inch (npi) in a direction transverse to a media feed direction. Preferably, the nozzle pitch is greater than 3000 npi.
[0000] Accordingly, the present invention provides a pagewidth inkjet printhead comprising:
[0074] an array of droplet ejectors for ejecting drops of printing fluid onto print media fed passed the printhead in a media feed direction, each drop ejector having a nozzle and an actuator for ejecting a drop of printing fluid through the nozzle; wherein,
[0075] the array has more than 100000 of the droplet ejectors and extends in a direction transverse to the media feed direct between 200 mm and 330 mm.
[0076] A pagewidth printhead with a large number of nozzles extending the width of the media provides a high nozzle pitch and a very high ‘true’ print resolution—i.e. the high number of dots per inch is achieved by a high number of nozzles per inch.
[0077] Preferably, the array has more than 140000 of the droplet ejectors. In a further preferred form, the nozzles are spaced apart from each other by less than 10 microns in the direction perpendicular to the media feed direction. In a particularly preferred form, the nozzles that are spaced apart from each other by less than 10 microns in the direction perpendicular to the media feed direction, are also spaced apart from each other in the media feed direction by less than 150 microns.
[0078] In specific embodiments, the array of droplet ejectors is supported on a plurality of monolithic wafer substrates, each monolithic wafer substrate supporting more than 10000 of the droplet ejectors, and preferably more than 12000 of the droplet ejectors. In these embodiments, it is desirable that the array has more than 700 of the droplet ejectors per square millimeter.
[0079] Optionally, the actuators are arranged in adjacent rows, each having electrodes spaced from each other in a direction transverse to the rows for connection to respective drive transistors and a power supply; wherein,
[0080] the electrodes of the actuators in adjacent rows have opposing polarities such that the actuators in adjacent rows have opposing current flow directions. Preferably the electrodes in each row are offset from its adjacent actuators in a direction transverse to the row such that the electrodes of every second actuator are collinear. In particularly preferred embodiments, the droplet ejectors are fabricated on an elongate wafer substrate extending parallel to the rows of the actuators, and power and data supplied along a long edge of the wafer substrate.
[0081] In some embodiments, the printhead has a print engine controller (PEC) for sending print data to the array of nozzles; wherein,
[0082] during use the print engine controller can selectively reduce the print resolution by apportioning print data for a single nozzle between at least two nozzles of the array. Preferably, the two nozzles are positioned in the array such that they are nearest neighbours in a direction transverse to the movement of the printhead relative to a print media substrate. In a particularly preferred form, the PEC shares the print data equally between the two nozzles in the array. Preferably, the two nozzles are spaced at less than 40 micron centers.
[0083] In a particularly preferred form, the printhead is a pagewidth printhead and the two nozzles are spaced in a direction transverse to the media feed direction at less than 16 micron centers. Preferably, the adjacent nozzles are spaced in a direction transverse to the media feed direction at less than 8 micron centers. Preferably, the printhead has a nozzle pitch greater than 1600 nozzle per inch (npi) in a direction transverse to a media feed direction. In a further preferred form, the nozzle pitch is greater than 3000 npi.
[0000] Accordingly, the present invention provides a printhead integrated circuit for an inkjet printer, the printhead integrated circuit comprising:
[0084] a monolithic wafer substrate supporting an array of droplet ejectors for ejecting drops of printing fluid onto print media, each droplet ejector having nozzle and an actuator for ejecting a drop of printing fluid the nozzle, the array being formed on the monolithic wafer substrate by a succession of photolithographic etching and deposition steps involving a photo-imaging device that exposes an exposure area to light focused to project a pattern onto the monolithic substrate; wherein,
[0085] the array has more than 10000 of the droplet ejectors configured to be encompassed by the exposure area.
[0086] The invention arranges the nozzle array such that the droplet ejector density is very high and the number of exposure steps required is reduced.
[0087] Preferably the exposure area is less than 900 mm 2 . Preferably, the monolithic wafer substrate is encompassed by the exposure area. In a further preferred form the photo-imaging device is a stepper that exposes an entire reticle simultaneously. Optionally, the photo-imaging device is a scanner that scans a narrow band of light across the exposure area to expose the reticle.
[0088] Preferably, the monolithic wafer substrate supports more than 12000 of the droplet ejectors. In these embodiments, it is desirable that the array has more than 700 of the droplet ejectors per square millimeter.
[0089] In some embodiments, the printhead IC is assembled onto a pagewidth printhead with other like printhead ICs, for ejecting drops of printing fluid onto print media fed passed the printhead in a media feed direction, wherein
[0090] the printhead has more than 100000 of the droplet ejectors and extends in a direction transverse to the media feed direct between 200 mm and 330 mm. In a further preferred form, the nozzles are spaced apart from each other by less than 10 microns in the direction perpendicular to the media feed direction. Preferably, the printhead has more than 140000 of the droplet ejectors. In a particularly preferred form, the nozzles that are spaced apart from each other by less than 10 microns in the direction perpendicular to the media feed direction, are also spaced apart from each other in the media feed direction by less than 150 microns.
[0091] Optionally, the actuators are arranged in adjacent rows, each having electrodes spaced from each other in a direction transverse to the rows for connection to respective drive transistors and a power supply; wherein,
[0092] the electrodes of the actuators in adjacent rows have opposing polarities such that the actuators in adjacent rows have opposing current flow directions. Preferably the electrodes in each row are offset from its adjacent actuators in a direction transverse to the row such that the electrodes of every second actuator are collinear. In particularly preferred embodiments, the droplet ejectors are fabricated on an elongate wafer substrate extending parallel to the rows of the actuators, and power and data supplied along a long edge of the wafer substrate.
[0093] In some embodiments, the printhead has a print engine controller (PEC) for sending print data to the array of nozzles; wherein,
[0094] during use the print engine controller can selectively reduce the print resolution by apportioning print data for a single nozzle between at least two nozzles of the array. Preferably, the two nozzles are positioned in the array such that they are nearest neighbours in a direction transverse to the movement of the printhead relative to a print media substrate. In a particularly preferred form, the PEC shares the print data equally between the two nozzles in the array. Preferably, the two nozzles are spaced at less than 40 micron centers.
[0095] In a particularly preferred form, the printhead is a pagewidth printhead and the two nozzles are spaced in a direction transverse to the media feed direction at less than 16 micron centers. Preferably, the adjacent nozzles are spaced in a direction transverse to the media feed direction at less than 8 micron centers. Preferably, the printhead has a nozzle pitch greater than 1600 nozzle per inch (npi) in a direction transverse to a media feed direction. In a further preferred form, the nozzle pitch is greater than 3000 npi.
BRIEF DESCRIPTION OF THE DRAWINGS
[0096] Preferred embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which:
[0097] FIG. 1A is a schematic representation of the linking printhead IC construction;
[0098] FIG. 1B shows a partial plan view of the nozzle array on a printhead IC according to the present invention;
[0099] FIG. 2 is a unit cell of the nozzle array;
[0100] FIG. 3 shows the unit cell replication pattern that makes up the nozzle array;
[0101] FIG. 4 is a schematic cross section through the CMOS layers and heater element of a nozzle;
[0102] FIG. 5A schematically shows an electrode arrangement with opposing electrode polarities in adjacent actuator rows;
[0103] FIG. 5B schematically shows an electrode arrangement with typical electrode polarities in adjacent actuator rows;
[0104] FIG. 6 shows the electrode configuration of the printhead IC of FIG. 1 ;
[0105] FIG. 7 shows a section of the power plane of the CMOS layers;
[0106] FIG. 8 shows the pattern etched into the sacrificial scaffold layer for the roof/side wall layer;
[0107] FIG. 9 shows the exterior surface of the roof layer after the nozzle apertures have been etched;
[0108] FIG. 10 shows the ink supply flow to the nozzles;
[0109] FIG. 11 shows the different inlets to the chambers in different rows;
[0110] FIG. 12 shows the nozzle spacing for one color channel;
[0111] FIG. 13 shows an enlarged view of the nozzle array with matching elliptical chamber and ejection aperture;
[0112] FIG. 14 is a sketch of a photolithographic stepper; and,
[0113] FIGS. 15A to 15 C schematically illustrate the operation of a photolithographic stepper.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0114] The printhead IC (integrated circuit) shown in the accompanying drawings is fabricated using the same lithographic etching and deposition steps described in the U.S. Ser. No. 11/246,687 (Our Docket MNN001US) filed 11 Oct. 2005), the contents of which are incorporated herein by reference. The ordinary worker will understand that the printhead IC shown in the accompanying drawings have a chamber, nozzle and heater electrode configuration that requires the use of exposure masks that differ from those shown in U.S. Ser. No. 11/246,687 (Our Docket MNN001US) filed 11 Oct. 2005 Figures. However the process steps of forming the suspended beam heater elements, chambers and ejection apertures remains the same. Likewise, the CMOS layers are formed in the same manner as that discussed MNN001US with the exception of the drive FETs. The drive FETs need to be smaller because the higher density of the heater elements.
[0000] Linking Printhead Integrated Circuits
[0115] The Applicant has developed a range of printhead devices that use a series of printhead integrated circuits (ICs) that link together to form a pagewidth printhead. In this way, the printhead IC's can be assembled into printheads used in applications ranging from wide format printing to cameras and cellphones with inbuilt printers. The printhead IC's are mounted end-to-end on a support member to form a pagewidth printhead. The support member mounts the printhead IC's in the printer and also distributes ink to the individual IC's. An example of this type of printhead is described in U.S. Ser. No. 11/293,820, the disclosure of which is incorporated herein by cross reference.
[0116] It will be appreciated that any reference to the term ‘ink’ is to be interpreted as any printing fluid unless it is clear from the context that it is only a colorant for imaging print media. The printhead IC's can equally eject invisible inks, adhesives, medicaments or other functionalized fluids.
[0117] FIG. 1A shows a sketch of a pagewidth printhead 100 with the series of printhead ICs 92 mounted to a support member 94 . The angled sides 96 allow the nozzles from one of the IC's 92 overlap with those of an adjacent IC in the paper feed direction 8 . Overlapping the nozzles in each IC 92 provides continuous printing across the junction between two IC's. This avoids any ‘banding’ in the resulting print. Linking individual printhead IC's in this manner allows printheads of any desired length to be made by simply using different numbers of IC's.
[0118] The end to end arrangement of the printhead ICs 92 requires the power and data to be supplied to bond pads 98 along the long sides of each printhead IC 92 . These connections, and the control of the linking ICs with a print engine controller (PEC), is described in detail in Ser. No. 11/544,764 (Docket No. PUA001US) filed 10 Oct. 2006.
[0000] 3200 dpi Printhead Overview
[0119] FIG. 1B shows a section of the nozzle array on the Applicants recently developed 3200 dpi printhead. The printhead has ‘true’ 3200 dpi resolution in that the nozzle pitch is 3200 npi rather than a printer with 3200 dpi addressable locations and a nozzle pitch less than 3200 npi. The section shown in FIG. 1B shows eight unit cells of the nozzle array with the roof layer removed. For the purposes of illustration, the ejection apertures 2 have been shown in outline. The ‘unit cell’ is the smallest repeating unit of the nozzle array and has two complete droplet ejectors and four halves of the droplet ejectors on either side of the complete ejectors. A single unit cell is shown in FIG. 2 .
[0120] The nozzle rows extend transverse to the media feed direction 8 . The middle four rows of nozzles are one color channel 4 . Two rows extend either side of the ink supply channel 6 . Ink from the opposing side of the wafer flows to the supply channel 6 through the ink feed conduits 14 . The upper and lower ink supply channels 10 and 12 are separate color channels (although for greater color density they may print the same color ink—eg a CCMMY printhead).
[0121] Rows 20 and 22 above the supply channel 6 are transversely offset with respect to the media feed direction 8 . Below the ink supply channel 6 , rows 24 and 26 are similarly offset along the width of the media. Furthermore, rows 20 and 22 , and rows 24 and 26 are mutually offset with respect to each other. Accordingly, the combined nozzle pitch of rows 20 to 26 transverse to the media feed direction 8 is one quarter the nozzle pitch of any of the individual rows. The nozzle pitch along each row is approximately 32 microns (nominally 31.75 microns) and therefore the combined nozzle pitch for all the rows in one color channel is approximately 8 microns (nominally 7.9375 microns). This equates to a nozzle pitch of 3200 npi and hence the printhead has ‘true’ 3200 dpi resolution.
[0000] Unit Cell
[0122] FIG. 2 is a single unit cell of the nozzle array. Each unit cell has the equivalent of four droplet ejectors (two complete droplet ejectors and four halves of the droplet ejectors on both sides of the complete ejectors). The droplet ejectors are the nozzle, the chamber, drive FET and drive circuitry for a single MEMS fluid ejection device. The ordinary worker will appreciate that the droplet ejectors are often simply referred to as nozzles for convenience but it is understood from the context of use whether this term is a reference to just the ejection aperture of the entire MEMS device.
[0123] The top two nozzle rows 18 are fed from the ink feed conduits 14 via the top ink supply channel 10 . The bottom nozzle rows 16 are a different color channel fed from the supply channel 6 . Each nozzle has an associated chamber 28 and heater element 30 extending between electrodes 34 and 36 . The chambers 28 are elliptical and offset from each other so that their minor axes overlap transverse to the media feed direction. This configuration allows the chamber volume, nozzle area and heater size to be substantially the same as the 1600 dpi printheads shown in the above referenced U.S. Ser. No. 11/246,687 (Our Docket MNN001US) filed 11 Oct. 2005. Likewise the chamber walls 32 remain 4 microns thick and the area of the contacts 34 and 36 are still 10 microns by 10 microns.
[0124] FIG. 3 shows the unit cell replication pattern that makes up the nozzle array. Each unit cell 38 is translated by its width x across the wafer. The adjacent rows are flipped to a mirror image and translated by half the width: 0.5x=y. As discussed above, this provides a combined nozzle pitch for the rows of one color channel ( 20 , 22 , 24 and 26 ) of 0.25x. In the embodiment shown, x=31.75 and y=7.9375. This provides a 3200 dpi resolution without reducing the size of the heaters, chambers or nozzles. Accordingly, when operating at 3200 dpi, the print density is higher than the 1600 dpi printhead of U.S. Ser. No. 11/246,687 (Our Docket MNN001US) filed 11 Oct. 2005, or the printer can operate at 1600 dpi to extend the life of the nozzles with a good print density. This feature of the printhead is discussed further below.
[0000] Heater Contact Arrangement
[0125] The heater elements 30 and respective contacts 34 and 36 are the same dimensions as the 1600 dpi printhead IC of U.S. Ser. No. 11/246,687 (Our Docket MNN001US) filed 11 Oct. 2005. However, as there is twice the number of contacts, there is twice the number of FET contacts (negative contacts) that punctuate the ‘power plane’ (the CMOS metal layer carrying the positive voltage). A high density of holes in the power plane creates high resistance through the thin pieces of metal between the holes. This resistance is detrimental to overall printhead efficiency and can reduce the drive pulse to some heaters relative to others.
[0126] FIG. 4 is a schematic section view of the wafer, CMOS drive circuitry 56 and the heater. The drive circuitry 56 for each printhead IC is fabricated on the wafer substrate 48 in the form of several metal layers 40 , 42 , 44 and 45 separated by dielectric material 41 , 43 and 47 through which vias 46 establish the required inter layer connections. The drive circuitry 56 has a drive FET (field effect transistor) 58 for each actuator 30 . The source 54 of the FET 58 is connected to a power plane 40 (a metal layer connected to the position voltage of the power supply) and the drain 52 connects to a ground plane 42 (the metal layer at zero voltage or ground). Also connected to the ground plane 42 and the power plane 40 are the electrodes 34 and 36 or each of the actuators 30 .
[0127] The power plane 40 is typically the uppermost metal layer and the ground plane 42 is the metal layer immediately beneath (separated by a dielectric layer 41 ). The actuators 30 , ink chambers 28 and nozzles 2 are fabricated on top of the power plane metal layer 40 . Holes 46 are etched through this layer so that the negative electrode 34 can connect to the ground plane and an ink passage 14 can extend from the rear of the wafer substrate 48 to the ink chambers 28 . As the nozzle density increases, so to does the density of these holes, or punctuations through the power plane. With a greater density of punctuations through the power plane, the gaps between the punctuations are reduced. The thin bridge of metal layer though these gaps is a point of relatively high electrical resistance. As the power plane is connected to a supply along one side of the printhead IC, the current to actuators on the non-supply side of the printhead IC may have had to pass through a series of these resistive gaps. The increased parasitic resistance to the non-supply side actuators will affect their drive current and ultimately the drop ejection characteristics from those nozzles.
[0128] The printhead uses several measures to address this. Firstly, adjacent rows of actuators have opposite current flow directions. That is, the electrode polarity in one rows is switched in the adjacent row. For the purposes of this aspect of the printhead, two rows of nozzles adjacent the supply channel 16 should be considered as a single row as shown in FIG. 5A instead of staggered as shown in the previous figures. The two rows A and B extend longitudinally along the length of the printhead IC. All the negative electrodes 34 are along the outer edges of the two adjacent rows A and B. The power is supplied from one side, say edge 62 , and so the current only passes through one line of thin, resistive metal sections 64 before it flows through the heater elements 30 in both rows. Accordingly, the current flow direction in row A is opposite to the current flow direction in row B.
[0129] The corresponding circuit diagram illustrates the benefit of this configuration. The power supply V+ drops because of the resistance R A of the thin sections between the negative electrodes 34 of row A. However, the positive electrodes 36 for all the heaters 30 are at the same voltage relative to ground (V A =V B ). The voltage drop across all heaters 30 (resistances R HA and R HB respectively) in both rows A and B is uniform. The resistance R B from the thin bridges 66 between the negative electrodes 34 of row B is eliminated from the circuit for rows A and B.
[0130] FIG. 5B shows the situation if the polarities of the electrodes in adjacent rows are not opposing. In this case, the line of resistive sections 66 in row B are in the circuit. The supply voltage V+ drops through the resistance R A to V A —the voltage of the positive electrodes 36 of row A. From there the voltage drops to ground through the resistance R HA of the row A heaters 30 . However, the voltage V B at the row B positive electrodes 36 drops from V A through R B from the thin section 66 between the row B negative electrodes 34 . Hence the voltage drop though the row B heaters 30 is less than that of row A. This in turn changes the drive pulse and therefore the drop ejection characteristics.
[0131] The second measure used to maintain the integrity of the power plane is staggering adjacent electrodes pairs in each row. Referring to FIG. 6 , the negative electrode 34 are now staggered such that every second electrode is displaced transversely to the row. The adjacent row of heater contacts 34 and 36 are likewise staggered. This serves to further widen the gaps 64 and 66 between the holes through the power plane 40 . The wider gaps have less electrical resistance and the voltage drop to the heaters remote from the power supply side of the printhead IC is reduced. FIG. 7 shows a larger section of the power plane 40 . The electrodes 34 in staggered rows 41 and 44 correspond to the color channel feed by supply channel 6 . The staggered rows 42 and 43 relate to one half the nozzles for the color channels on either side—the color fed by supply channel 10 and the color channel fed by supply channel 12 . It will be appreciated that a five color channel printhead IC has nine rows of negative electrodes that can induce resistance for the heaters in the nozzles furthest from the power supply side. Widening the gaps between the negative electrodes greatly reduces the resistance they generate. This promoted more uniform drop ejection characteristics from the entire nozzle array.
[0000] Efficient Fabrication
[0132] The features described above increase the density of nozzles on the wafer. Each individual integrated circuit is about 22 mm long, less than 3 mm wide and can support more than 10000 nozzles. This represents a significant increase on the nozzle numbers (70,400 nozzles per IC) in the Applicants 1600 dpi printhead ICs (see for example U.S. Ser. No. 11/246,687 (Our Docket MNN001US) filed 11 Oct. 2005). In fact, a true 3200 dpi printhead nozzle array fabricated to the dimensions shown in FIG. 12 , has 12,800 nozzles.
[0133] The lithographic fabrication of this many nozzles (more than 10,000) is efficient because the entire nozzle array fits within the exposure area of the lithographic stepper or scanner used to expose the reticles (photomasks). A photolithographic stepper is sketched in FIG. 14 . A light source 102 emits parallel rays of a particular wavelength 104 through the reticle 106 that carries the pattern to be transferred to the integrated circuit 92 . The pattern is focused through a lens 108 to reduce the size of the features and projected onto a wafer stage 110 the carries the integrated circuits 92 for ‘dies’ as they are also known). The area of the wafer stage 110 illuminated by the light 104 is called the exposure area 112 . Unfortunately, the exposure area 112 is limited in size to maintain the accuracy of the projected pattern—whole wafer discs can not be exposed simultaneously. The vast majority of photolithographic steppers have an exposure area 112 less than 30 mm by 30 mm. One major manufacturer, ASML of the Netherlands, makes steppers with an exposure area of 22 mm by 22 mm which is typical of the industry.
[0134] The stepper exposes one die, or a part of a die, and then steps to another, or another part of the same die. Having as many nozzles as possible on a single monolithic substrate is advantageous for compact printhead design and minimizing the assembly of the ICs on a support in precise relation to one another. The invention configures the nozzle array so that more than 10,000 nozzles fit into the exposure area. In fact the entire integrated circuit can fit into the exposure area so that more than 14,000 nozzles are fabricated on a single monolithic substrate without having to step and realign for each pattern.
[0135] The ordinary worker will appreciate that the same applies to fabrication of the nozzle array using a photolithographic scanner. The operation of a scanner is sketched in FIG. 15A to 15 C. In a scanner, the light source 102 emits a narrower beam of light 104 that is still wide enough to illuminate the entire width of the reticle 106 . The narrow beam 104 is focused through a smaller lens 108 and projected onto part of the integrated circuit 92 mounted in the exposure area 112 . The reticle 106 and the wafer stage 110 are moved in opposing directions relative to each other so that the reticle's pattern is scanned across the entire exposure area 112 .
[0136] Clearly, this type of photo-imaging device is also suited to efficient fabrication of printhead ICs with large numbers of nozzles.
[0000] Flat Exterior Nozzle Surface
[0137] As discussed above, the printhead IC is fabricated in accordance with the steps listed in cross referenced U.S. Ser. No. 11/246,687 (Our Docket MNN001US) filed 11 Oct. 2005. Only the exposure mask patterns have been changed to provide the different chamber and heater configurations. As described in MNN001US, the roof layer and the chamber walls are an integral structure—a single Plasma Enhanced Chemical Vapor Deposition (PECVD) of suitable roof and wall material. Suitable roof materials may be silicon nitride, silicon oxide, silicon oxynitride, aluminium nitride etc. The roof and walls are deposited over a scaffold layer of sacrificial photoresist to form an integral structure on the passivation layer of the CMOS.
[0138] FIG. 8 shows the pattern etched into the sacrificial layer 72 . The pattern consists of the chamber walls 32 and columnar features 68 (discussed below which are all of uniform thickness. In the embodiment shown, the thickness of the walls and columns is 4 microns. These structures are relatively thin so when the deposited roof and wall material cools there is little if any depression in the exterior surface of the roof layer 70 (see FIG. 9 ). Thick features in the etch pattern will hold a relatively large volume of the roof/wall material. When the material cools and contracts, the exterior surface draws inwards to create a depression.
[0139] These depressions leave the exterior surface uneven which can be detrimental to the printhead maintenance. If the printhead is wiped or blotted, paper dust and other contaminants can lodge in the depressions. As shown in FIG. 9 , the exterior surface of the roof layer 72 is flat and featureless except for the nozzles 2 . Dust and dried ink is more easily removed by wiping or blotting.
[0000] Refill Ink Flow
[0140] Referring to FIG. 10 , each ink inlet supplies four nozzles except at the longitudinal ends of the array where the inlets supply fewer nozzles. Redundant nozzle inlets 14 are an advantage during initial priming and in the event of air bubble obstruction.
[0141] As shown by the flow lines 74 , the refill flow to the chambers 28 remote from the inlets 14 is longer than the refill flow to the chambers 28 immediately proximate the supply channel 6 . For uniform drop ejection characteristics, it is desirable to have the same ink refill time for each nozzle in the array.
[0142] As shown in FIG. 11 , the inlets 76 to the proximate chambers are dimensioned differently to the inlets 78 to the remote chambers. Likewise the column features 68 are positioned to provide different levels of flow constriction for the proximate nozzle inlets 76 and the remote nozzle inlets 78 . The dimensions of the inlets and the position of the column can tune the fluidic drag such that the refill times of all the nozzles in the array are uniform. The columns can also be positioned to damp the pressure pulses generated by the vapor bubble in the chamber 28 . Damping pulses moving though the inlet prevents fluidic cross talk between nozzles. Furthermore, the gaps 80 and 82 between the columns 68 and the sides of the inlets 76 and 78 can be effective bubble traps for larger outgassing bubbles entrained in the ink refill flow.
[0000] Extended Nozzle Life
[0143] FIG. 12 shows a section of one color channel in the nozzle array with the dimensions necessary for 3200 dpi resolution. It will be appreciated that ‘true’ 3200 dpi is very high resolution—greater than photographic quality. This resolution is excessive for many print jobs. A resolution of 1600 dpi is usually more than adequate. In view of this, the printhead IC sacrifice resolution by sharing the print data between two adjacent nozzles. In this way the print data that would normally be sent to one nozzle in a 1600 dpi printhead is sent alternately to adjacent nozzles in a 3200 dpi printhead. This mode of operation more than doubles the life of the nozzles and it allows the printer to operate at much higher print speeds. In 3200 dpi mode, the printer prints at 60 ppm (full color A4) and in 1600 dpi mode, the speed approaches 120 ppm.
[0144] An additional benefit of the 1600 dpi mode is the ability to use this printhead IC with print engine controllers (PEC) and flexible printed circuit boards (flex PCBs) that are configured for 1600 dpi resolution only. This makes the printhead IC retro-compatible with the Applicant's earlier PECs and PCBs.
[0145] As shown in FIG. 12 , the nozzle 83 is transversely offset from the nozzle 84 by only 7.9375 microns. They are spaced further apart in absolute terms but displacement in the paper feed direction can be accounted for with the timing of nozzle firing sequence. As the 8 microns transverse shift between adjacent nozzles is small, it can be ignored for rendering purposes. However, the shift can be addressed by optimizing the dither matrix if desired.
[0000] Bubble, Chamber and Nozzle Matching
[0146] FIG. 13 is an enlarged view of the nozzle array. The ejection aperture 2 and the chamber walls 32 are both elliptical. Arranging the major axes parallel to the media feed direction allows the high nozzle pitch in the direction transverse to the feed direction while maintaining the necessary chamber volume. Furthermore, arranging the minor axes of the chambers so that they overlap in the transverse direction also improves the nozzle packing density.
[0147] The heaters 30 are a suspended beam extending between their respective electrodes 34 and 36 . The elongate beam heater elements generate a bubble that is substantially elliptical (in a section parallel to the plane of the wafer). Matching the bubble 90 , chamber 28 and the ejection aperture 2 promotes energy efficient drop ejection. Low energy drop ejection is crucial for a ‘self cooling’ printhead.
[0000] Conclusion
[0148] The printhead IC shown in the drawings provides ‘true’ 3200 dpi resolution and the option of significantly higher print speeds at 1600 dpi. The print data sharing at lower resolutions prolongs nozzle life and offers compatibility with existing 1600 dpi print engine controllers and flex PCBs. The uniform thickness chamber wall pattern gives a flat exterior nozzle surface that is less prone to clogging. Also the actuator contact configuration and elongate nozzle structures provide a high nozzle pitch transverse to the media feed direction while keeping the nozzle array thin parallel to the media feed direction.
[0149] The specific embodiments described are in all respects merely illustrative and in no way restrictive on the spirit and scope of the broad inventive concept.
|
An inkjet printhead with an array of nozzles arranged in a series of rows, each nozzle having an ejection aperture, a chamber for holding printing fluid and a heater element for generating a vapor bubble in the printing fluid contained by the chamber to eject a drop of the printing fluid through the ejection aperture. The nozzle, the heater element and the chamber are all elongate structures that have a long dimension that exceeds their other dimensions respectively. The respective long dimensions of the nozzle, the heater element and the chambers are parallel and extend normal to the row direction. To increase the nozzle density of the array, each of the nozzle components—the chamber, the ejection aperture and the heater element are configured as elongate structures that are all aligned transverse to the direction of the row. This raises the nozzle pitch, or nozzle per inch (npi), of the row while allowing the chamber volume and therefore drop volume to stay large enough for a suitable color density. It also avoids the need to spread the over a large distance in the paper feed direction (in the case of pagewidth printers) or in the scanning direction (in the case of scanning printheads).
| 1
|
BACKGROUND OF THE INVENTION
The present invention relates generally to computer programs, and more particularly to a method and apparatus for correcting common errors in multiple versions of a computer program using pattern substitution.
It is commonly known that software programs are constantly updated, adding new features and repairing errors. Each update is considered a new version and oftentimes, there are many versions of a software program in existence at any given time. As a result, many versions of a program may have commonly-shared problems, such as a common Year 2000 (Y2K) problem.
To repair a Y2K problem in multiple versions of a computer program by conventional methods would include modifying the source code and creating yet another new version. If there are N existing versions of a given program, such a repair could require the creation of N new versions. Furthermore, when creating a new version of the program using compilation tools, the variables may be at different memory locations than in the prior version, which could result in additional problems. For example, because complex software may contain small errors that are sensitive to the locations of these variables, this technique may result in an unexpected change in the behavior of the program. Therefore, additional testing is required to determine that no undesired behavioral changes were induced. In other words, the programmer who is repairing the program for one problem, for example a Y2K problem, must thoroughly test each version of the program to ensure that no additional problems have been caused because of the repair.
In order to avoid this problem, one method of correcting a problem in a program includes modifying specific locations in the software. This prior art method is known as a “software patch” and the benefits of reduced testing are widely understood. However, one disadvantage of a software patch is that it requires intervention at a machine code level, and thus is not in an easily readable form. Another disadvantage of this method is that repeating this for each and every version of the software that has been created is time consuming and labor intensive.
It would therefore be desirable to have a method and apparatus that is capable of repairing many versions of a software program to address a common problem, such as the Y2K problem, with little intervention and minimal programmer time.
SUMMARY OF THE INVENTION
The present invention relates to a method and apparatus for correcting a common problem in multiple versions of a computer programming using a pattern substitution method that solves the aforementioned problems.
The present invention was developed to address a Y2K problem in multiple versions of a software program within a limited time period. However, the invention is not limited to Year 2000 repairs, but is applicable to any common problem experienced in multiple versions of a software program. The benefits of this technique are exemplified, however, when given a fixed deadline, such as what the Year 2000 problem imposes. The invention expands upon the prior art software patch technique by allowing a means of repairing multiple versions of software with a single repair program. The benefits of reduced testing are then multiplied by the number of versions of the program that are in existence, while the disadvantage of machine code intervention is incurred but a single time and reduces the potential of altering the behavior of any particular version of the program.
Therefore, in accordance with one aspect of the invention, a method of correcting a common error in multiple versions of a computer program includes identifying the common error in the computer program and finding a common code section that contains the common error. The method next includes locating a segment of the common code section that is modifiable, modifying the segment located to correct the common error, and then writing a repair program to search the other versions of the computer program and perform the modification step automatically for each version of the computer program.
In accordance with another aspect of the invention, a computer repair program stored on a computer readable storage medium and designed to repair an error in a main computer program stored in a computer is disclosed. The computer program is designed to search the main computer program for an affected segment of the code defined by a predetermined word string that is based on a previous review of an exemplary version of the main computer program. Once the repair program locates the affected segment, the repair program replaces the affected segment of code with a repaired segment.
Various other features, objects and advantages of the present invention will be made apparent from the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrate the best mode presently contemplated for carrying out the invention.
In the drawings:
FIG. 1 is a schematic view of a general purpose computer.
FIG. 2 is a flowchart of the method of creating the repair program.
FIG. 3 is a flowchart of the repair program of the present invention for use on the computer of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a general purpose computer 10 is commonly thought of as including a computer monitor 12 and the computer itself 14 . The computer 14 includes a hard drive 16 capable of storing computer programs and a disk drive 18 for reading data and computer program files from a transportable medium 20 . The transportable medium 20 may be a floppy disk or any other computer readable storage medium that can transport data into and from the computer 14 . Typically, the computer program to be repaired is located on the hard drive 16 and the repair program of the present invention would reside on a transportable computer readable storage medium 20 to repair the main program on the hard drive 16 . Alternatively, a network connection to the computer could be used to download the repair program.
Referring now to FIG. 2, a method of generating the repair program is shown. The method is designed to generate a repair program for the repair of multiple versions of a computer program affected by an error from a review of a single version of the computer program affected by the error. In general, to write the repair program, the following steps must first be performed. First 100 , the common error in the computer program must be identified 104 , and then a common code section that contains the common error must be found 106 from a review of the source code 102 . Specifically, to begin 100 , an engineer reviews the source code 102 of one version of a computer program affected by an error. By reviewing 102 one version of the program affected by the error, the specific error as implemented in the source code of the affected program, can be identified 104 . Then, a larger section of code, which contains the code including the error, is identified 106 .
In further detail, the step of finding a common code section is determined not only on a section that contains the common error, but also on one that has not been previously modified as between multiple versions of the main computer program. The machine code that is examined is generated when compiling the common code to locate a segment that has relocatable code that can be modified manually. Therefore, once a specific section of code containing the error is identified 106 , a determination 108 of whether the identified section is common to other versions of the computer program is made. In a Y2K or other repair, it is preferable to use a segment containing relocatable code where the address of the date data is relative. It is also preferred to avoid areas that require a linker to resolve the final location of variables since these addresses may differ from version to version. A subroutine that receives the date data, or its address, as an argument is preferred if the other criteria are met. The digital pattern of this affected segment of machine code is the original pattern that can then be found in multiple versions of the main program.
If it is determined that the identified section of code is not common to other versions of the affected program 110 , the identified section is augmented to include more or less source code 112 in attempt to find a section of code that is common to other versions of the affected computer program. Following augmentation 112 , the identified section is again checked to determine whether the section is common to other versions of the affected program 108 .
Once a determination is made that the identified section is common to other versions of the affected program 114 , a determination is made as to whether the identified section is able to be modified without rendering the program inoperable or causing further errors 116 . Specifically the identified section must be able to be modified to correct the error without significantly changing the operation of the program or changing the operation of the program in a manner contrary to the programs intended purpose. Simply, if the identified section can be edited to correct the error without hindering the operation of the program or incurring negative effects, then the section is “modifiable.” If the identified section is not deemed modifiable 118 , the identified section must again be augmented 112 and another determination of whether the identified section is common to other versions of the affected program must be made 108 .
Once the identified section is deemed modifiable 120 , the error is corrected 122 and a repair program is created 124 to automatically search and repair other versions of the affected program.
In repairing the error and creating a repaired segment, the machine code of the affected segment is optimized to perform the same functionality, but with fewer machine codes in order to free machine code space. This freed space, saved by optimizing, is then available for the insertion of additional machine code to correct the error or problem in the code. The repaired segment, or the replacement pattern, is made identical in size to that of the original pattern, or the affected segment. Preferably, the byte size of the pattern is selected large enough so that the pattern is not mistakenly matched to other code segments that while similar, are not in need of repair. Therefore, it is preferred that the size of a pattern be at least approximately 20 words to easily avoid other code paths. However, the pattern size is clearly application specific and will vary. Optionally, the repair can be tested with a test run through the main program to ensure the search results are accurate, preferably, resulting in no more than one hit.
Once the common original pattern and a common replacement pattern have been identified, the repair program is written 124 that is capable of repairing multiple versions of the main program by locating the original pattern in the affected segment and substituting the replacement pattern comprising the repaired segment. The step of writing a repair program includes the steps of automatically searching for a word string matching the segment that is modifiable and replacing the located segment with a segment containing a repair code
Referring to FIG. 3, a repair method and program 130 is shown in flowchart form. The repair program is designed to repair an error in the main computer program by, generally, searching the main computer program for an affected segment of code as defined by a predetermined word string based on a previous review of the code in an exemplary version of the main program, and then replacing the affected segment of the code with a repaired segment. Once the repair program is called 132 the program is checked to see if it has a patch identifier at the end 134 , and if it does 136 , the repair program exits at 138 because the patch identifier indicates that the program was already patched with this repair.
As long as there is no patch identifier 134 , 140 a variable i is initiated 142 . The variable i references a byte at the beginning of the original pattern that is to be replaced. An input byte from the main program is then read at 144 and the repair program checks to see if it is at the end of the file of the main program at 146 . If it is 148 , the computer exits the repair program 150 indicating that the main program is either not repairable with this repair program or does not require a repair, and that no patch was inserted. As long as the repair program is not at the end of the file 146 , 152 the byte read at 144 is checked to see if it matches the original pattern 154 , and if it does 156 , the byte is added to a buffer 158 . The buffer is used to store potential output bytes while the repair program searches for a match. The variable i is then incremented at 160 and the length of the variable is compared to a predetermined pattern length 162 . As long as the variable is less than the predetermined pattern length 164 , the repair program continues to loop and reads another byte at 144 .
If the main program is still not at the end of the file 146 , 152 , and a byte does not match the pattern 154 , 166 , the buffer contents are checked at 168 . If the buffer is empty 168 , 170 , the input byte is sent to an output 172 and the next input byte is read at 144 . However, if the buffer is not empty 168 , 174 the buffer content is emptied to the output 176 and the variable i is reinitialized 178 . The input byte is written to the output 172 , and the system returns to the beginning of the loop to read another input byte at 144 .
This iterative loop continues until the variable is greater than the pattern length 162 , 180 , at which time the replacement pattern containing the repaired segment is inserted by first writing the replacement pattern to the output 182 , reading the input byte from the main program 184 , and while the main program is not at the end of the file 186 , 188 , writing the input byte to the output 190 , and continuing to read another input byte from the main program 184 . Once the end of the file is reached 186 , 192 , the output patch identifier is inserted at 194 and the repair program is ended at 196 with a succcssful program repair. The aforementioned output is an output that creates a new copy of the main program that has been repaired.
Although it is preferred to initially determine which versions of the main program were created using the same compilation tools and procedures, it is not necessary if there is an uncertainty of the options selected. As long as the repair program is able to find the original pattern in its search of a particular version of the main program, then it will likely be able to perform the repair successfully, and therefore, the repair program can be run on any version of the main program even if the compilation options used to create that version cannot be determined.
In applications that use a common subroutine, it would be preferable to make the repair in the common subroutine if the subroutine contains an appropriate pattern. In this case, it may be possible to use the present invention to repair a problem in multiple versions of multiple programs.
To accomplish the aforementioned test run through the main program, a test can be accomplished by running the repair program shown in FIG. 3, then running the repair program a second time while ignoring the patch identifier in decision 134 . In other words, a test run would begin at initializing i at 142 . If the program exits without a patch at 150 , then there was only one pattern. Otherwise, the pattern should be made longer.
The present invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.
|
The present invention relates to a repair program for multiple versions of computer programs that have a common error by using a pattern search and substitution technique. The invention includes identifying a common error in a main computer program, finding a common code section that contains the common error, and locating a segment of the common code section that is modifiable. The code section is then modified by optimizing the code to perform the same functionality and adding additional code to correct the error. A repair program is then written to search other versions of the main computer program and perform the modification step automatically without having to manipulate the source or machine code manually on the various versions of the software.
| 6
|
CLAIM OF PROVISIONAL APPLICATION RIGHTS
This application claims the benefit of U.S. Provisional Patent Application No. 60/039,332 on Mar. 17, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to silicon wafer handling machines, and more particularly to systems adapted for automatically unloading silicon wafers from a Standard Mechanical InterFace ("SMIF") pod and then transferring such wafers to a process carrier, and conversely.
2. Description of the Prior Art
Certain semiconductor wafer processing operations require that a number of disk-shaped silicon wafers be loaded into a process carrier arranged in a vertical orientation. Examples of such processes are "wet bench" processing and horizontal diffusion furnace processing. Presently, silicon wafers are transported between processing tools in a SMIF pod which orients the wafers horizontally. Accordingly, in addition to transferring wafers between the SMIF pod and the process carrier, performing any wafer processing operation in which the wafers must be oriented vertically requires reorienting the wafers from their horizontal orientation in the SMIF pod into a vertical orientation in the process carrier. In addition to reorientation of wafers between the SMIF pod and the process carrier, frequently the process carrier is capable of holding more wafers than the SMIF pod. Accordingly, in general preparing wafers for a process in which they are vertically oriented requires:
1. removing a SMIF pod's wafer carrier from within the protective environment provided by the SMIF pod;
2. removing the wafers from the SMIF pod's wafer carrier;
3. rotating the wafers from a horizontal to a vertical orientation either while they are present in, or after they are removed from, the SMIF pod's wafer carrier;
4. depositing the now vertically oriented wafers into a process carrier; and
5. perhaps performing the preceding operations more than once to combine wafers from more than one SMIF pod's wafer carrier into one process carrier.
To prevent contamination of silicon wafers during processing, present semiconductor processing technology requires that all of the preceding operations be performed automatically by a machine without human intervention in the process. Thus far, automation of this wafer handling process has been achieved by cascading a general purpose SMIF pod-load interface apparatus with a wafer mass-transfer machine with a process tool, e.g. a wet bench or a horizontal diffusion furnace. Assembling an entire apparatus for either of these process tools therefore results in two mechanical interfaces, i.e. the mechanical interface between the SMIF pod-load interface apparatus and the wafer mass-transfer machine, and the mechanical interface between the wafer mass-transfer machine and the process tool. Alignment of a mechanical interface, e.g. the mechanical interface between the SMIF pod-load interface apparatus and the wafer mass-transfer machine, can be so difficult that after the two devices have been disconnected, perhaps for repair or maintenance, several hours may be required to properly realign them.
In addition to the mechanical interfaces, there also exist electrical interfaces between the SMIF pod-load interface apparatus and a wafer mass-transfer machine, and the wafer mass-transfer machine with the process tool. In particular, the electrical interfaces between each of the devices must be arranged so the combined devices operate in a coordinated manner. Interfacing the SMIF pod-load interface apparatus with the wafer mass-transfer machine has proven to be troublesome and particularly annoying for process tool manufacturers desirous of selling an integrated system which includes the SMIF pod-load interface, the wafer mass-transfer machine, and the process tool.
In addition to the difficulties associated with interfacing the SMIF pod-load interface apparatus with the wafer mass-transfer machine, the combined devices occupy more floor space than desirable, and operate comparatively slowly because they are general purpose rather than special purpose devices. For example, a standard pod load interface opens a SMIF pod and transfers the wafer carrier to the process tool. For certain processes, the wafers must also be transferred from the original carrier to a different carrier. Under such circumstances, a wafer transfer machine has to be combined with a pod load interface to translate a carrier from a position within the pod load interface to a position within the wafer mass-transfer machine. For translating the SMIF pod's wafer carrier from one location to another location, generally the pod load interface includes an arm having at least two rotary joints which merely picks up the SMIF pod's wafer carrier, translates the carrier to a new location, and then set the SMIF pod's wafer carrier down. Accordingly, if the pod load interface is to also reorient the wafers from a horizontal orientation to a vertical orientation, an end-effector must be added to the standard pod load interface for performing the prescribed rotation.
In addition, the combined SMIF pod-load interface apparatus and wafer mass-transfer machine unnecessarily replicate certain subsystems. For example, a general purpose SMIF pod-load interface and a wafer mass-transfer machine each includes an environmental control system to prevent wafer contamination. Similarly, the SMIF pod load/unload device and wafer mass-transfer machine each include a separate electronic circuit for controlling their respective operation.
In addition to a horizontal orientation for the silicon wafers within the SMIF pod, it is often desirable to arrange the wafers with the backside of one wafer facing the frontside of the immediately adjacent wafer, or conversely. Generally, the backside of a silicon wafer is more likely to be contaminated than the wafer's frontside. Therefore, during wafer processing in which the wafers retain their SMIF pod's wafer carrier arrangement, contamination of the frontside of a wafer is more likely than if the wafers were arranged backside-to-backside and frontside-to-frontside. Such a rearrangement of the wafers into the more desirable backside-to-backside and frontside-to-frontside orientation is difficult to achieve with the combined SMIF pod-load interface apparatus and wafer mass-transfer machine.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an integrated wafer pod-load/unload and mass-transfer system having higher throughput.
Another object of the present invention is to provide an integrated wafer pod-load/unload and mass-transfer system that reduces mechanical interfaces.
Another object of the present invention is to provide an integrated wafer pod-load/unload and mass-transfer system that eliminates electrical interface problems between the wafer transfer machine and the pod loader.
Another object of the present invention is to provide an integrated wafer pod-load/unload and mass-transfer system having lower cost.
Another object of the present invention is to provide an integrated wafer pod-load/unload and mass-transfer system that loads faster.
Another object of the present invention is to provide an integrated wafer pod-load/unload and mass-transfer system that occupies less floor space.
Another object of the present invention is to provide an integrated wafer pod-load/unload and mass-transfer system that can provide back-to-back silicon wafer loading into a process carrier.
Briefly, the present invention integrates a SMIF pod loader, a wafer transfer machine, and mini-environment into a single system. For exchanging wafers between a carrier contained in a SMIF pod and a process carrier, the integrated wafer pod-load/unload and mass-transfer system links directly to a process tool. The pod load interface maintains an ultra clean environment for silicon wafers, and provides an ergonomic load port platform height for operator manual pod loading. A common operator panel is used to control all aspects of the process tool operation. The electronic controls are shared between several robotic elements.
The integrated pod-load/unload and mass-transfer system in accordance with the present invention automatically transfers silicon wafers between a SMIF pod and a wafer processing tool. As is known to those skilled in the art, the SMIF pod includes a wafer carrier adapted to receive a plurality of wafers. A base of the SMIF pod receives the wafer carrier and a SMIF pod cover mates with and seals to the base of the SMIF pod. In this way, the SMIF pod's cover and base completely enclose the SMIF pod's wafer carrier and any wafers carried therein.
The pod-load/unload and mass-transfer system itself includes a pod loader interface adapted to receive the SMIF pod, and either to expose or to reenclose the SMIF pod's wafer carrier. The pod-load/unload and mass-transfer system also includes a carrier load mechanism that is mechanically coupled to the pod loader interface. The carrier load mechanism transfers the SMIF pod's wafer carrier between a position in which the wafer carrier is exposed within the pod loader interface and a load platform.
Also included in pod-load/unload and mass-transfer system is a mass-transfer machine that includes the load platform. The mass-transfer machine, which is mechanically coupled directly to the pod loader interface, includes a gantry arm for transferring the wafer carrier between the load platform and a first wafer transfer station included in the mass-transfer machine. A retainer assembly, also included in the mass-transfer machine is positionable over either the SMIF pod's wafer carrier, when the wafer carrier is present at the wafer transfer station, and over a process carrier used in the wafer processing tool. The retainer assembly includes moveable retainers adapted for receiving and holding wafers. The mass-transfer machine includes at least one elevator moveable between positions in which the elevator is located either beneath the wafer transfer station or beneath the process carrier. The elevator extends and retracts for transferring silicon wafers either between the wafer carrier present at the wafer transfer station and a position within the retainer assembly in which the retainers thereof may receive the wafers, or between the process carrier and a position within the retainer assembly in which the retainers thereof may receive the wafers.
One embodiment of the present invention includes motorized turntable that receives the process carrier. The motorized turntable used in combination with the wafer elevators and the retainer assembly permits automatically reorienting the silicon wafers from a frontside-to-backside orientation to a backside-to-backside and frontside-to-frontside orientation.
These and other features, objects and advantages will be understood or apparent to those of ordinary skill in the art from the following detailed description of the preferred embodiment as illustrated in the various drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of an integrated wafer pod-load/unload and mass-transfer system in accordance with the present invention depicting a pod load interface on which rests a SMIF pod, a SMIF pod's wafer carrier unloaded from the SMIF pod and resting on a load platform of a wafer transfer machine, and a mounting plate to which both the wafer pod-load/unload device and the mass-transfer machine are secured;
FIG. 2 is a front elevational view of the integrated wafer pod-load/unload and mass-transfer system taken along the line 2--2 in FIG. 1;
FIG. 3 is a plan view of the integrated wafer pod-load/unload and mass-transfer system taken along the line 3--3 in FIGS. 1 and 2;
FIG. 4 is the side elevational view of the integrated wafer pod-load/unload and mass-transfer system of FIG. 1 depicting a mini-environment for enclosing a SMIF pod's wafer carrier, two carriers loaded onto the wafer transfer machine, and is partially cut-away along a line 4--4 in FIG. 3 to illustrate operation of a carrier load mechanism;
FIGS. 5a-5e are schematic diagrams forming a sequence that illustrates transfer of a SMIF pod's wafer carrier from one location to another within the wafer transfer machine by a gantry included in the integrated wafer pod-load/unload and mass-transfer system;
FIGS. 6a through 6c respectively are side elevational, front elevational, and plan views of an alternative embodiment integrated wafer pod-load/unload and mass-transfer system with the front elevational view 6b being taken along the line 6b-6b in FIGS. 6a and 6c;
FIG. 7 is a plan view of the mounting plate depicted in FIG. 1;
FIG. 8 is a partially cross-sectioned front elevational view of the mounting plate taken along the line 8--8 in FIG. 7; and
FIG. 9 is a perspective view showing the retainer assembly and retainer arm which takes wafers in a horizontal array from two wafer carriers (each holding up to twenty-five wafers) at one loading platform and transfers the wafers to a larger carrier (holding up to fifty wafers) at another platform arranging the wafers in a backside-to-backside and frontside-to-frontside orientation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-4 depict different views of an integrated wafer pod-load/unload and mass-transfer system in accordance with the present invention referred to by the general reference character 20. The system 20 includes a SMIF pod-load interface 22, a wafer mass-transfer machine 24, a mini-environment 26 and an L-shaped mounting plate 28. As illustrated with dashed lines in FIGS. 2 and 3, the system 20 abuts a process tool 32 which may be a "wet bench" for liquid immersion processing of silicon wafers, a horizontal diffusion furnace, or any other processing tool which requires vertically oriented wafers. The process tool 32 includes a robot arm (not depicted in any of the FIGs.) that positions a process carrier (also not depicted in FIGS. 1-4) onto the wafer mass-transfer machine 24 either to receive wafers from, or deliver wafers to, the system 20.
As illustrated in FIGS. 1 and 4, the SMIF pod-load interface 22 receives a SMIF pod 36 onto a loading platform 38. The pod load interface includes a pod present sensor (not separately depicted in any of the FIGs.) for detecting arrival or removal of a pod. The SMIF pod 36 includes a motorized pod opener mechanism (not separately depicted in any of the FIGs.). To open the SMIF pod 36, the pod opener mechanism releases a SMIF cover 44 from a SMIF base 46, and then raises the SMIF cover 44 above a SMIF pod's wafer carrier 48 carried within the SMIF pod 36 while concurrently enclosing the SMIF pod's wafer carrier 48 within the mini-environment 26. An optical sensor (not separately depicted in any of the FIGs. and distinct from the pod present sensor described above) detects the presence of the SMIF pod's wafer carrier 48 in the SMIF pod 36. When the SMIF cover 44 is raised, the SMIF pod's wafer carrier 48 remains within the mini-environment 26 to be thereby maintained in a class 1 environment. The SMIF pod's wafer carrier 48 in each SMIF pod 36 holds twenty-five (25) silicon wafers that are oriented horizontally. The SMIF pod-load interface 22 is similar to that described in U.S. patent application Ser. No. 08/400,039 filed Mar. 7, 1995, in the name of John Rush, that is entitled "Pod Loader Interface," and that is hereby incorporated by reference.
A window 52, that pierces a pod-loader-interface bulkhead 54, permits a motorized carrier load mechanism 56 to access the SMIF pod's wafer carrier 48. The carrier load mechanism 56 includes an end-effector 58 that rotates about a horizontal axis 62 to thereby enter through the window 52 into the mini-environment 26. After entering the mini-environment 26, the end-effector 58 engages the SMIF pod's wafer carrier 48. The end-effector 58 then raises the SMIF pod's wafer carrier 48 off guides (not separately depicted in any of the FIGs.), and carrying the SMIF pod's wafer carrier 48 rotates in the reverse direction about the horizontal axis 62 so wafers 64 in the SMIF pod's wafer carrier 48 become oriented vertically over the wafer mass-transfer machine 24. The end-effector 58 then deposits the SMIF pod's wafer carrier 48, about the center of gravity of the SMIF pod's wafer carrier 48, onto a load platform 72 of the wafer mass-transfer machine 24. Dedicating the carrier load mechanism 56 to transferring the SMIF pod's wafer carrier 48 between the SMIF pod-load interface 22 and the wafer mass-transfer machine 24 results in a simple mechanism that operates much more swiftly than previous systems.
Directly coupling the SMIF pod-load interface 22 to the wafer mass-transfer machine 24 reduces errors caused by mechanical interfaces between two independent units. The SMIF pod-load interface 22 and the wafer mass-transfer machine 24 also share common control electronics thereby eliminating potential software communications problems.
The wafer mass-transfer machine 24 transfers wafers 64 from SMIF pods' wafer carriers 48 to a process carrier used in the process tool 32. The wafer mass-transfer machine 24 includes a motorized gantry arm 76 that, as illustrated in FIGS. 5a-5e, rises to pick-up the SMIF pod's wafer carrier 48 resting on the load platform 72, and transports the SMIF pod's wafer carrier 48 horizontally away from the SMIF pod-load interface 22 to transfer stations 78 of the wafer mass-transfer machine 24. The system 20 can be configured so the gantry arm 76 transports the SMIF pod's wafer carrier 48 different distances within the wafer mass-transfer machine 24 as required for compatibility with process carrier of the process tool 32.
The SMIF pod-load interface 22 and the gantry arm 76 illustrated in FIGS. 1-4 may load one or preferably two SMIF pods' wafer carriers 48 onto the wafer mass-transfer machine 24 at transfer stations 78 as illustrated in FIG. 4. After the SMIF pods' wafer carriers 48 are located in the transfer stations 78, a motorized retainer assembly 82, that is elevated above the SMIF pods' wafer carriers 48, moves horizontally across a fixed top plate 84 of the wafer mass-transfer machine 24 to a position over the SMIF pods' wafer carriers 48. Dual pedestal, U-shaped, motorized wafer elevators 86 then rise through the top plate 84 to lift the wafers 64 out of the SMIF pods' wafer carriers 48 up to the retainer assembly 82. If necessary, after the wafer elevators 86 raises the wafers 64 above the SMIF pods' wafer carriers 48 but before elevating them to the retainer assembly 82, a motorized indexing mechanism 88 moves the wafer elevator 86 furthest from the SMIF pod-load interface 22 horizontally toward or away from the SMIF pod-load interface 22. Moving the wafer elevator 86 horizontally adjusts the position of the wafers 64 lifted out of the SMIF pod's wafer carrier 48 furthest from the wafer mass-transfer machine 24 to match the requirements of the process carrier of the process tool 32. A pair of elongated motorized retainers 92 carried within and extending almost the entire length of the retainer assembly 82 then rotate under the wafers 64, then supported on the wafer elevators 86, to receive the wafers 64. The wafer elevators 86 then retract downward beneath the top plate 84, and the retainer assembly 82 now carrying the wafers 64 moves horizontally across the top plate 84 to position the wafers 64 over the process carrier of the process tool 32. The wafer elevators 86 again rise to pick-up the wafers 64, the retainers 92 then retract, and the wafer elevators 86 then descend to deposit the wafers 64 into the process carrier. The robot arm included in the process tool 32 then transfers the process carrier carrying the wafers 64 into the process tool 32 for processing. Operating in the manner described thus far, the system 20 may load up to fifty (50) wafers 64 at a time from two (2) SMIF pods' wafer carriers 48 into a single process carrier.
After the wafers 64 undergo processing in the process tool 32, a reverse sequence of operations removes the wafers 64 from the process carriers and stores them back into the SMIF pod 36.
FIG. 7 illustrates the L-shaped mounting plate 28 upon which rest both an intermediate plate 94 for the SMIF pod-load interface 22, and a base plate 96 for the wafer mass-transfer machine 24. To facilitate radial alignment of the base plate 96 to the process tool 32, the base plate 96 is secured to the L-shaped mounting plate 28 by threaded bolts 98 which pass through large apertures piercing the base plate 96 to screw into mating threaded holes in the L-shaped mounting plate 28. A large washer 102 is interposed between the head of each bolt 98 and the base plate 96. In a similar manner, the intermediate plate 94 is also secured to the L-shaped mounting plate 28 using bolts 98 passing through large apertures piercing the intermediate plate 94 and by large washers 102 that encircle the bolts 98. Both the intermediate plate 94 and a base plate 95 of the SMIF pod-load interface 22 are joined together by guide pins 104 that fit into apertures piercing the intermediate plate 94 and the base plate 95. The guide pins 104 ensure accurate repositioning of the SMIF pod-load interface 22 on the L-shaped mounting plate 28 after removal therefrom for repair or maintenance.
Referring now to FIG. 8, the L-shaped mounting plate 28 rests upon a pair of guide rails 103 that extend along sides of the L-shaped mounting plate 28. A pair of stiffeners 105, secured to the L-shaped mounting plate 28 beneath the L-shaped mounting plate 28, extend from below the wafer mass-transfer machine 24 to below the SMIF pod-load interface 22 to support and stiffen that portion of the L-shaped mounting plate 28 which projects outward beyond the guide rails 103. Supporting the L-shaped mounting plate 28 on the guide rails 103 permits sliding the entire system 20 forward or backward horizontally with respect to the process tool 32 to facilitate maintenance or repair. Bolts 108 lock the system 20 to the guide rails 103 during normal operation. The guide rails 103 rest upon and are secured to an interface plate 112. The interface plate 112 in turn is supported from a frame 114 of the process tool 32 by four threaded jack screws 116, only two of which appear in FIG. 8. Four threaded bolts 118, only two of which appear in FIG. 8, pass through apertures piercing the interface plate 112 to secure the interface plate 112 to the frame 114. Adjustment of the jack screws 116 permits lowering the interface plate 112 toward or raising the interface plate 112 away from the frame 114. In this way, the system 20 may be raised, lowered and tilted with respect to the process tool 32 both parallel to the process tool 32 and orthogonal to the process tool 32. The adjustments permitted by this structure facilitate aligning the mechanical interface between the system 20 and the process tool 32 both radially and rectilinearly.
FIGS. 6a-6c depict an alternative embodiment of the system 20 that includes two (2) SMIF pod-load interfaces 22. Those elements depicted in FIGS. 6a-6c that are common to the system 20 depicted in FIGS. 1-5 carry the same reference numeral distinguished by a prime ("'") designation. The two (2) SMIF pod-load interfaces 22' and carrier load mechanisms 56' of the alternative embodiment system 20' respectively transfer SMIF pods' wafer carriers 48' onto two (2) load platforms 72' of the wafer mass-transfer machine 24'. Similar to the system 20, a single gantry arm 76' of the wafer mass-transfer machine 24' appropriately position the SMIF pods' wafer carriers 48' horizontally with respect to the SMIF pod-load interfaces 22' over the wafer elevator 86'. However, the system 20' locates the wafers 64' in the SMIF pods' wafer carriers 48' from one of the SMIF pod-load interface 22' half-way between the wafers 64' in the SMIF pods' wafer carriers 48' from the other SMIF pod-load interface 22'.
With the wafers 64' from the two SMIF pod-load interfaces 22' located half-way between each other, similar to the system 20, the wafer elevator 86' then lifts the wafers 64' out of the SMIF pods' wafer carriers 48' up to the retainer assembly 82'. However, instead of a single pair of retainers 92 as in the system 20, the retainer assembly 82' of the system 20' includes two (2) pairs of intermeshing retainers 92' that are adapted to hold the wafers 64' from both of the SMIF pod-load interfaces 22' at a pitch, i.e. spacing between immediately adjacent wafers 64', that is one-half of the pitch between immediately adjacent wafers 64' in the SMIF pods' wafer carriers 48'. In this way, the system 20' combines on the retainer assembly 82' the twenty-five (25) wafers 64' from four (4) SMIF pods' wafer carriers 48' into a single group of one hundred (100) wafers 64' for loading into a process carrier 122.
As illustrated in FIG. 9, the mass-transfer machine 24' may also include a motorized turntable 128 at one of three (3) transfer stations 78' for reversing the direction of a larger wafer carrier 132 resting thereupon. As described in greater detail below, inclusion of the motorized turntable 128 in the mass-transfer machine 24' permits automatic reorientation of wafers from two (2) SMIF pods' wafer carriers 48 into a backside-to-backside and frontside-to-frontside orientation within the single wafer carrier 132. To effect such a reorientation of the wafers, first two SMIF pods' wafer carriers 48' are deposited respectively onto two (2) of the transfer stations 78 from a SMIF pod-load interface, not depicted in FIG. 9. After the SMIF pods' wafer carriers 48' are present on the transfer stations 78', the motorized retainer assembly 82', moves horizontally to a position above the SMIF pods' wafer carriers 48'. Analogously to the description set forth above in connection with FIGS. 1-4, notorized wafer elevators then rise to lift the wafers out of the SMIF pods' wafer carriers 48' up to the retainer assembly 82'. Two pairs of elongated motorized retainers 92', carried within and occupying almost the entire length of the retainer assembly 82', then rotate under the wafers to receive the wafers. As described above, while the wafers 64 are being raised toward the retainer assembly 82' the wafer elevators move closer together to match the pitch of all the wafers carried by the retainer assembly 82' with the pitch of the wafer carrier 132. The wafer elevators then retract downward beneath the transfer stations 78', and both the elevators and the retainer assembly 82' now carrying as many as fifty (50) wafers move horizontally across the mass-transfer machine 24' to align with the wafer carrier 132.
With the wafers now disposed in the retainer assembly 82' over the motorized turntable 128, a wafer elevator included therein rises to receive from alternating locations along the retainers 92' as many as twenty-five (25) of the wafers, i.e. twelve (12) from one of the SMIF pod's wafer carrier 48' and thirteen (13) from the other SMIF pod's wafer carrier 48' or the converse. The elevator, carrying up to twenty-five (25) wafers, then descends into the mass-transfer machine 24 thereby depositing the wafers into the wafer carrier 132. After the wafers are deposited in the wafer carrier 132, the motorized turntable 128 rotates 180° so the frontsides of the wafers in the wafer carrier 132 face the backsides of the wafers still remaining above in the retainer assembly 82'. The wafer elevator carrying the now reoriented wafers again rises to the retainer assembly 82' to receive the wafers remaining there. Carrying all the wafers now arranged in a backside-to-backside and frontside-to-frontside orientation, the elevator again descends into the mass-transfer machine 24' to deposit the reoriented wafers into the wafer carrier 132. A robot arm included in a process tool then transfers the wafer carrier 132 and the reoriented wafers into the tool for processing. As described above, organizing wafers backside-to-backside and frontside-to-frontside within the wafer carrier 132 for processing within the process tool eliminates transfer of contamination from the backside of one wafer to the frontside of the immediately adjacent wafer.
After the wafers have been processed in the tool, reversing the sequence of operations describe above transfers the wafers from the wafer carrier 132 back into the SMIF pods' wafer carriers 48' restoring all of the wafers to a uniform orientation.
Although the present invention has been described in terms of the presently preferred embodiment, it is to be understood that such disclosure is purely illustrative and is not to be interpreted as limiting. Consequently, without departing from the spirit and scope of the invention, various alterations, modifications, and/or alternative applications of the invention will, no doubt, be suggested to those skilled in the art after having read the preceding disclosure.
|
A system includes an interface for receiving a pod having a carrier that receives wafers, and that is initially enclosed within a base and a pod cover. The system also includes a mechanism that transfers an exposed carrier between the interface and a platform of a mass-transfer machine included in the system. The machine includes a gantry arm for transferring the carrier between the platform and a transfer station. A retainer assembly is positionable over the carrier at the transfer station, and over a process carrier that is used in a processing tool. Moveable retainers of the assembly receive and hold wafers. The machine includes an elevator that moves between the transfer station and the process carrier. The elevator extends and retracts for transferring wafers between the retainers and either the carrier or the process carrier. A turntable, that receives the process carrier, permits automatically reorienting wafers.
| 8
|
FIELD OF THE INVENTION
[0001] The present invention relates to a tray-positioning device and in particular relates to a tray-positioning device that utilizes the upper sidewalls of a tray for positioning. Having no mold lines or deformations commonly found on the lower sidewalls of a tray, the upper sidewalls possess smoother surfaces. Hence the tray-positioning device in the present invention is capable of providing higher degree of precision for tray positioning.
BACKGROUND OF THE INVENTION
[0002] Having undergone hundreds of processing steps, a semiconductor wafer is divided into a plurality of dies before being tested and packaged for delivery. To facilitate handling and management, dies are contained and carried around in a designated tray.
[0003] [0003]FIG. 1 shows a perspective view of a tray 1 for containing dies 2 . Being square-slab shaped, said tray 1 possesses a total of four stair-contoured sides, each having a lower sidewall 12 and an upper sidewall 14 such that the upper sidewall 14 is situated on the inner side and above the lower sidewall 12 . Said tray 1 provides a number of slots 16 , each capable of containing a die 2 . The step for transferring die 2 to slot 16 is loading.
[0004] In order to raise loading speeding and avoid human contact, most semiconductor plant uses robot arm for loading. If tray positioning is not accurate, the robot arm could not place individual dies on individual slots precisely as programmed.
[0005] To point out the importance of tray positioning, the loading process in die sorter is illustrated in the following. FIG. 2 shows a perspective view of a prior art die sorter 3 , which comprises a die tray 32 , a conveyor 34 , a push unit 36 and a robot arm 38 . Said die tray 32 is designated to hold a number of dies 2 , being divided from semiconductor wafers, for loading. Said conveyor 34 provides an input terminal 341 , an output terminal 342 and a sorter position 343 . By placing an empty tray 1 on conveyor 34 at terminal 341 and having it carried to the sorter position 343 for loading, followed by sending out an full stray 1 at output terminal 342 after said empty tray 1 is filled with dies. Said conveyor 34 can deliver one or a plurality of trays 1 , depending on the programmed loading operation. Prior art die sorter 3 as disclosed in FIG. 2 is useful for delivering a first tray 1 and a second tray 1 a.
[0006] Being L-shaped, said push unit 36 includes a pivot 361 and a push rod 362 , wherein saidpivot 361 is located on one side of the conveyor 34 and said push rod 362 is situated above the conveyor 34 and at an angle with respect to the horizontal position. Knowing that the conveyor 34 can only deliver the first tray 1 and the second tray 1 a to the ballpark sorter position 343 , pivot 361 will cause the push rod 362 to turn to a horizontal position and drive push rod 362 so as to push the second tray 1 a, located behind the first tray 1 , and the first tray 1 to the ballpark sorter position 343 , simultaneously.
[0007] Said robot arm 38 is capable of loading dies by picking up die 2 from die tray 32 and placing it onto slot 16 until all slots of the first tray 1 and the second tray 1 a are filled with dies 2 .
[0008] Being a plastic material, the first tray 1 's lower sidewall 12 often includes mold lines with rough surface. Being the outer rim of tray 1 , the lower sidewall 12 is prone to deformation caused by collision or heat. Using the lower sidewall 12 , which lacks the smooth surface, for positioning, the prior art tray 1 is incapable of being positioned accurately at the exact sorter position 343 , hence preventing the robot arm from loading individual dies precisely and causing production losses.
SUMMARY OF THE INVENTION
[0009] Aimed at resolving the above disadvantage, the main object of the present invention is to provide a tray-positioning device capable of utilizing the smoother upper sidewall, which has no mold lines or deformations commonly found on the lower sidewalls of a tray, for precision positioning.
[0010] The following Description and Designation of Drawings are provided in order to help understand the features and content of the present invention.
BRIEF DESCRIPTION OF DRAWINGS
[0011] The accompanying drawings form a material part of this description, in which:
[0012] [0012]FIG. 1 is a prospective view of a tray 1 .
[0013] [0013]FIG. 2 is a prospective view of a die sorter 3 .
[0014] [0014]FIGS. 3A and 3B is a prospective view of a tray-positioning device 4 in accordance with the first preferred embodiment of the present invention.
[0015] [0015]FIGS. 4A, 4B and 4 C are a tray-positioning device 5 in accordance with the second preferred embodiment of the present invention.
[0016] [0016]FIG. 5 is an explosive view of a tray-positioning device 6 in accordance with the third preferred embodiment of the present invention.
[0017] [0017]FIG. 6 is an operational view of a tray-positioning device 6 in accordance with the third preferred embodiment of the present invention.
[0018] [0018]FIG. 7 is a prospective view of a positioned tray-positioning device 6 in accordance with the third preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] In the following description, the present invention is described in connection with a specific and preferred embodiment. It will be understood that the present invention is not limited to these embodiments, but rather is to be construed as the spirit and scope defined by the appended claims.
[0020] Please refer to FIGS. 3A and 3B, which prospectively illustrate a tray-positioning device 4 in accordance with the first preferred embodiment of the present invention. Said tray-positioning device 4 comprises a positioning unit 42 and a driving unit 44 . Said positioning unit 42 has four sidewalls 421 , which provide four guiding corners 423 on the inner side. Said guiding corner 423 and the upper sidewalls 14 are capable of fitting closely with each other. Said sidewall 421 has a pivot 425 and said driving unit 44 is connected to the pivot 425 .
[0021] Prior to the positioning process, the positioning unit 42 is set at a proper angle above the horizontal position with tray 1 located in the general area below it. When the driving unit 44 drives the positioning unit 42 and causes it to rotate around the pivot 425 towards the tray 1 . When the positioning unit 42 nears the horizontal position, the position of tray 1 is so adjusted that its upper sidewalls 14 are confined by the sidewalls 421 within the guiding corners 423 , thus accomplishing the positioning of tray 1 as shown in FIG. 3B.
[0022] Please refer to FIGS. 4A, 4B and 4 C, which prospectively illustrate a tray-positioning device 5 in accordance with the second preferred embodiment of the present invention. Capable of simultaneous positioning a first tray 1 and a second tray 2 , said tray-positioning device 5 comprises a first positioning unit 52 , a second positioning unit 54 and a driving unit 56 . The first positioning unit 52 has four first sidewalls 521 , which provide four guiding corners 523 on the inner side. The guiding corner 523 and the upper sidewalls 14 are capable of fitting closely with each other. The second positioning unit 54 has four second sidewalls 541 , one of which being connected to one of the four first sidewalls 521 . The second sidewalls 541 provide four guiding corners 543 on the inner side. Said guiding corner 543 and the upper sidewalls 14 a are capable of fitting closely with each other. Provided by the first positioning unit 52 and the second positioning unit 54 , a pivot 527 allows the first positioning unit 52 and the second positioning unit 54 to rotate around it.
[0023] The tray-positioning device 5 in accordance with the second preferred embodiment of the present invention is positioned in a ballpark sorter position 343 on a conveyor 34 . Prior to the positioning process, the positioning unit 52 is set at a proper angle above the horizontal position. In one delivery, the die sorter 3 is capable of transferring a first tray 1 and a second tray 1 a . After being adjusted by the push unit 36 , the first tray 1 and the second tray 1 a are located in the general area below the first positioning unit 52 and the second positioning unit 54 , respectively. When the first positioning unit 52 and the second positioning unit 54 , driven by the driving unit 56 , rotate to the horizontal position, the position of first tray 1 and second tray 1 a are so adjusted that the upper sidewalls 12 and the upper sidewalls 12 a are confined by the first sidewalls 521 and the second sidewalls 541 within the first guiding comers 523 and the second guiding comers 543 , respectively, thus accomplishing the positioning of the first tray 1 and the second tray 1 a as shown in FIG. 4C.
[0024] Please refer to FIGS. 5, 6 and 7 , which illustrate an explosive view, an operational view and a prospective view of a tray-positioning device 6 , respectively, in accordance with the third preferred embodiment of the present invention. Said tray-positioning device 6 comprises a first driving unit 62 and a positioning unit 64 . The first driving unit 62 includes a cylinder 621 and a tray push-pull rod 623 , being secured to the cylinder 621 . The positioning unit 64 has a positioning base 641 , a positioning block 642 , a first positioning spring 643 and a second positioning spring 644 wherein said positioning block 642 further comprises a extruded edge stopper 645 . The extruded edge stopper 645 and the second positioning spring 644 are provided in proper locations on the positioning base 641 . The first positioning spring 643 is secured to the tray push-pull rod 623 . A third sidewall 646 and a fourth sidewall 647 are provided on the right hand side of the second positioning spring 644 where it is turns and it is about to turn straight, respectively. A first sidewall 648 is provided on the positioning block 642 where it faces a tray 71 . A second sidewall 649 is provided on the inner side of the extruded edge stopper 645 . The first sidewall 648 and the second sidewall 649 are perpendicular to each other.
[0025] Please refer to FIGS. 6 and 7, which illustrate an operational view and a prospective view of a tray-positioning device 6 , respectively, in accordance with the third preferred embodiment of the present invention. A tray 71 provides a first upper sidewall 711 , a second upper sidewall 712 , a third upper sidewall 713 , and a first lower sidewall 714 wherein the first upper sidewall 711 and the second upper sidewall 712 are in parallel with the third upper sidewall 713 and the first lower sidewall 714 , respectively, and the first upper sidewall 711 is in perpendicular to the second upper sidewall 712 . Driven by a second driving unit 73 , the tray 71 located at 72 -input output location is moved to the general area on the positioning base 64 as shown in FIG. 7. The first positioning spring 643 is situated behind the tray 71 and the tray 71 is located between the positioning block 642 and the first positioning spring 643 . Meanwhile, the first upper sidewall 711 is situated between the third sidewall 646 of second positioning spring 644 and the second sidewall 649 of the extruded edge stopper 645 . Responding to a positioning instruction, the cylinder 621 drives the tray push-pull rod 623 to pull the first positioning spring 643 such that the first positioning spring 643 hooks on the tray 71 and cause it to move toward the positioning block 642 . As it nears the first sidewall 648 of the positioning block 642 , the first upper sidewall 711 of the tray 71 has just passed entrance between the third sidewall 646 of the second positioning spring 644 and the second sidewall 649 of the extruded edge stopper 645 and is about to enter an area bounded by the a fourth sidewall 647 of second positioning spring 644 and the second sidewall 649 of the extruded edge stopper 645 for containing the tray 71 . When the tray 71 further approaches, the pulling force by the first positioning spring 643 causes the first upper sidewall 711 of the tray 71 to be in close contact with the first sidewall 648 of the positioning block 642 . By bringing the first upper sidewall 711 and the second upper sidewall 712 of the tray 71 to be in close contact with the first sidewall 648 and the second sidewall 649 , respectively, the present invention establishes the first upper sidewall 711 and a second upper sidewall 712 as the bases for precision positioning of the tray 71 in FIG. 8.
[0026] It is apparent that, by utilizing tray positioning devices 4 , 5 or 6 , the tray 3 is capable of achieving elevated precision for positioning, improving the successful loading rate by the robot arm 38 and lowering the production cost.
[0027] While the invention has been described in terms of a preferred embodiment, various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives that fall within the scope of the claims.
|
A tray-positioning device comprises a driving unit and a positioning unit, wherein the positioning unit provides a plurality of sidewalls that correspond to a plurality of upper sidewalls of a tray. By allowing the driving unit to move the positioning unit toward the tray or vice versa that said individual upper sidewalls are in close contact with the corresponding sidewalls, the tray-positioning device is capable of providing precise positioning for the tray.
| 7
|
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to a truly novel fruit harvesting apparatus for picking oranges, apples and other fruits.
(2) Description of the Prior Art
Fruit picking has heretofore been a manual operation and its mechanization has not been developed to date. It is strongly desired to mechanize the fruit picking operation since it not only requires many hands but is a harder labor than it seems.
SUMMARY OF THE INVENTION
Having regard to the above state of the art, an object of this invention is to free the workers from the laborious fruit picking operation and to provide a substantially automatic apparatus to replace the manual work.
In order to achive this object, a fruit harvesting apparatus according to this invention comprises fruit detector means to search and detect positions of fruit, mover means to move a fruit picking section, and control means to control the mover means according to the positions of fruit detected by the fruit detector means in order to move the fruit picking section to positions suited to pick the fruit.
The apparatus of this invention having the above characteristic construction is capable of automatically picking an objective fruit, which almost completely frees the worker from the hard labor practised heretofore. Since this apparatus picks fruit one after another, it is not limited in its range of picking operation to one kind of fruit but is applicable to a wide variety of fruits.
Other objects and advantages of this invention will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrates fruit harvesting apparatus according to this invention, in which:
FIGS. 1 and 2 are perspective views each depicting a fruit harvesting apparatus,
FIG. 3 is a vertical section of a picking section,
FIG. 4 is a sectional view taken on line IV--IV of FIG. 3,
FIGS. 5(A) and (B) are flow charts showing an arm control sequence,
FIG. 6(A) is a view showing a principle of an example of fruit detector,
FIGS. 7(A) and (B) are a view and a flow chart corresponding to FIGS. 6(A) and (B), respectively, and pertaining to another example of fruit detector, and
FIGS. 8(A) and (B) are a view and a flow chart corresponding to FIGS. 6(A) and (B), respectively, and pertaining to a further example of fruit detector.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
(I) Overall Construction
FIGS. 1 and 2 each show an outward appearance of a fruit harvesting apparatus according to this invention. The apparatus of FIG. 1 is an example of the riding type, while the apparatus of FIG. 2 is an example of remote control type operable in response to instructions from a monitor 8 located separately from the main frame as shown.
The riding type fruit harvesting apparatus in FIG. 1 is adapted to pick fruit from under a tree, and is therefore suitable for picking apples and the like which are borne on relatively tall trees. On the other hand, the remote control type fruit harvesting apparatus of FIG. 2 has an arch-like frame 1 to straddle over a tree while picking fruit therefrom, which permits the apparatus to operate where small trees, such as of orange, stand close together with narrow spaces among one another.
In order to be movable to a desired position, each of these fruit harvesting apparatus comprises a main frame 1 provided with running means 2, a fruit position detector 3 mounted on the main frame 1 to detect a position of fruit, and a picking means 4.
The picking means 4 of either apparatus comprises an articulated arm assembly 5 having a high degree of freedom and a picking section 6 mounted at an extreme end of the arm assembly 5, the picking section 6 being movable by the arm assembly 5 to a suitable position for picking fruit. The articulated arm assembly 5 acting as the mover means may comprise a hydraulically actuated link mechanism as shown in FIG. 1, an electrically actuated mechanism made of highly rigid elements as shown in FIG. 2, or any other flexible mechanism including a plurality of joints to have a high degree of freedom.
Fruit picked by the picking section 6 at the extreme end of the arm assembly 5 may be taken to a collecting section provided at a certain position by moving the arm assembly 5. However, for the interest of havesting efficiency, the apparatus of FIGS. 1 and 2 include a stretchable and flexible conveyer tube 7 extending between the picking section 6 and the main frame 1 for conveying fruit to a collecting section (not shown) in the main frame 1. FIG. 1 shows the conveyor tube 7 mounted in the arm assembly 5 to prevent the tube 7 from interfering with movement of the arm assembly 5 whereby the arm assembly 5 has a wide range of choice for its attaching position.
Furthermore, reference number 3 in FIGS. 1 and 2 denotes an example of fruit position detector including a TV camera 9, and its construction and operation will be described in detail later.
The running means 2 may be be vertically movable relative to the main frame 1, or an auxiliary device such as an outrigger may be provided, in order that the apparatus may operate on a sloped ground.
(II) Construction of the Picking Section
Referring to FIG. 3, the picking section 6 comprises a cylindrical trap 10, and an upwardly diverging guide 11 mounted around a top opening of the trap 10 to facilitate capture of fruit in the trap 10, air being drawn in through the top opening.
The guide 11 acts also as a contact sensor to detect and transmit a signal as to the direction in which a contact is made with an object, this function being particularly described later. This signal provides a basis for controlling the arm assembly 5 to bring the picking section 6 at the end of the arm assembly 5 to a position to introduce a fruit into the trap 10. Furthermore, the picking section 6 includes an air exhaust port 19 opening upwardly around the guide 11 to blow away leaves lying close to the fruit as the picking section approaches the fruit.
In order to function also as contact sensor 11c as mentioned above, the guide 11 comprises a plurality of contact members 11a each slightly oscillatable downwardly. Each of the contact members 11a has a switch 11b to detect its oscillation upon contact with the fruit. The contact sensor 11c is not limited to the described construction but may comprise, for example, a tough sensor mounted on an inner wall of the guide 11.
The trap 10 carries a calyx cutter 12 on a top portion thereof to cut a calyx of the fruit introduced into the trap 10 by means of the described construction.
As shown in FIG. 4, the cutter 12 comprises a plurality of blades 14 arranged interiorly of an outer ring gear 13, each of the blades 14 having a gear portion in mesh with the ring gear 13 and rotatable on an axis X. The outer ring gear 13 is concentric with the top opening of the trap 10. An air motor 15 is mounted on the trap 10 to rotate the outer ring gear 13. When the outer ring gear 13 is rotated by the air motor 15 in a direction shown by an arrow, the blades 14 swing on their respective axes X fixed to the trap 10 in directions shown by arrows with the crossing points of the blades 14 concentrating to cut the calyx. Thus, the calyx is cut after being brought to the center of the top opening of the trap 10, which does not apply an excessive force to the fruit which would damage it. This cutter positively breaks the calyx without permitting its elusion.
Position setting required for the cutter 12 in cutting the calyx is carried out by a control method to be described hereinafter which utilizes signals given by a plurality of photosensors 16 disposed immediately below the blades 14 of the cutter 12.
Each of these photosensors 16 comprises a pair of light emitters 16a and a pair of light receivers 16b, and is disposed such that the lights travel across the top opening of the trap 10 as deviated sideways from the center of the opening of approximately by a calyx thickness, respectively. Therefore all the lights are intercepted when a fruit lies opposed to the cutter 12 but, when the thin calyx lies opposed to the cutter 12, at least part of the lights is not intercepted and the photosensors 16 transmit signals accordingly. On the basis of such signals the picking section is set in position where the calyx is opposed to the cutter 12.
Similar photosensors 17 are provided at a lower portion of the trap 10 which are arranged vertically at certain intervals and which emit lights crossing a cetral axis of the trap 10. When the position is set in accordance with the signals given by the foregoing photosensors 16a and 16b, these sensors 17 detect a bottom position of the fruit to provide information as to the size of the fruit. Although the sensors 17 are provided for the purpose of detecting the fruit size, they may also be utilized to ensure that the fruit is positively contained in the trap 10.
The trap 10 is connected at a bottom opening to the collecting section in the main frame 1 through the flexible and stretchable conveyor tube 7 as already described. The picked fruit with its calyx cut passes through the conveyor tube 7 to the collecting section driven by the air taken in at the trap 10 and by gravity.
The air is drawn by an air pump 18 mounted on the main frame 1, and exhaust air therefrom is sent through an exhaust duct 20 securely supported by the conveyor tube 7, to the air exhaust port 19 around the guide 11 and to the air motor 15 to actuate the cutter 12. The exhaust duct 20 leading to the air motor 15 is provided with magnet valves 21 and 21' which receives signals from a computer and control the air motor 15 as necessary. While the calyx cutter 12 is actuated by using the exhaust air in this example, a pneumatic cylinder may be used in place of the air motor, or any other power source such as an electric motor may be used to actuate the cutter 12.
Further, the fruit picking operation may be carried out reliably be serecting a material having an appropriate rigidity (such as rubber) to form the contact members 11a of the guide 11, in accordance with the fruit to be picked.
Part of the exhaust air may be blown out inside the top opening of the trap 10 in order to place the fruit centrally of the opening of the trap 10.
(III) Arm Assembly Control
The arm assembly 5 is controlled by a computer which is programmable with what is known as the robot language by preparing basic routines such as a routine for moving the extreme end of the arm assembly 5 to a given coordinate or a routine for moving the extreme end by a given degree. The robot language as well as the control system for the arm assembly 5 may be the same as or similar to those which are already known.
This computer is adapted to take signals from a plurality of sensors and to vary controls according to these signals. Specifically, the signals from the contact sensors 11c consisting of the contact members 11a and the switches 11b and from the photosensors 16 and 17 in the trap 10 are fed to the computer to provide bases for its control action.
The arm assembly 5 is controlled by this computer in a sequence as shown in FIGS. 5(A) and (B).
Referring to FIG. 5(A), at an opening stage (i) a position of fruit to be picked is read from a memory of the computer, and at stage (ii) the picking section 6 is moved to a position R right under and at a certain distance from the position of the fruit. Positions of fruit are determined by means of and steps to be described later, a picking order is determined and the positions are rearranged and stored in that order in the memory in advance. During this picking stages the fruit positions are just read from the memory on after another.
The control action then moves on to the stages (iii) to (vii) in which, in response to signals from the contact sensors 11c of the guide 11, the picking section is moved in a direction of the contact sensor or sensors 11c which has/have contacted the fruit and gradually upwardly to bring the trap 10 to a position immediately under the fruit while adjusting its horizontal position.
When the photosensors 16 at the top opening of the trap 10 give a signal during the upward movement that all the lights are intercepted, the computer detects this signal at stage (vi) and its control action moves on to stage (x). If, on the other hand, the light interception is not given by the photosensors 16 till after they have risen above a height read from the memory, the control moves from the stage (vii) to stages (viii) and (ix) to stop the picking operation for this fruit and start for a next fruit to be picked. The control moves on to the stage (x) if the photosensors 16 give the signal, as described above, that the bottom of the fruit has entered the top opening of the trap 10 during the stages (iii) to (vii). The subsequent control checks to see whether or not what has entered the trap 10 is a fruit and actuates the cutter 12 to do the picking only when the fruit is confirmed.
The fruit is confirmed by measuring a distance by which the picking section 6 ascends after the above light interception signal is given by the photosensors 16 at the top opening of the trap 10 until a non light interception signal is given by a certain number of the photosensors 16. Only when this distance is in a certain range, it is judged the fruit lies inside the trap 10 and its calyx lies opposed to the photosensors 16, whereupon the cutter 12 is actuated for the picking operation.
Thus the ascent distance measurement starts at the stage (x). The next stage (xi) is for permitting a cut-in when the non light interception signal is given by the photosensors at the top opening of the trap 10.
The picking section 6 is raised by the arm assembly 5 according to a sequence shown by reference (xii). If the cut-in occurs during the ascent, the control moves on to the sequence of FIG. 5(B) in which the cutter 12 is actuated after checking to find out that the distance of ascent is in the certain range. On the other hand, where no cut-in takes place until after the picking section 6 rises by a certain distance, the control moves on to a sequence denoted by reference (xiii) and (xiv) to stop the picking operation for this fruit and return the picking section 6 to the initial position R to be ready to pick the next fruit.
When the control action moves to the sequence of FIG. 3(B) following the cut-in, checking is made at a stage (xv) as to whether the picking section 6 has moved up by a distance predetermined according to a fruit size. If the distance of ascent is short of the predetermined value, the control passes a stage (xxii) and returns to the stage (iii) of FIG. 5(A) whereupon the operation is carried out all over again from the introduction of the fruit. Thus, the checking of the distance of ascent eliminates an operational error due to entry to the trap 10 of leaves or other unwanted things.
An ascent by the predetermined distance proves that fruit is inside the trap 10, and the control action moves on to stages (xvi) to (xxi) of FIG. 5(B). The picking section 6 is brought to a standstill, and the cutter 12 is actuated to pick the fruit after its size is detected by the photosensors 17 provided in a lower portion of the trap 10. Thereafter the picking section 6 is returned to the initial position R which ends the picking operation for this fruit and the apparatus is ready for a next operation.
The fruit size detected by the photosensors 17 in the lower portion of the trap 10 is for the purpose of sorting, but may be used to avoid operational errors. That is, these photosensors 17 are used to find out whether a fruit is in the trap 10 or not, and only when its presence is detected the cutter 12 is actuated by operating the valves 21 and 21'.
(IV) Position Detector
FIG. 6(A) is a view showing a principle of an example of fruit position detector which comprises a TV camera 9 and a laser source 22 and is operable according to the sequence of FIG. 6(B).
The TV camera 9 is pivotable by means of a motor (not shown) on a first horizontal axis E1 with an optic axis t thereof perpendicular to the first horizontal axis E1. The laser source 22, which is a spot beam emitter, also is pivotable by means of a motor (not shown) on a second horizontal axis E2 with an optic axis r thereof perpendicular to the second horizontal axis E2. Both the TV camera 9 and laser source 22 are pivotable by means of motors (not shown) on a vertical axis E3 also.
The two horizontal axes E1 and E2 are parallel to each other. The first horizontal axis E1, the optic axis t of the TV camera 9, and the vertical axis E3 cross one another at one point, and the second horizontal axis E2, the optic axis r of the laser source 22, and the vertical axis E3 also cross one another at one point. The two horizontal axes E1 and E2 are pivotable on the vertical axis E3 while remaining parallel to each other, and the second horizontal axis E2 is movable along the vertical axis E3 while remaining parallel to the first horizontal axis E1.
Therefore, the TV camera 9 and the laser source 22 have the respective optic axes t and r constantly lying on one plane which is rotatable on the vertical axis E3. The optic axes t and r are rotatable and cross each other at one point on that plane except when parallel to each other.
Turning angles θ1, θ2 and θ3 from references on the respective axes E1, E2 and E3 are detected by a first, a second and a third rotary encoders 25, 26 and 27 mounted thereon.
Further, the TV camera 9 is pivotable on the first horizontal axis E1 by a control console (not shown) as desired. The computer which controls this position detector 3 receives instructions concerning movement of the laser source 22, detection of the position, completion of the operation, and the turning angle on the second horizontal axis E2 which is an offset of the laser source 22.
On instructions the computer moves the laser source 22 in a certain sequence as shown in the flow chart of FIG. 6(B). According to the sequence of this embodiment, on each instruction the laser source 22 is made to rotate by a certain degree within a predetermined range about the vertical axis E3. When the rotation over the predetermined range is complete, the laser source 22 is raised intermittently along the vertical axis E3 by a certain distance within a predetermined range and is made to repeat the rotation at each stopping position. Thus a laser beam along the optic axis r, which moves at each moving instruction, is emitted at certain intervals within a certain searching range.
The operation causes the TV camera 9 to pivot on the first horizontal axis E1 each time the laser beam is moved, whereby the fruit A irradiated by the laser beam is caught at a reference point on a screen and its coodinate is put into the computer. The screen is the same as a type picture optically shown at S and the reference point corresponds to the optic axis t of the TV camera 9. The coordinate of the fruit position is calculated on the basis of turning angles θ1, θ2 and θ3 about the respective axes E1, E2 and E3 and a distance d between the TV camera 9 and the laser source 22.
As shown in FIG. 6(B), an instruction to detect the position is given to the computer which then takes in each of the above information, is angles θ1, θ2, θ3 and distance d and calculates the coordinate of the position of fruit A by using the principle of triangulation and cylindrical coordinates. The computer judges on the basis of the resulting coordinate whether or not the coordinate is within reach of the picking means 4. If it is out of reach, the computer merely gives an indication to that effect to the operator. If it is within reach, the coordinate is compared with fruit positions thus far detected in certain respects described below, in order to determine a picking order, and the positions are stored in the memory after a sorting operation to arrange the positions in that order. In the picking order first priority is given to fruit in lower positions and then to fruit in nearer positions. Therefore, the picking operation proceeds from fruit at a lowermost position, and from the nearest fruit on a substantially equal height.
To describe the offset angle θ2 of the laser source 22, the fruit searching range is variable with changes in the degree of this angle and, when the laser beam hits obstacles such as leaves, the degree of this angle may be changed to avoid them.
FIG. 7(A) shows a principle of another example of fruit position detector which is operable according to a sequence shown in FIG. 7(B).
A TV camera 9 is pivotable by means of a motor (not shown) on a first horizontal axis E1 with an optic axis t thereof adjusted to be perpendicular to the first horizontal axis E1. A laser source 22, which is a spot beam emitter, also is pivotable with an optic axis r along which a laser beam travels adjusted to be perpendicular to the second horizontal axis E2. Both the TV camera 9 and laser source 22 are pivotable by means of motors (not shown) on a vertical axis E3 also.
Both the first and second horizontal axes E1 and E2 are perpendicular to the vertical axis E3 and rotatable on the vertical axis E3 independently of each other. Turning angles φ1 and φ2 of the two horizontal axes E1 and E2 on the vertical axis E3 are detected by rotary encorders 27 and 28 relative to a common reference. A turning angle φ3 of the TV camera 9 on the first horizontal axis E1 and turning angle φ4 of the laser source 22 on the second horizontal axis E2 are detected by rotary encorders 25 and 26. The rotations on these axes E1, E2 and E3, respectively, are effected by motors (not shown) under control by a computer.
As shown in FIG. 7(A), the TV camera 9 and the laser source 22, respectively, are mounted in position such that the vertical axis E3, the first horizontal axis E1 and the optic axis t of the TV camera 9 cross on another at one point and that the vertical axis E3, the second horizontal axis E2 and the optic axis r of the laser source 22 cross one another at one point.
Facing directions of this TV camera 9 is controlled by the computer. On the basis of signals from a control console (not shown) the computer turns the TV camera 9 from one facing direction to another as shown in the flow chart of FIG. 7(B). The console is adapted to take input of a coordinate on a screen (schematically shown at S) of a monitor television (not shown) for the TV camera 9 by means of a light pen. This coordinate is given to the computer which calculates component φ5 and component φ6 of an angle of deviation from the optic axis t of the TV camera 9 of a line y corresponding to the point on the screen S, and a compensation angle of deviation. In particular, a supplementary line z extends on a plane defined by the optic axis t of the TV camera 9 and the first horizontal axis E1, and a crossing line w between this plane and a plane perpendicular to the vertical axis E3 extends parallel to the first horizontal axis E1. Therefore, the compensation angle φ8 is derived from an equation,
φ8=Arctan (tan φ5/sin φ3)
and angle φ7 between the line y and the vertical axis E3 is derived from an equation,
φ7=Arcsin (sin φ3 sec φ8/sec φ5).
On the basis of the angle φ8 derived as above, the computer rotates the laser source 22 about the vertical axis E3 to bring the optic axis r of the laser source 22 to a plane defined by the line y and the vertical axis E3, and about the second horizontal axis E2 to a predetermined position. At this time the laser source 22 is at an angle of φ2=(φ1-φ8) to the reference about the vertical axis E3.
The computer then takes in and memorizes brightness and color tone of an appointed point on the screen S which are transmitted by an image signal.
Thereafter the operation moves on to the stages (iv) in which the laser source 22 is gradually rotated on the horizontal axis E2 while monitoring the image signal of the appointed point on the screen S. More particularly, changes in the image signal are checked each time the laser source 22 is rotated by a slight degree, and the rotary encoder 26 detects the angle φ4 of the line y about the second horizontal axis E2 when certain changes in the image signal are detected. Then a coordinate is calculated on the basis of the principle of triangulation and cylindrical coordinates using the angle φ7 of the line y relative to the vertical axis E3, the angle φ2 about the vertical axis E3 and the angle φ4 about the second horizontal axis E2.
By means of the light pen the operator appoints first A appearing on the screen of the monitor TV each time the TV camera 9 changes its facing direction, whereupon the laser source 22 moves as described above and a laser beam irradiates the fruit A. At this time changes occur in the image signal of the appointed point on the monitor TV screen, and the coordinate of the fruit is put into the computer. Then the computer judges on the basis of the resulting coordinate whether or not the the coordinate is within reach of the picking means 4. If it is out of reach, the computer merely gives an indication to that effect to the operator. If it is within reach, the coordinate is stored in the memory. At this time the coordinate is compared with fruit positions thus far detected in certain respects described below, in order to determine a picking order, and the positions are stored in the memory after a storing operation to arrange the positions in that order. In the picking order first priority is given to fruit in lower positions and then to fruit in nearer positions. Therefore, the picking operation proceeds from fruit at a lowermost position, and from the nearest fruit on a substantially equal height.
FIG. 8(A) shows a principle of a further example of fruit position detector which is operable according to a sequence shown in FIG. 8(B). A TV camera 9 and an infrared distance measuring device 23 are disposed at one optical point. By appointing a point on a screen shown by the TV camera 9, the infrared distance measuring device 23 automatically turns to face a direction corresponding to the appointed point and measures a distance to an object lying in that direction.
The TV camera 9 and a reflector 24 or a prism provided thereabove are pivotable on a first horizontal axis E1. The TV camera 9 has an optic axis t' refracted by the reflector 24 or the prism to extend in a direction t which is perpendicular to the first horizontal axis E1.
The first horizontal axis E1 is perpendicular to and rotatable about a vertical axis E3, and the TV camera 9 and the reflector 24 are rotatable together with the first horizontal axis E1 about the vertical axis E3. On the other hand, the infrared distance measuring device 23 disposed at a crossing point of the first horizontal axis E1 and the vertical axis E3 has an optic axis r crossing a second horizontal axis E2 at right angles, and is pivotable on the second horizontal axis E2. The second horizontal axis E2 crosses the vertical axis E3 at right angles, and is rotatable thereabout. Therefore, the infrared distance measuring device 23 is rotatable together with the second horizontal axis E2 about the vertical axis E3.
A first rotary encorder 27 detects a turning angle φ1 of the first horizontal axis E1 about the vertical axis E3 relative to a reference line x fixed to the main frame (not shown), and a second rotary encorder 25 detects a turning angle φ2 about the first horizontal axis E1 of the line t corresponding to the optic axis of the TV camera relative to a plane perpendicular to the vertical axis E3. A third rotary encorder 28 which is connected to the first horizontal axis E1 detects a turning angle φ3 of the second horizontal axis E2 about the vertical axis E3 relative to the first horizontal axis E1. A fourth rotary encorder 26 detects a turning angle φ4 of the optic axis r of the infrared distance measuring device 23 about the second horizontal axis E2.
The rotations of the TV camera 9 and the infrared distance measuring device 23 on the axes E1, E2 and E3 are effected by pulse motors (not shown) which operate according to pulse outputs of a computer.
Therefore, the facing directions of the TV camera 9 are controlled by the computer. The computer turns the TV camera 9 from one facing direction to another every time the computer receives an instruction from a control console (not shown) to turn the TV camera 9, as shown in the flow chart of FIG. 8(B).
This console has a monitor TV (not shown) which displays a picture transmitted from the TV camera 9. By appointing a point on a screen of the monitor TV with a light pen, its coordinate is put into the computer. The computer turns the infrared distance measuring device 23 to direct the optic axis r thereof in a direction corresponding to the above apointed point on the basis of the turning angles φ1 and φ2 of the line t corresponding to the optic axis of the TV camera 9 and the coordinate of the appointed point.
Assuming that the optic axis t of the TV camera 9 extends in the direction shown in FIG. 8(A) and at turning angles φ1 and φ2 about the vertical axis E3 and the first horizontal axis E1, respectively, the screen at this time is as schematically shown at S in FIG. 8(A). This screen S shows an image of the reflector 24 which is a picture S' optically shown by broken lines. As soon as a point on the screen S' is appointed, angles φ3 and φ4 of the line r extending in a direction corresponding to its coordinate relative to the optic axis t of the TV camera 9 are detected. According to the described construction, a plane including the lines y and t includes the first horizontal axis E1.
Thus the computer transmits a pulse signal to each of the pulse motors to rotate the infrared distance measuring device 23 on the vertical axis E3 and the second horizontal axis E2, whereby the infrared distance measuring device 23 faces the direction corresponding to the appointed point. The rotary encorders 25, 26, 27 and 28 detect actual turning angles φ1, φ2, φ3 and φ4 about the respective axes for use in correcting operational errors of the pulse motors.
Thereafter the computer measures the distance by moving the reflector 24 from the optic axis r of the infrared distance measuring device 23.
The infrared distance measuring device 23 has a construction, in principle, similar to that of a device commonly used with a camera, which emits an infrared ray and measures the time it takes to return. This device 23 measures time with a precision of 0.1-0.2 nanosecond to provide a several centimeter precision.
Thus, a coordinate of the position of fruit A is detected on the basis of polar coordinates using the angle of the infrared distance measuring device 23 about the vertical axis E3 relative to the main frame, the angle about the second horizontal axis E3 relative to the vertical axis E3, and the distance of the objective fruit.
Then the computer judges on the basis of the resulting coordinate whether or not the coordinate is within reach of the picking means 4. If it is out of reach, the computer merely gives an indication to that effect to the operator. If it is within reach, the coordinate is stored in the memory. At this time the coordinate is compared with fruit positions thus for detected in certain respects described below, in order to determine a picking order, and the positions in that order. In the picking order first priority is given to fruit in lower positions and then to fruit in nearer positions. Therefore, the picking operation proceeds from fruit at a lowermost position, and from the nearest fruit on a substantially equal height.
To put the coordinates of fruit into the computer the operator has only to appoint with the light pen the fruit which appear on the monitor TV screen each time the facing direction of the TV camera 9 is changed. After the fruit on the screen are all dealt with, the TV camera is turned to another direction and by repeating this process, the coordinates of all the fruits that can be picked are stored in the computer.
|
A fruit harvesting apparatus in which the positions of fruit are searched and detected by a television camera with a variable shooting direction. Both the television camera and a spot light emitting device, such as a laser, are varied in position and direction in accordance with instructions to locate a fruit. A movable fruit picker is then moved to the determined position of the fruit and operated to pick the fruit.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority from, and incorporates herein by reference, the subject matter of U.S. application Ser. No. 61/433,604 filed Jan. 18, 2011.
FIELD OF INVENTION
[0002] The present invention relates to a system for storing medication and information, and an internet or web based system for creating storage systems for containing medication and related medical information.
BACKGROUND OF THE INVENTION
[0003] As the severity and prevalence of allergies, asthma and diabetes continue to increase, there is also an increasing need for the prompt availability of individualized treatment information and prescription antidotes. In the case of children, where food allergies affect up to 6% of all young children and asthma is the most common chronic medical condition of childhood, the need for emergency information may arise at a variety of inconvenient times, for example, at school or camp, such as during recess or field trips, when students are away from their class room or from the school or camp. In the case of adult employees, emergency information may be necessary when an individual is working on an assembly line, or away from available health information. Since information regarding student health issues, such as food allergies or asthmatic responses, and the associated emergency medications are normally kept in the classroom for application by a teacher, or with a school nurse or camp health care provider, the absence of vital information at the scene of an emergency can become critically important. As a result of the need for such information on an urgent basis, a need has arisen to provide better information which can be more promptly and accurately accessed, as well as readily transported.
SUMMARY OF THE INVENTION
[0004] The present application provides a system for easily accessing medical information and medications for use by educators or other individuals assisting a child in a health emergency. The present application provides for an individualized storage container sufficient for storing emergency medications, such as Epipen® hypodermic injectors or epinephrine auto-inject syringes, insulin medications, blood testing or treatment materials and equipment, inhalers, or other oral medications, which have been prescribed for an individual patient. Additionally, the storage container is provided with information specific to the individual to enable ready identification, such as a photograph, name, age, weight, and the illness which may most commonly arise with respect to that individual. Specific information regarding the contents of the storage container may also be shown, so that easy identification of whether the desired antidote may be found within the storage container is possible. Lacking such information regarding the contents, a care giver may waste valuable time searching for an antidote, only to discover none is to be found. Where information regarding the contents of the storage container, or lack of contents, is provided externally of the storage container, it may enable a health care provider to more quickly make a 911 call for emergency assistance, instead of searching through the storage container in vain.
[0005] To ensure that the desired information is provided externally of the storage container, a website is provided to enable a patient or a parent of a child patient, to provide the desired information, and either immediately print the information for application to the storage container, or to have the information printed and shipped.
[0006] Once the storage container is provided with the necessary information externally of the container, and the medications or other antidotes are stored within the container, the container may be provided to the school or camp, or taken to a place of employment. At the location where the storage container is to be kept for emergency use, a further cabinet or other container may be provided. Such a storage cabinet, for example, located in the camp infirmary or the school nurse's office, is positioned to enable ready and easy identification of the patient to whom the individual containers belong. For example, the storage containers may be stored in such a way that a small end of each storage container is visible when multiple storage containers are stacked within the cabinet.
[0007] The present application thus provides a system for medication information and medication storage for prompt accurate access to necessary emergency health information. The present system may make use of an internet based system to provide a storage container with the necessary individualized patient information on the external surface of the storage container, as well as additional health information and medications within the storage container, such as necessary emergency medications or antidotes for an individual patient. Still further, the system may include a storage container for storing multiple individual storage containers for easy identification of an individual container for a specific patient in an emergency health situation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 illustrates a perspective view of a closed container of the present application showing desired emergency medical information regarding an individual depicted on the container, the medical condition of the individual depicted, the medications contained within the container and additional emergency treatment and contact information.
[0009] FIG. 2 illustrates a top view of the container of FIG. 1 , showing the medical condition of an individual who is also depicted, named and described on the container (date of birth and specific nut allergy, for example), desired emergency medical information regarding the individual depicted on the container (Severe Symptoms and Treatment for severe symptoms and Mild Symptoms and Treatment for mild symptoms, for example), and additional emergency contact information.
[0010] FIG. 3 illustrates an end view of the container of FIG. 1 , showing the medical condition of an individual who is also named and described on the end panel of the container (date of birth and specific nut allergy, for example), and additional emergency contact information.
[0011] FIG. 4 illustrates an open container of the present application showing the medicines for the individual depicted on the container, and identified by printed name on the sides of the container, and the Treatment Action Plan or medical treatment instructions or information provided within the container.
[0012] FIG. 5 illustrates the open container of FIG. 1 , with the medicine contents and emergency information removed for inspection.
[0013] FIG. 6 schematically illustrates the system components for implementing the system and method disclosed in the present application.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The present disclosure for a mediation, information and storage container 10 , and a system and method for its creation, is designed to securely store the desired individual patient's emergency medications while clearly identifying the individual, their medical condition and information, and a treatment plan from an external surface of the container.
[0015] By placing the individual patient photo 12 for viewing from an external surface 14 of the storage container, nurses, teachers, and other care givers can easily recognize and access the medical information and medication during an emergency health care situation. Customizing the information for viewing from the outside of the container 10 emphasizes the specific details of the individual patient's specific condition 16 , recommended treatment 18 and highlights emergency contact information 20 . The convenient side label 22 , shown in FIG. 3 , also offers quick access information and more storage options for the storage container. Providing the information for viewing from an external surface 14 of the container 10 can be extremely helpful and provide critical time saving in certain settings, such as school or camp, where multiple individual patients may have medications being stored.
[0016] In FIGS. 1 , 2 and 3 illustrate the semi-transparent, rigid, closed storage container 10 of the present application showing the desired emergency medical information regarding an individual depicted from an external surface of the container 14 , the medical condition 16 of the individual is depicted, and a list of the medications stored within the container, as well as additional emergency treatment 18 and contact information 20 . In FIGS. 4 and 5 , the open container shows the Treatment Action Plan or other medical treatment instructions 28 or information and the listed medications provided within the container.
[0017] With respect to information regarding the method and operating environment for supplying the storage container, there are numerous environments in which on-line ordering websites may operate. The present system and method is provided to be any suitable system for inputting private medical or confidential information by a parent of a child patient CP or an adult patient P, and for printing or manufacturing the information and providing it into or onto a container, and shipping the completed container 10 to the requesting parent or adult, where it may be provided with the necessary medicines or treatment equipment, in preparation for use in an emergency situation. It should be understood that the confidential health information provided by the parent or adult is not transferred to any third parties, but is merely formatted and printed for use in connection with the container system 10 , as authorized by the ordering patient or adult P, in the case of a child patient CP. An exemplary environment includes one or more conventional computer devices in communication via a communication network, such as the Internet.
[0018] As schematically shown in FIG. 6 , devices used to implement the purchase, manufacture and shipment of the present container 10 are typically computing devices including a variety of configurations or forms such as, but not limited to, laptop or tablet computers, personal computers, smart phones, work stations, and the like. Conventional computer components may be used for conducting the purchase and input of information for the container system, and for shipment of the present system according to the method. Of course, those skilled in the art of computers will recognize a wide selection of commercially available components that can be used to construct systems suitable for performing the components of the present system and method.
[0019] The computer system includes a buyers system, generally referenced at 24 and a sellers system generally referenced at 24 ′, which include a processor in communication with a variety of other components over a system bus. The other components include, by way of example, a network interface, an input device, interface, a display interface, a computer-readable medium drive, and a memory. As appreciated by those skilled in the art, the network interface enables the systems to communicate data, control signals, data requests, and other information with a computer network, such as the Internet 26 . The network interface may be configured to communicate with the Internet 26 over a wired or wireless connection.
[0020] The input device interface sometimes also embodied as an input/output interface, enables the systems to be accessed for purchase 24 and shipment 24 ′ of a container system 10 , and to obtain the data input for manufacturing the container. Input devices in communication with the input device interface may include, but are not limited to, a digital pen, a touch screen, a keyboard, a mouse, and the like. In addition, a display interface is typically connected to a display device (e.g., a CRT monitor, an LCD screen, a TV, etc.) for visually displaying information regarding the container system. Those skilled in the art may discern that the display device may be incorporated with a computer device as an integral element or, alternatively, may be an external component that is attached to the computer device.
[0021] A processor in the systems 24 , 24 ′ is configured to operate in accordance with programming instructions stored in memory. The memory generally comprises RAM, ROM, and/or a permanent memory. Thus, in addition to storage in read/write memory (RAM), programming instructions may also be embodied in read-only format, such as those found in ROM or other permanent memory.
[0022] The memory also typically stores an operating system, for controlling the general operation of the computer device. The operating system may be a general purpose operating system such as Microsoft® operating system, for example. The memory may further store user executable applications or programs for conducting various functions on the computing device. For example, the memory includes a browser application that may be used by the Customer to navigate on the Internet and through which the Customer may communicate via the Internet to purchase and input data regarding the container system. Examples of such browser applications include Microsoft's Internet Explorer® or Mozilla's Firefox, and the like.
[0023] A computer readable medium drive provides an optional and alternative means by which a purchaser may store information externally and/or retrieve external information. Examples of computer readable medium drives include, but are not limited to CD ROM drives, DVD ROM drives, floppy disk drives, flash member readers, and the like.
[0024] Once the adult patient P has provided the necessary data or information is to the memory of the computer system 24 ′, the manufacture of the container using the system and method may be commenced, and the purchaser may be requested to perform a review operation within the system to confirm that the desired information has been input. The buyer's computer system is connected to the seller's system via a communication network, such as the Internet 26 , using a confidential connection, perhaps a user name and password which is unique and provided on a confidential basis to each purchaser. Once the desired review of the information is confirmed, the adult purchaser may instruct that edits be made and again reviewed, finally confirming when manufacture may commence, such as by transferring the information to a printer 30 or other device such that the storage container 10 may be completed and shipped to the purchaser. Once manufacture is completed, all data input regarding the container may be removed or retained from the system, depending on the purchaser confidentiality instructions.
[0025] Upon receipt by the purchaser P, the medicine and treatment equipment 32 contents listed on the storage container 10 are included by the individual patient P or the individual responsible for the patient within the storage container, and the storage container may then be provided to a care giver for emergency use in connection with the health of the individual patient P, CP.
[0026] While the present application for the storage container 10 , system and method for providing the storage container, has described in detail, persons skilled in the art will readily understand that it will have applications for a variety of patients have a variety of illnesses. It will of course be understood that the above has been given by way of illustration and that all modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention, as defined in the following claims.
|
A system and method for storing medical information and medications for use in an emergency. The system includes a rigid storage container with personalized individual patient medical information on an external surface of the storage container, including a photograph of the individual patient, information regarding the contents of the storage container and emergency contact information. The method uses an internet-based computer system to generate a summary of patient medical information which is mounted for viewing on an external surface of the storage container. The summary is supplied and mounted for viewing from an external surface of the storage container. Once the medications are included within the storage container, a care giver is provided with the storage container for safe keeping in the event of a health emergency.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of the pending U.S. patent application Ser. No. 13/485,247, filed May 31, 2012, which application claims priority from German patent application No. 11 168 177.1 filed on May 31, 2011. The content of all prior applications is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a trocar sleeve for minimally invasive surgery, having a first sleeve part that essentially has the form of a straight tubular piece with a longitudinal axis, and having a second sleeve part that at least partly surrounds the first sleeve part in close contiguity with it and is movable during use in relation to the first sleeve part.
BACKGROUND OF THE INVENTION
[0003] A trocar sleeve of this type is known from patent WO 2010/136805 A1, although the two sleeve parts are two telescope-type straight tubular pieces that can slide into and out of one another and whose relative sliding either follows a straight line or moves along a helical spiral. The radial outer sleeve part is connected on its proximal end with a head piece that comprises an insulation for gas-tight insertion of an instrument into the trocar sleeve and a fluid connection support, and the radially inner sleeve part has a flexible ring-shaped flange on its distal end.
[0004] A trocar sleeve is a medical instrument that is used in minimally invasive surgery for inserting instruments into the human or animal body. In a minimally invasive surgical procedure, a trocar, which consists of a trocar sleeve and a trocar mandrel that is enclosed in the trocar sleeve, is used, first, to provide access to a body cavity. For this purpose the tip of the trocar mandrel is applied on an incision on the skin and is then pushed through the epithelium. Then the trocar mandrel is withdrawn from the trocar sleeve; the trocar sleeve remains inserted in the body. Through the trocar sleeve it is then possible to insert, in alternation, instruments such as endoscopes, forceps, scissors, sewing instruments and the like into the body cavity to perform surgical procedures.
[0005] The flexible flange on the distal end of a trocar sleeve unfolds below the perforated epithelium and can then be secured with a corresponding additional flange from outside in order to ensure secure anchoring on the epithelium. To make it possible for the flange to unfold below the epithelium, the trocar sleeve must be slid relatively deeply into the body, and in addition a flexible flange made of rubber or the like must be relatively thick to allow it to be effectively secured from outside, so that the flange, even during an intervention, takes up relatively much space below the epithelium. In addition, most trocar sleeves are designed for a certain minimum thickness of the epithelium. For these reasons the known trocar sleeves are not suited for some operations, for instance operations on small children or on the thyroid.
[0006] The documents US 2008/0242930 A1, DE 10 2009 014 525 A1 and US 2002/0042606 A1 each disclose an instrument for providing access for surgical interventions, said access comprising two elements that can pivot around an axis running perpendicular to the instrument longitudinal axis and that can be unfolded below the epithelium to form a type of flange, likewise requiring relatively a great deal of space below the epithelium.
SUMMARY OF THE INVENTION
[0007] It is the object of the invention to provide a trocar sleeve that requires a very small insertion depth and no minimum thickness of the epithelium and that is also simple to produce, easy to install and can be cleaned well.
[0008] This object is achieved by means of a trocar sleeve with the characteristics of claim 1 . Advantageous refinements of the invention are indicated in the dependent claims.
[0009] According to the invention, the two sleeve parts each comprise on their distal axial ends a flange part that extends outward at an angle of less than 180 degrees from the respective sleeve part. If the sleeve parts are turned into a relative position in which both flange parts point in the same direction and essentially are situated one above the other congruently, the two flange parts together can be slid through and below the epithelium without needing to be flexible, because the elasticity of the epithelium is sufficient in itself. This is particularly true when the flange parts, as preferred, have approximately U-shaped contours, as seen in a plane perpendicular to the longitudinal axis, such that the distance of the two legs of the U-shape is approximately equal to the diameter of the first or preferably of the second sleeve part.
[0010] After insertion, the sleeve parts can easily be turned by hand into a relative position in which the two flange parts point in contrary directions to one another and are situated in a plane perpendicular to the longitudinal axis, so that the trocar sleeve is anchored on the perforated epithelium.
[0011] Because the flange parts are not required to be flexible, they can be made of a stable material just like the sleeve parts and thus are preferably of one-piece construction. Flange parts of this type can be substantially thinner than a flexible flange, for example approximately 1 mm thick. In the insertion position in which the two flange parts are situated directly one above the other, their total thickness is then equal to 2 mm, which is still comparatively little, so that the trocar sleeve has a very small insertion depth in a body.
[0012] According to the invention, the mobility of the second sleeve part in relation to the first sleeve part consists essentially only in an ability of the second sleeve part to rotate around the first sleeve part. With respect to the foregoing, this should be understood as indicating that it is harmless to have an axial mobility that serves in the course of the rotation to bring only one of the two flange parts, which are situated in insertion position one above the other, into the working position, in precisely the same plane as that of the other flange part, in order to produce a plane anchoring surface below the epithelium. In the cited example of flange parts 1 mm thick, a sliding of this type would be equal to 1 mm. It is likewise harmless when, in the course of a rotation, between the insertion position and the working position, there is a particular installation position in which the second sleeve part can be slid in the axial direction in order to be able to release it easily from the first sleeve part and the head part. It is useful to provide an installation position of this type in order to allow the trocar sleeve to be assembled easily and dismantled again quickly for cleaning.
[0013] In theory, each of the two sleeve parts can comprise essentially, that is as one base body, a straight full tube. In this case the first, inner sleeve part must be detachably fastened on the body part, for example by means of cap nuts and positioning pins so that the second sleeve part can be installed and dismantled.
[0014] In an alternative embodiment, the portion of the second sleeve part that is contiguous with the first sleeve part is essentially in the form of a half of a lengthwise two-part tube. In this case the second sleeve part can simply be slid axially over the first sleeve part and along the longitudinal axis in the direction toward the head part of the trocar sleeve and then allowed to engage in the guide and locking means configured in the head part.
[0015] The cross-section of the second sleeve part perpendicular to the longitudinal axis can be, for example, simply a semicircle.
[0016] It is better for the cross-section of the second sleeve part perpendicular to the longitudinal axis to be a circular arc, which comprises a few more degrees than a semicircle. In this case the second sleeve part surrounds the first sleeve part at an angle of something more than 180 degrees and is thereby held firmly in form-locked manner on the first sleeve part along its entire length, also ensuring good cohesion of the two sleeve parts during use. To facilitate the axial sliding of the second sleeve part onto the first sleeve part, the flange part of the first sleeve part can be provided with small indentations at the point where it makes a transition into the first sleeve part.
[0017] Optimal gas-proof insulation between the trocar sleeve and the body opening held open by it, can be achieved with an embodiment in which each of the two sleeve parts has essentially the shape of a straight full tube, such that the first, inner sleeve part is detachably fastened on the head part and the second sleeve part can be assembled on and disassembled from the first sleeve part when the first sleeve part is separated from the head part.
[0018] In this case the second sleeve part is preferably guided in such a way that it can be rotated between two end positions that are situated about 180 degrees apart with respect to the longitudinal axis, such that the one end position corresponds to an insertion position in which the flange parts of the first and second sleeve parts point in the same direction and are situated precisely in a plane perpendicular to the longitudinal axis, and such that the other end position corresponds to a working position in which the flange parts of the first and second sleeve parts point in approximately opposite directions to one another and likewise are situated in a plane precisely perpendicular to the longitudinal axis. Here the flange parts of the first and second sleeve parts have, preferably together, a U-shaped radial contour as seen in a plane perpendicular to the longitudinal axis.
[0019] The detachable fastening of the first sleeve part on the head part can include a screw-in lock or a type of bayonet lock.
[0020] A trocar mandrel especially suitable for the invention has a blunt distal end whose contour concludes essentially flush with the contour of the distal end of the trocar sleeve when the trocar mandrel is inserted completely into the trocar sleeve.
[0021] To secure the flange parts on the outside of the epithelium, it is possible in principle to use any disc-shaped element, in particular a two-part element, that can be installed around the sleeve parts after assembly of the second sleeve part.
[0022] Especially useful for the invention, however, is a securing element in the form of a one-piece, rubber disc, with gap, which can be slid laterally over the sleeve parts of the trocar sleeve with the gap stretched wide and then closes more or less firmly around the sleeve parts because of its own elasticity. After the trocar sleeve has been anchored in the epithelium, the rubber disc is simply slid along the longitudinal axis in the direction toward the epithelium in order to protect the flange part from outside the epithelium. The rubber disc then remains in this position simply by static friction.
[0023] Even more useful, because it attaches with particular reliability on the sleeve parts, is a securing element made of a rigid element with a gap that fits with the outer diameter of the outer sleeve part and with an elastic element that can be detached from the rigid element, or alternatively made only of rigid elements, namely a plate with a gap that fits with the outer diameter of the outer sleeve part, a clamping element for the outer sleeve part that can be slid onto the plate, and an actuation element mounted on the plate for the slidable clamping element. Securing elements of this type are also useful for other trocar sleeves and trocars as described herein.
[0024] Because it is possible to dismantle the trocar sleeve, and the additional parts that form a trocar, easily and rapidly into their components, said parts are also easy to clean, so that the trocar sleeve or the trocar constructed with it meets stringent hygienic requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] There follows a description of embodiments with reference to the drawings. The drawings are as follows:
[0026] FIG. 1 shows a perspective view of a trocar sleeve whose outer sleeve part is separated from it and is in a position before assembly.
[0027] FIG. 2 shows a perspective view of the trocar sleeve of FIG. 1 in an assembly position, that is, in a phase shortly before it is completely assembled.
[0028] FIG. 3 shows a perspective view of the assembled trocar sleeve with the outer sleeve part in an insertion position in which the trocar sleeve can be inserted into an opening produced in an epithelium.
[0029] FIG. 4 shows a perspective view of the assembled trocar sleeve with the external sleeve part in a working position, in which the trocar sleeve can be anchored behind an opening produced in an epithelium.
[0030] FIG. 5 shows a perspective view of the trocar sleeve from FIG. 4 with a superimposed rubber disc as securing element.
[0031] FIG. 6 shows a side view of the trocar sleeve from FIG. 5 as it is anchored and secured in an epithelium.
[0032] FIG. 7 shows a perspective view of an embodiment for a trocar sleeve in which each of the two sleeve parts has essentially the shape of a straight full tube, in an assembled condition, whereby the outer sleeve part is in an insertion position in which the trocar sleeve can be inserted into an opening produced in an epithelium.
[0033] FIG. 8 shows another perspective view of the trocar sleeve from FIG. 7 , on which a securing element is additionally installed.
[0034] FIG. 9 shows an enlarged perspective view of the distal end of the trocar sleeve from FIG. 7 in the insertion position.
[0035] FIG. 10 shows an enlarged perspective view of the distal end of the trocar sleeve from FIG. 7 in a working position in which the trocar sleeve can be anchored behind an opening produced in an epithelium.
[0036] FIG. 11 shows an enlarged perspective view of the distal end of the inner sleeve part of the trocar sleeve from FIG. 7 .
[0037] FIG. 12 shows an enlarged perspective view of the distal end of the outer sleeve part of the trocar sleeve from FIG. 7 .
[0038] FIG. 13 shows an enlarged perspective view of the distal end of the trocar sleeve from FIG. 7 in the course of a rotation of the outer sleeve part from the insertion position into the working position.
[0039] FIG. 14 shows an interrupted longitudinal sectional view of the two sleeve parts of the trocar sleeve in the position from FIGS. 7 and 9 .
[0040] FIG. 15 shows an explosion perspective view of the trocar sleeve from FIG. 7 in the area of the fastening of the inner sleeve part on the head part.
[0041] FIG. 16 shows an enlarged perspective view of the cap nut from FIG. 15 .
[0042] FIG. 17 shows an enlarged perspective view of the spring packet from FIG. 15 .
[0043] FIG. 18 shows a longitudinal sectional view of the trocar sleeve from FIG. 7 in the area of the fastening of the inner sleeve part on the head part.
[0044] FIG. 19 shows a side view of a proximal resistance path in an inner sleeve part for a fastening on the head part by means of a type of bayonet lock.
[0045] FIG. 20 shows an unfolding of the resistance path of the inner sleeve part from FIG. 19 into the plane.
[0046] FIG. 21 shows a sectional view of the inner sleeve part from FIG. 19 and of a head part suited to it, which are connected with one another by a type of bayonet lock.
[0047] FIG. 22 shows a perspective view of the trocar sleeve portion shown in FIG. 18 .
[0048] FIG. 23 shows a perspective view of a trocar mandrel for insertion into the shown trocar sleeve.
[0049] FIG. 24 shows a securing element consisting only partly of an elastic material, in a perspective view.
[0050] FIG. 25 shows another securing element consisting only partly of an elastic material, in a perspective view.
[0051] FIG. 26 shows a securing element consisting only of rigid parts, in a sectional view.
DETAILED DESCRIPTION OF THE INVENTION
[0052] The trocar sleeve shown in FIGS. 1 through 6 consists of a head part 2 , a first, inner sleeve part 4 and a second, outer sleeve part 6 .
[0053] The head part 2 is an approximately rotation-symmetrical housing that contains an axial clearance hole. Situated in a proximal end of the head part 2 , shown in the upper part of FIGS. 3 through 6 , is a flexible insulation 8 for gas-tight insertion of an instrument in and through the clearance hole in the head part 2 . In addition, the head part 2 has a fluid connection support 10 with a valve 12 . Carbon dioxide or flushing liquid, for example, can be supplied by way of the fluid connection support 10 .
[0054] Attached to the distal end of the head part 2 is a proximal end of the inner sleeve part 4 , which consists mainly of a piece of tube that extends in the axial extension of the clearance hole in the head part 2 to a distal end.
[0055] All the way at the distal end of the inner sleeve part 4 , a first flange part 14 is shaped that has approximately the form of a spatula. In particular, the flange part 14 has a U-shaped contour, as seen in a plane perpendicular to the longitudinal axis of the inner sleeve part 4 , such that the distance between the two legs of the U-shape is equal to or somewhat smaller than the diameter of the inner sleeve part 4 . In the embodiment the first flange part 14 consists of the same material as the inner sleeve part 4 and is, for example, 1 mm thick.
[0056] The outer sleeve part 6 consists mainly of a lengthwise halved piece of tube of about the same length and of the same material as the inner sleeve part 4 . The cross-section of the outer sleeve part 6 perpendicular to the longitudinal axis is a circular arc, which is a few degrees greater than a half-circle. The inner diameter of the outer sleeve part 6 is equal to the outer diameter of the inner sleeve part 4 .
[0057] On the distal end of the outer sleeve part 6 , a second flange part 16 is shaped, which has practically the same contour and the same thickness as the first flange part 14 and, in the same manner that the first flange part 14 forms a right-angle deviating continuation of the inner sleeve part 4 , it forms a radially outward running and thus right-angle deviating continuation of the outer sleeve part 6 .
[0058] In the vicinity of the proximal end of the outer sleeve part 6 , a gripping member 18 is shaped on it and, similarly as the second flange part 16 , forms a radially outward running continuation of the outer sleeve part 6 , but is thicker and wider. Somewhat closer to the proximal end of the outer sleeve part 6 , a small, round stud 20 is formed on it and extends a few millimeters axially from the outer sleeve part 6 .
[0059] The head part 2 on its distal end has a ring 22 , with gap, that extends radially around the inner sleeve part 4 at a distance that is somewhat greater than the thickness of the outer sleeve part 6 . Interacting with the stud 20 on the outer sleeve part 6 , the ring 22 with gap forms guide and locking elements for the outer sleeve part 6 in the manner of a bayonet lock, as is described in greater detail below.
[0060] As shown in FIGS. 1 and 2 , the trocar sleeve is installed by sliding the outer sleeve part 6 in the indicated direction of the arrow onto the inner sleeve part 4 , so that both flange parts 14 , 16 point in directions approximately opposite to one another.
[0061] To facilitate this pushing motion, the first flange part 14 has two small indentations 24 in its edges, specifically located where it is connected with the first sleeve part 4 . The indentations 24 also allow rotation of the outer sleeve part 6 by a few degrees when it is seated on the inner sleeve part 4 . In particular, the outer sleeve part 6 can be rotated into the position shown in FIG. 2 , in which both flange parts 14 , 16 point in directions about 160 degrees apart, and then the outer sleeve part 6 can be pushed completely onto the inner sleeve part 4 .
[0062] When the outer sleeve part 6 has been pushed completely onto the inner sleeve part 4 , the outer sleeve part 6 is rotated around the inner sleeve part 4 into the position shown in FIG. 3 , in which the two flange parts 14 and 16 are situated congruently one over the other. During the rotation, whose rotating direction is indicated in FIG. 3 with an arrow, the stud 20 glides within the ring 22 with gap and is guided thereby.
[0063] In the position shown in FIG. 3 , the two flange parts 14 and 16 of the trocar sleeve can easily be inserted into an opening produced in an epithelium without penetrating deep therein, while the trocar sleeve is held more or less perpendicular over the epithelium and is moved somewhat downward and to the side so that the two flange parts 14 and 16 together glide below the epithelium.
[0064] After the trocar sleeve has reached its end position in and above the body opening, the outer sleeve part 6 is rotated back, with the assistance of the gripping member 18 , around the inner sleeve part 4 , namely into the position shown in FIG. 4 in which the two flange parts 14 and 16 are pointing in directions exactly opposite to one another and are situated precisely in a plane perpendicular to the longitudinal axis of the sleeve parts 4 and 6 . The rotation direction is indicated with an arrow in FIG. 4 . In this position the stud 20 is held firmly on the first sleeve part 4 by an indentation in the ring 22 with gap, so that the second sleeve part 6 is locked on the trocar sleeve. Within the boundaries dictated by its own elasticity, the second sleeve part 6 is also locked along its length, because the outer sleeve part 6 encloses the inner sleeve part 4 by more than 180 degrees.
[0065] The guiding effect of the ring 22 with gap on the head part is either purely rotational or it also causes a slight longitudinal sliding by the thickness of the flange parts 14 and 16 , so that the second flange part 16 is automatically moved from the position shown in FIG. 3 , in which it is situated congruently over the first flange part 14 , into the position shown in FIG. 4 , in which it is situated precisely in a plane with the first flange part 14 . A displacement of this type can also be achieved by corresponding configuration of the section of the ring 22 , with gap, in which the stud 20 is locked by an indentation in the ring 22 with gap.
[0066] As shown in FIG. 5 , after anchoring the trocar sleeve in a body opening, a with gap, rubber disc 26 , in the form of a so-called optic stopper for instance, which can be stretched by hand, is pushed from the side over both sleeve parts 4 and 6 of the trocar sleeve. When the rubber disc 26 contracts again, it surrounds the sleeve parts 4 and 6 with a certain force. The rubber disc 26 can then be pushed by hand in the direction toward the flange parts 14 and 16 until an epithelium 28 , indicated schematically in a sectional view in FIG. 6 , is contiguous with the flange parts 14 , 16 below and with the rubber disc 26 above, so that the trocar sleeve is securely anchored on the epithelium 28 .
[0067] Instead of the rubber disc 26 , any other suitable securing element can be used, for example a two-part securing element, which can be installed around the sleeve parts 4 and 6 .
[0068] In the illustrated embodiment, the flange parts 14 and 16 are spatula-shaped or U-shaped. Although this special configuration is particularly advantageous in terms of sparing tissue and avoiding great insertion depth in the epithelium, other contour shapes are also possible. For example, the flange parts 14 and 16 can be of any leaf shape, as occurs with plant leaves, but their contours should be rounded. It is essential that each flange part 14 , 16 extends radially outward at an angle of less than 180 degrees from the respective sleeve part 4 or 6 .
[0069] In the illustrated embodiment, the flange parts 14 and 16 are in addition level and situated always parallel to one another. They could also, for example, form conical parts or spherical parts, which could be advantageous for operations on more convex or concave body parts.
[0070] An additional embodiment is distinguished from the embodiment in FIGS. 1 through 6 essentially in that the base body of the outer sleeve part does not have a semicircular cross-section, as in the outer sleeve part 6 , but instead, as with the inner sleeve part 4 , is a full tube. To be able to assemble and dismantle the outer sleeve part in this case, the distal end of the inner sleeve part must be detachably fastened on the head part, for example by means of cap nuts and positioning pins.
[0071] This embodiment, which is distinguished in further details from the embodiment in FIGS. 1 through 6 , is described in greater detail hereinafter with reference to FIGS. 7 through 26 .
[0072] The trocar sleeve with two full tubes as sleeve parts contains a head part 32 , a first, inner sleeve part 34 and a second, outer sleeve part 36 . The head part 32 is similar to the head part 2 of the foregoing embodiment, except that the inner sleeve part 34 , which consists principally of a piece of tube that extends in the axial extension of the clearance hole in the head part 32 all the way to a distal end, is detachably assembled on the distal end of the head part 2 . The outer sleeve part 36 , like the inner sleeve part 34 , has the form of a full tube, and the inner sleeve part 34 , beginning with its distal end, can be inserted into the outer sleeve part 36 , such that the outer sleeve part 36 encloses the inner sleeve part 34 with little play.
[0073] A first flange part 44 is formed on the distal end of the inner sleeve part 34 , said flange part having approximately the shape of a spatula longitudinally cut in half and forming a continuation of the inner sleeve part 34 that runs radially outward and thus protrudes at a right angle. A second flange part 46 is formed on the distal end of the outer sleeve part 36 , said flange part having the shape of the other half of the spatula longitudinally cut in half and forming a continuation of the outer sleeve part 36 that runs radially outward and thus protrudes at a right angle.
[0074] When the inner sleeve part 34 and the outer sleeve part 36 are completely pushed together lengthwise, as shown in FIGS. 7 through 10 , 13 and 14 , both flange parts 44 and 46 extend precisely in a plane perpendicular to the longitudinal axis of the sleeve parts 34 and 36 .
[0075] In the insertion position shown in FIGS. 7 , 8 , 9 and 14 , the two flange parts 44 and 46 supplement one another to form the (halved) spatula, in that they together have a U-shaped contour, as seen in a plane perpendicular to the longitudinal axis of the sleeve parts 34 and 36 , such that the distance between the two legs of the U-shape is approximately equal to, or somewhat smaller than, the diameter of the inner sleeve part 34 .
[0076] The side of the inner sleeve part 34 that is opposite the flange part 44 has a protruding nose 38 , which fits into a groove 40 open to the distal end, which is configured in the side of the outer sleeve part 36 opposite the flange part 44 . The groove 40 merges into a radially surrounding indentation 42 in the inner circumference of the outer sleeve part 36 .
[0077] In the relative angular position shown in FIGS. 7 through 10 , 13 and 14 , the inner sleeve part 34 and the outer sleeve part 36 can be completely pushed together lengthwise, such that the nose 38 slides into the groove 40 and makes contact with its base. At the same time, the plane surface on the flange part 44 of the inner sleeve part 34 that points in the proximal direction makes contact with a distal front end of the outer sleeve part 36 . Both flange parts 44 and 46 are then situated in the same plane perpendicular to the longitudinal axis of the sleeve parts 34 and 36 .
[0078] If now the outer sleeve part 36 is rotated somewhat around the inner sleeve part 34 as shown in FIG. 13 , the nose 38 on the inner sleeve part 34 enters into the indentation 42 in the outer sleeve part 36 , so that the inner sleeve part 34 and the outer sleeve part 36 can no longer be pushed axially toward one another. The outer sleeve part 36 can then be rotated further around the inner sleeve part 34 until the two flange parts 44 and 46 are situated in a working position or operating position, in which they point in directions contrary to one another as shown in FIG. 10 , in order to anchor the trocar sleeve below an epithelium. During the entire rotation process, both flange parts 44 and 46 remain in the same plane perpendicular to the sleeve longitudinal axis.
[0079] When the inner sleeve part 34 is fastened on the head part 32 , then in the insertion position in which the nose 38 does not yet engage in the indentation 42 , an axial sliding of the outer sleeve part 36 in the proximal direction is restricted by the head part 32 .
[0080] As shown in FIG. 14 , there is, situated on the proximal end of the outer sleeve part 36 , a radially surrounding cuff 48 into which an O-ring 50 fits that insulates the outer sleeve part 36 from the longer inner sleeve part 34 . Also fastened on the cuff 48 is an actuation lever to turn the external sleeve part 36 . Said actuation lever consists of a metallic spring 52 that springs in the sleeve longitudinal direction, with a round plastic cap 54 whose function is explained further below.
[0081] There are several possibilities for fastening the inner sleeve part 34 , on which the outer sleeve part 36 is mounted, on the head part 32 . Described below with reference to FIGS. 15 through 18 is an example for fastening the inner sleeve part 34 on the head part 32 by means of a screw-in lock.
[0082] The proximal end of the inner sleeve part 34 with the outer sleeve part 36 assembled on it can be recognized in FIG. 15 . The proximal end of the inner sleeve part 34 has a double-V-shaped contour 56 with two locking holes 58 in the peaks of the double-V-shaped contour 56 . A cap nut 60 , in whose smallest diameter the inner sleeve part 34 fits precisely, has on its inside two pins 62 ( FIG. 16 ) that protrude radially inward beyond the smallest diameter. The indents in the double-V-shaped contour 56 are rounded with the same radius as the pins 62 .
[0083] When the proximal end of the inner sleeve part 34 on the side with the smallest diameter is pushed into the cap nut 60 , then the pins 62 of the cap nut 60 touch the diagonal sides of the double-V-shaped contour 56 . When the inner sleeve part 34 is pushed farther into the cap nut 60 , the cap nut 60 is thereby rotated until the pins 62 are situated precisely in the indents of the double-V-shaped contour 56 . The inner sleeve part 34 thereby assumes a firm position in the cap nut 60 both radially and axially.
[0084] Inside the cap nut 60 are situated two recesses 64 , which extend perpendicular to the axis of the pins 62 . One segment of one of two groove stones 66 , which are fastened on opposite points on an oval spring 68 , fits into each of the recesses 64 in order to form a spring packet as shown in FIG. 17 . The oval spring 68 exerts a pretension force radially outward onto the groove stones 66 when the spring packet is seated in the cap nut 60 , as shown in FIG. 18 .
[0085] The groove stones 66 each bear a bolt extension 70 , which fits precisely into a locking hole 56 of the inner sleeve part 34 and is flush with it when the pins 62 of the cap nut 60 are situated precisely in the indents of the double-V-shaped contour of the inner sleeve part 34 . In addition, diagonally outward-pointing conical surfaces 72 are configured on the groove stones 66 .
[0086] The screw-in portion 74 of the head part 32 shown in FIGS. 15 and 18 bears an outer thread 76 that matches an inner thread 78 in the cap nut 60 . When the screw-in portion 74 is rotated into the cap nut 60 while the inner sleeve part 34 and the spring packet are situated in it, then a conical portion 80 on the screw-in portion 74 presses against the conical surfaces 72 of the groove stones 66 . The groove stones 66 are thereby moved inward against the spring force of the oval spring 68 , so that the bolt extensions 70 engage in the locking holes 56 in the inner sleeve part 34 and thus lock the inner sleeve part 34 on the head part 32 .
[0087] On releasing the threads 76 and 78 from one another, the groove stones 66 move outward so that the bolt extensions emerge from the locking holes 56 and the inner sleeve part 34 , together with the outer sleeve part 36 , can be withdrawn from the head part 32 . Then the sleeve parts 34 and 36 can be separated from one another.
[0088] As can be recognized in FIG. 18 , two O-rings insulate the cap nuts 60 from the inner sleeve part 34 or from the screw-in portion 74 of the head part 32 .
[0089] With reference to FIGS. 19 through 21 , an example for a fastening of an inner sleeve part 34 ′ on a head part 32 ′ by means of a type of bayonet lock is now described, however with a distinction from a conventional bayonet lock in that the lock cannot be released by simple rotation of the connected parts in relation to one another.
[0090] The inner sleeve part 34 ′ and the head part 32 ′ are distinguished from the previously described inner sleeve part 34 and head part 32 only in the area of the fastening with one another. That is, in the area of the proximal end of the inner sleeve part 34 ′ a resistance path 82 is hollowed out in its outer circumference, which seen from the side resembles FIG. 19 and appears unfolded into a plane as shown in FIG. 20 . Protruding radially inward from the inner circumference of the head part 32 ′ is a bayonet pin 84 ( FIG. 21 ) that fits into the resistance path 82 .
[0091] To fasten the inner sleeve part 34 ′ on the head part 32 ′, the head part 32 ′ is pushed onto the inner sleeve part 34 ′ in such a way that the bayonet pin 84 engages in the resistance path 82 and then is guided by it. If the head part 32 ′ is then further pushed onto the inner sleeve part 34 ′ and turned, then the head part 32 ′ at first moves further in the distal direction by the inner sleeve part 34 ′ until it is contiguous with the distally furthermost point of the resistance path 82 . If the head part 32 ′ is rotated further, then it moves again a short distance in the proximal direction. In this position the inner sleeve part 34 ′ is fixed on the head part 32 ′, in that a distancing sleeve 86 is inserted into the head part 32 ′ starting from the proximal end of the head part 32 ′ until it is contiguous with the inner sleeve part 34 ′. This is possible because the head parts 32 and 32 ′ each comprise an unscrewable cap 30 (see FIG. 8 ) on the proximal end. By screwing the cap 30 back onto the head part 32 ′ after inserting an insulation in the head part 32 ′, the distancing sleeve 86 and thus the inner sleeve part 34 ′ are fastened on the head part 32 ′. Because in this condition axial and radial movements overlap, no radial movement is possible between the inner sleeve part 34 ′ and the head part 32 ′ by the axial fastening.
[0092] In addition, in the area between maximum axial relative sliding and axial relative sliding in the assembled condition, as shown in FIG. 21 , the metallic spring 52 of the actuation lever is elastically reshaped on the outer sleeve part 36 . This provides a haptic feedback by the catch-locking of the bayonet lock.
[0093] Likewise as in the previously described embodiment, in the embodiment in FIGS. 7 through 21 as well, the trocar sleeve can be broken down easily and quickly into several components, facilitating their sterilization.
[0094] Characteristics of the embodiment in FIGS. 7 through 21 can also be combined with characteristics of the embodiment in FIGS. 1 through 6 .
[0095] There follows a description of additional details and additional parts of the embodiment in FIGS. 7 through 21 , which can also be applied in FIGS. 1 through 6 .
[0096] To indicate to the user the position in which the instrument is found, that is, the insertion position, in which the flange parts 44 , 46 of the two sleeve parts 34 , 36 point in the same direction, or the working position, in which the flange parts 44 , 46 point in approximately contrary positions to one another, two partially cylindrical indentations, which are displaced from one another by 180 degrees, are foreseen on a distal plane surface of the head part 32 or 32 ′ or of the cap nut 60 . In FIG. 22 , which gives a perspective view of the trocar sleeve portion shown in FIG. 18 , these are two cylindrical indentations 88 for the insertion position or the working position, only one of which is visible in the drawing, on the cap nut 60 . As long as the synthetic cap 54 of the actuation lever is situated in one of these indentations 88 , its metallic spring 52 is not impacted. If the outer sleeve part 36 is rotated by means of the actuation lever, the actuation lever must overcome the rim of the corresponding indentation 88 . Thus the axial distance between the head part 32 and the outer sleeve part 36 changes, and the metallic spring 52 is pretensed. As soon as the actuation lever moves over one of the indentations 88 , it catches easily therein, as the metallic spring 52 is relaxed.
[0097] FIG. 23 shows a trocar mandrel 90 , which is especially suited for inserting the described trocar sleeves in a body. The trocar mandrel 90 has, instead of the otherwise customary sharp point, a blunt distal end 92 with a slightly curved front surface with small fibers or roundings in the transition to the cylindrical shaft of the trocar mandrel 90 . The contour of the distal end 92 of the trocar mandrel 90 ends essentially flush with the contour of the distal end of the trocar sleeve, which can be recognized more precisely in FIG. 14 , when the trocar mandrel 90 is completely inserted in the trocar sleeve, as can be seen in FIG. 7 . This condition can be recognized by an operator from the fact that the proximal end 94 of the trocar mandrel 90 ends flush with the proximal end of the trocar head 32 , as can be seen in FIG. 8 .
[0098] To be used, the trocar mandrel 90 is inserted from the proximal end through the trocar sleeve in order thereby to close its distal end. The spatula formed by the flange parts 44 and 46 (or 14 and 16 ) is inserted in a scalpel cut, while the trocar is held diagonally above the epithelium. The trocar is pivoted into perpendicular position, and the sleeve parts 34 and 36 and thus the flange parts 44 and 46 are rotated with respect to one another by means of the actuation lever, so that the trocar is inserted atraumatically in the body opening. Then the trocar mandrel 90 can be withdrawn from the trocar sleeve. The trocar sleeve is now open in order to perform a minimally invasive procedure through the trocar sleeve.
[0099] Then the flange parts 44 and 46 are secured on the outside of the epithelium with a securing element that surrounds the outer sleeve part 36 and can be slid axially along the outer sleeve part 36 by overcoming or switching off its clamping force. Even better suited for this purpose than the previously described one-piece rubber disc with gap are securing elements, as are described below.
[0100] The securing element shown in FIG. 24 can be broken down into two parts, namely a disc-shaped part 100 , with gap, of an elastic material such as silicon that has a somewhat smaller inner diameter than the outer diameter of the outer sleeve part 36 , and a support plate 102 , with gap, of a rigid material such as steel. Protruding at a right angle from the support plate 102 are extensions 104 that fit in matching recesses in the elastic part 100 . Said extensions 104 hold the elastic part 100 firmly to the rigid support plate 102 and stabilize it in order achieve sufficient clamping force. The elastic part 100 and the support plate 102 have sufficiently extensive gaps so that they can be separately pushed laterally onto the outer sleeve part 36 and then connected together in the axial direction.
[0101] The securing element shown in FIG. 25 can also be broken down into two parts, namely a ring-shaped enclosure 110 of a rigid material such as steel with a U-shaped gap 112 , and an insert 114 of an elastic material such as silicon that is inside the gap 112 and can be fixed somewhat in the gap 112 by form-locking or force-locking but is removable. The enclosure 110 stabilizes the insert 114 in order to produce sufficient clamping force. The enclosure 110 and insert 114 can be pushed simultaneously or sequentially onto the outer sleeve part 36 and then axially slid along on it into the desired position as illustrated in FIG. 8 .
[0102] The securing element shown in FIG. 26 cannot be dismantled and consists of an approximately rigid plate 120 with a radial gap 122 , a clamping element 124 that can be slid in the direction toward the inner end of the gap 122 , and an actuation lever 126 , which is mounted to pivot on the plate 120 and comprises at its base a cam 128 that grips on the clamping element 124 . After this securing element has been pushed laterally onto the outer sleeve part 36 , the clamping element 124 is pressed against the outer sleeve part 36 by pivoting the actuation lever 126 and remains in this position by gripping action of the cam 128 on the clamping element 124 .
|
A trocar sleeve for minimally invasive surgery, having a first sleeve part, which has essentially the shape of a straight tubular piece with a longitudinal axis, and having a second sleeve part, which at least partly surrounds the first sleeve part in close contiguity and is movable during use with respect to the first sleeve part. The mobility of the second sleeve part in relation to the first sleeve part consists essentially only in rotatability of the second sleeve part around the first sleeve part, and in addition the first sleeve part and the second sleeve part each comprise on their distal axial ends a flange part that extends radially outward at an angle of less than 180 degrees from the respective sleeve part.
| 0
|
This is a nationalization of PCT/IE01/00058 filed May 3, 2001 and published in English.
The present invention relates to the biofiltration of volatile organic compounds (VOCs). A VOC may be defined as an organic species i.e. one containing Carbon and Hydrogen and possible other components such as Nitrogen, Sulphur or Halogens, which is readily evaporated at room temperature. The term VOCs covers a wide range of chemical classes, including aliphatic, aromatic and chlorinated hydrocarbons, alcohols, ketones, acids, ethers, esters and aldehydes.
These species contribute either directly or indirectly to a number of environmental issues and concerns, the nature and extent of the contributions depend on the chemical structures of the individual compounds. The major issues for concern are:
effects on human health and on natural ecosystems through toxicity, carcinogenicity and other adverse physiological effects; tropospheric photochemical oxidant formation; stratospheric ozone depletion; global climate change; odour; and ground level ozone formation.
VOC's arise from the activities of man and also from natural sources. The activities, which contribute to elevated VOC concentrations in the environment, include:
printing and coating industries which use solvents; transportation-hydrocarbon fuel combustion and storage; waste management-landfills, water treatment plants; petrochemical industries; and pharmaceutical manufacturing.
It has long been recognised that biofiltration is a suitable and cost effective method of VOC emission destruction for low to medium concentration regimes. Conventional teaching dictates that the longer the resident time effluent gas is in a biofilter, the greater the removal efficiencies (Ottengraf S. P. P., J. J. P. Meesters, A. H. C. van der Oever, H. R. Rozema. Biological Elimination of Volatile Xenobiotic Compounds in Biofilters). A residence time of typically 60-90 seconds in the filter medium is recommended. This generally follows zero order removal kinetics where a concentration gradient forms in the biofilter with greatest concentration at the inlet and removal is thus greater for longer retention. It has been found that retention times of greater than about 90 seconds are not applicable as the air moves so slowly through the filter, that channelling can occur. Additionally, it becomes very uneconomical as filter sizes must be increased significantly. The literature maintains that the VOC elimination capacity for conventional biofilters is in the range 10 to 40 g VOC/m 3 media/hr.
Our British Patent Specification No. 2300824 describes and claims various new packing materials that have considerable advantages over packing materials used heretofore. One of the major problems that was identified in this British Patent Specification was the fact that in dealing with effluent treatment, the level of contaminant produced can vary widely. Industrial waste can vary widely, depending on the conditions of operation of the plant, the source of the waste. Thus, there can be extensive daily variations in the VOC levels experienced both in sewage treatment plants and in industrial and agricultural plants. Further factors, as have been described in this British patent specification, can impact on the levels of contaminants experienced. A major problem is that if the average inlet concentration of VOC's is used in the design specification, then the system may not be capable of coping with peak levels. If, on the contrary, the system is designed for peak loadings, then it may not produce an optimum result due to nutrient starvation of microorganisms within the biofilter at the much lower VOC levels. A further problem with designing for peak levels is obviously one of cost in that the filter bed and consequently the biofilter must be larger than is required for average conditions. The system of British Patent Specification No. 2300824 goes a considerable way towards increasing the ability of a biofilter to handle these various loads.
It should be noted that in this present specification, when we refer to biofiltration, we are also referring to bioscrubbing systems and that the former term is used to describe both systems.
It should also be noted that the term “biofilter throughput rate” refers to the rate at which effluent gas passes through the gas inlet and outlet as distinguished from the “filter media throughput rate”, which refers to the rate at which effluent gas is drawn through the actual filter media bed.
The terms “packing”, “packing materials”, “filter media bed”; “media” and “shell media”, as used in this specification, are intended to have the same meaning and are used interchangeably such that while a reference to shell media may be used as a specific reference to one type or media it is to be understood that other suitable media may be used.
As mentioned above, one of the major problems and design limitations appears to be that if the concentration of the VOCs increase beyond a certain level, then the biofiltration system does not appear to be able to remove sufficient quantities and it is necessary to either reduce the gas flow thereby increasing residence time or to dilute the incoming gas. Unfortunately, previously, both of these courses led to an increase in biofilter size.
An obvious requirement for an efficient biofilter is that microorganisms are present at sufficient cell densities to degrade the levels of contaminants entering the biofilter. Also once a biofilm is formed the fraction of active biomass to the total biomass may be relatively small. It follows thus that the more concentrated the organics in the air stream the more biomass will be formed.
This is a problem with biofilters generally i.e. the need for the prevention of excessive build-up of biomass due to high VOC concentrations. Consequences of biomass formation are that it can cause clogging of the biofilter and spoiling of the recirculation water. Researches and pilot studies carried out by the Applicant have shown that back pressure can increase up to five times the original value, through a clogged media bed. This leads to a decrease in the efficiency of the biofilter and an increase in the energy needed to deliver the effluent gas through the biofilter. With particulate filter media especially, the microorganisms bridge the gap between the particles and blockages begin to occur. The preferential growth of filamentous bacteria within the biofilm may be one of the primary reasons that the filter media becomes clogged. This causes an increase in the pressure drop over the filter bed and thus treatment of the contaminants becomes significantly reduced if not stopped. There is thus a need for a preventive mechanism inhibiting the proliferation of excessive biomass whilst not affecting viability of the “desired” microorganisms.
Another well-known problem associated with biofilters is the relative insolubility of VOCs in water. A well-known feature of biofiltration of airborne contaminants is the requirement to transfer the pollutant into the aqueous phase before biodegradation can occur.
The present invention is also directed towards promoting more efficient mass transfer of VOCs into the aqueous phase.
Microbial starvation can also be due to low inlet air levels. British Patent Specification No. 2300824 went a considerable way to ensuring that the biological system was adequately seeded with bacteria and that the culture would survive during periods of starvation as inlet VOC concentrations drop.
Another of the major problems with any biofiltration system is the necessity to keep the energy consumption low. Effectively, this means that there must be a low back pressure generated in the packing material. Thus, the correct choice of packing material is vital.
There is a need for such systems to handle high and variable levels of contaminant gases generally and in particular, high and variable concentrations of VOC's. The present invention is directed towards this.
STATEMENT OF INVENTION
According to the invention, there is provided a process for the biofiltration of volatile organic compounds (VOCs) of the type comprising delivering contaminated effluent gas through a biofilter, the biofilter having an inlet, outlet and a micro-organism laden filter media bed, the filter media bed additionally having moisture retaining properties and which filter media bed is suitable for the absorption, microbial oxidation and degradation of the VOCs characterised in that the method comprises:—
delivering contaminated effluent gas to the biofilter inlet at a biofilter throughput rate and removing the filtered gas through the outlet at the same rate; and recirculating the contaminated effluent gas within the biofilter whereby the rate at which gas passes through the filter media exceeds the biofilter throughput rate at the inlet and the outlet and wherein the inlet gas is effectively diluted within the biofilter.
This process of recirculating the air within the biofilter apparatus has the effect of significantly enhancing removal efficiency of VOCs from contaminated effluent gases without a significant increase in the running and maintenance costs of an apparatus according to this invention.
This novel recirculation of contaminated air results in a number of advantages over traditional abatement systems. Previously, such systems were not very efficient in handling contaminated air in which the VOC levels vary over time. Recirculation using this process results in an apparent dilution of the incoming effluent gas. Therefore, the effects of variable VOC concentration are minimised and removal can be effected more efficiently. Traditionally, a system coping with widely variable VOC levels would have to be very large. Consequently, running costs are significantly increased. A recirculation process negates the need for a large costly apparatus thereby running and maintenance costs are reduced.
In further embodiments, the VOC concentration at the inlet and outlet is monitored. This measurement of inlet and outlet VOC levels allows a determination to be made as to the efficiency of the biofiltration process. If the outlet levels of the VOC are above predetermined levels then action can be taken to reduce these levels to below the limit. In a preferred embodiment the VOC concentration in the output gas is monitored and when the concentration exceeds a preset limit recirculation is carried out. Also, as has been stated previously, it is obviously desirable to have as low running costs as possible. By monitoring the VOC content of the inlet and outlet gas, the recirculation process can be switched on or off depending on the VOC concentration. At high VOC concentrations recirculation switches on and at low concentration recirculation is off.
In another embodiment according to the present invention the biofilter throughput rate is determined having regard to the volume of effluent gas to be processed. The volume of effluent gas to be processed may vary widely and as such, it is desirable that the biofilter throughput rate is adjusted to cope with the varying volumes of gases. For example, if the volume of effluent gases produced increases then it may be necessary to increase the biofilter throughput rate to cope with this increased volume and vice versa.
The rate at which contaminated air travels through the system is very important to maintain a constant and efficient removal of VOCs. If gas travels through at too high a rate, then the VOCs are not in contact with the filter media bed for sufficient time to effect efficient VOC removal. If the gas is travelling through too slowly, then channelling may occur and efficient treatment of the total contaminated gas is not effected.
In another embodiment, the number of times recirculation is carried out and hence the media throughput achieved, depends on the back pressure generated by the filter media.
Maintaining back pressure at a low level is very important to energy efficient biofilter operation. When back pressure increases significantly, energy output increases considerably as more energy is need to draw air through the filter media. Thus, in order to maintain an energy efficient system, the maximum rate at which air travels through the system and the number of times the air is recirculated is controlled in order to prevent an excessive build-up of back pressure.
In a preferred embodiment, the VOC concentration in the output air is monitored and when the VOC concentration exceeds a preset limit, recirculation is carried out.
The colony forming unit counts of microbes in the filter media bed has to be maintained at levels that will provide efficient removal of the VOCs. The recirculation process is carried out and maintained at a level that allows the microorganisms to remain viable for periods of time when the VOC concentration is at or below the minimum level. Thus in one embodiment, when the VOC levels of the inlet gas are too low recirculation is carried. Alternatively in another embodiment when the inlet level of VOCs falls below a preset limit for a predetermined length of time VOCs are added to the filter media bed. Traditionally with biofilters and the bioscrubbers nutrients can be added in order to maintain a viable biomass during periods of starvation. Microbes in a biofilter according to the present invention however, can remain viable for up to seven days after complete shut-down of the biofilter by utilising residual VOCs dissolved in the liquid reservoirs. When these residual dissolved VOCs have been exhausted trace levels of VOCs are added to the filter media via in one embodiment the sump and recirculating liquid, or in another embodiment by delivering liquid with dissolved VOC's across the filter media bed. Again, this prevents the microorganisms from perishing due to low VOC levels in the effluent gas.
According to one embodiment of the invention there is provided a process in which the filter media bed is kept moist by delivering liquid across the filter media bed. It is advantageous that the filter media bed be kept wet as the break down of VOCs by the microorganisms is facilitated by a moist environment. However, if VOC levels are low in the effluent gas this may lead to microbial starvation as stated previously. Deliberate VOC addition to maintain a viable biomass, by the liquid that is delivered across the filter media bed ensures that the VOCs are uniformly dispersed within the filter media bed.
Moisture retention is a major problem in any biofiltration system and this has been long appreciated by the use of material in the formation of the media that is inherently adapted to retain moisture. Unfortunately, there are consequent problems in using such materials. Thus, it is known to use some of these with calcareous materials. With a calcareous material, it is essential that sufficient moisture be retained within the media to ensure the growth of bacteria thereon. This can only be done if the media is sufficiently moisture retentive and heretofore required that it should be mixed with, for example, peat, or indeed be continuously sprayed. The use of liquid reservoirs overcomes this problem.
It is almost impossible to overemphasise the importance of the liquid retention portion of the calcareous elements on the efficient operation of the effluent treatment system according to the invention. As mentioned previously moisture retention as with traditional biofilters is of utmost important in order to satisfy the liquid requirements of the microbial population. Advantageously the moisture retaining properties of the present invention also allow the microbial population to remain viable for sustained periods of low VOC levels or periods whereby no VOCs are entering the biofilter, by providing a reservoir of dissolved VOCs to sustain the microbes.
Another important feature of the process according to the present invention is the rate at which water passes through the biofiltration system. This unlike traditional biofilter processes where liquid is provided only to satisfy the moisture requirements of the micro-organisms the rate at which the liquid passes through the media bed is important in ensuring an efficient VOC elimination capacity of the biofilter. This rate is very high when compared to traditional biofilters. A high rate is advantageous as it is this in conjunction with a high media throughput rate of gas that promotes a more efficient biological degradation of dissolved VOCs. However, the rate can vary according to the level of VOCs passing through the biofilter. At high VOC levels the rate is higher. At low VOC levels the rate need not be so high and can be reduced in order to conserve energy output of the pump, thereby reducing running costs of the biofilter.
Accordingly, there is provided a process for the biofiltration of VOCs wherein the rate at which liquid passes through the filter media bed is varied according to the level of VOC passing through the filter media bed. Preferably the rate is between 20 and 50 l/m 3 media per minute and is ideally 30 l/m 3 media per minute.
In a further embodiment the wetting is achieved by recirculating water over the packing from a storage sump.
In yet another embodiment of the process the liquid delivered across the filter media bed is stimulated electromagnetically.
According to one embodiment a process for the biofiltration of volatile organic compounds (VOCs) of the type comprising delivering contaminated effluent gas containing odorous compounds through a biofilter having an inlet, outlet and a filter media bed, the filter media bed having micro-organisms, nourishment and moisture retaining properties which are suitable for the absorption, chemical degradation and microbial oxidation of the VOCs and which process also includes delivering liquid across the filter media bed characterised in that the method comprises:—
delivering contaminated gas to the biofilter inlet at a biofilter throughput rate and removing the filtered gas at the same rate; recirculating the contaminated gas within the biofilter whereby the media throughput of gas through the filter media exceeds the filter throughput rate from inlet to outlet; and electromagnetically stimulating the liquid which is delivered across the filter media bed;
is provided.
In another embodiment, the VOC concentration in the output gas is monitored and when the VOC concentration exceeds a pre-set limit, recirculation is carried out.
In yet another embodiment when the inlet concentration of VOC falls below a pre-set limit for a predetermined length of time VOCs are added to the filter media bed.
In a further embodiment the biofilter throughput rate is determined having regard to the volume of effluent gas to be processed.
According to the invention, a biofiltration system is provided for the removal of VOCs from contaminated effluent gas. The system is of the type comprising a biofilter housing, a gas inlet in the housing for reception of the contaminated effluent gas, a gas outlet for delivery of de-contaminated gas from the biofilter, a microbe carrying filter media comprising a plurality of randomly arranged elements of calcarous material having a liquid retention portion, many of which are oriented to form an individual and liquid retaining reservoir within the packing characterised in that gas recirculation means are provided for capturing some of the air adjacent the gas outlet for delivery back into the biofilter housing adjacent the gas inlet.
Ideally, the filter media has a bulk density of less than 900 g/liter, in some instances less than 600 g/liter, and indeed in one embodiment has a bulk density of approximately 500 g/liter. The lighter the media can be, the less problems there are with structural integrity of any column of the packing material, also, the greater depth of packing material that can be achieved before the structural integrity of the elements becomes important.
In one particularly advantageous embodiment of the invention, the filter media is spent shell of shell fish. There are enormous and unforeseen advantages in using the spent shell of shell fish. Firstly, it is a by-product of various food operations in that oysters, whelks, mussels, clams and so on are processed in factories which produce a large amount of spent shells which then have to be disposed of, causing pollution. In any event, the disposal of such shells is expensive. Anything that removes the necessity to spend money on the disposal of the shells but additionally makes them a valuable commodity is obviously extremely advantageous. It has long been appreciated that spent shells of shell fish are a major source of calcium material. It would be wrong to underrate the disposal problem experienced by many shell fish processors. A further advantage of the use of spent shells is that they are of a particularly useful shape in that some of the shells will be broken, others will have their full structural integrity and so on, so that the bed formed by the use of the spent shells will be a bed that will ensure adequate flow of gases and adequate retention and moisture by providing a sufficient number of shells which will form individual liquid reservoirs. It has been found that mussel shell or, more correctly, a half mussel shell is particularly advantageous as there is a large amount of mussel shell available after processing in factories. It is particularly appropriate to use such a shell as it is not alone efficient in use, but equally needs to be disposed of on a regular basis. Thus, the raw material for the initial preparation of the system packing, together with its replacement when the shell used has passed its useful life, is readily available and inexpensive. Further, mussel shell is particularly structurally rigid.
Ideally, the shell material is a half mussel shell and preferably is of the species Mytilus Edulis. Mytilus Edulis , which is readily available, has in practice turned out to be particularly useful as a form of shell for use in the present invention.
In a biofiltration system in accordance with the invention, the packing may include one or more additional packing materials. In many instances, it will be advantageous to provide different filter media materials because they can add to the efficiency of the effluent treatment particularly where specific effluent gases are likely to be treated on a regular basis. However, the calcarous material according to the present invention and in particular, elements of calcarous material each having a liquid retention portion are particularly advantageous for mixing with other media in the sense that these liquid retention portions will also provide a means for retaining the other media in position in the bed and ensuring that such other media is not washed away or otherwise removed from the bed.
Some or all of the elements may be formed from ground calcarous material mixed with a binding agent. If ground calcarous material is used to make what is effectively a totally artificial element to form the packing, there are considerable advantages. Firstly, the binding agent can be chosen to provide the correct degradation of the calcarous material. Suitable trace elements and additives may also be combined with the calcarous material to further enhance the efficiency of the system. Additionally, because a binding agent is used and the media is manufactured, the correct size and shape of the media can be chosen to provide the most efficient filtration system.
Thus, the packing chosen can be totally uniform in shape or can be provided by a number of different shapes to ensure there is an adequate flow of gas through the media. Also, the use of different shapes can allow the mixing of other materials therewith and the medium can be so shaped as to ensure that such other additional packing materials can be retained within the medium. Structural requirements to ensure such additional packing materials are adequately supported can be achieved by manufacturing the elements in the desired and optimum shape. Shapes can be devised and designed to ensure, for example, in conditions where evaporation could be a problem, that the liquid retention portion is so designed as to have a large capacity and a relatively small surface area exposed to ambient conditions.
Preferably, the binding agent is acid resistant. It will be appreciated that the binding materials must be such as to ensure that in generation of acid within the system, the elements do not degrade and cause the packing to lose its structural integrity.
Ideally, the binding agent is Keratin. This is a particularly suitable binding agent for combination with the calcarous material used in accordance with the invention.
Many additional packing materials such as one or more of heather, peat nodules, activated carbon, alumina and plastics media may be used. Heather, peat nodules, activated carbon, alumina and plastics media have all been shown to have their advantages. While in many instances, certain of these may not be totally biodegradable, they have other advantages in, for example, with a plastics material, adding to the structural rigidity of the structure and providing, if suitably shaped, further individual liquid reservoirs.
Ideally, wetting means are used and such wetting means usually comprises a spray operating under gravity. It is obviously very useful to ensure that the packing is sufficiently moist. The wetting means may be operated intermittently. This is assisted by the fact that the packing according to the present invention is formed from a number of randomly arranged elements each having a liquid retention portion which may form an individual liquid reservoir depending on the orientation of the element within the packing and thus it is not necessary to continuously wet the packing and this leads to both operational and other savings. In many instances in accordance with the invention, the wetting means is operated continuously and may indeed be achieved by recirculating water over the packing. It is obviously generally advantageous to wet the packing continuously if water can be recycled and recirculated. In many instances, the water used will be the final run water of the treatment plant itself.
In a particularly useful embodiment of the invention, the wetting is carried out in concurrent flow to the flow of the gas stream through the packing. The advantage of this is that with concurrent flow, the maximum reaction with the calcarous material takes place at the top of the packing bed and hence the maximum amount of chemical reaction with the elements of calcarous material occurs at the top of the packing and thus, as it deteriorates, it contributes less, by its deterioration, to the general reduction in structural rigidity of the packing than it would if the water and gas were in counterflow.
In another useful embodiment, the liquid provided by the wetting means is stimulated electromagnetically.
A preferred embodiment according to the invention has a biofiltration system for the removal of VOCs from contaminated effluent gas of the type comprising a biofilter housing, a gas inlet in the housing for reception of the contaminated air, a gas outlet for delivery of de-contaminated air from the biofilter, a bacteria carrying packaging comprising a plurality of randomly arranged elements of calcareous material having a liquid retention portion, many of which are oriented to form an individual and liquid retaining portion within the packaging and a means for wetting the packaging characterised in that gas recirculation means are provided for capturing some of the air adjacent the gas outlet for delivery back into the biofilter housing adjacent the gas inlet and wherein means are also provided for electromagnetic stimulation of the liquid provided by the wetting means.
Preferably, a biofiltration system is provided wherein the wetting means comprises a spray means. Ideally, the wetting means is achieved by recirculating water over the packing from a storage sump.
Another aspect of the system incorporates a filter media bed with a bulk density of less than 900 g/liter. According to another aspect, the calcareous material is half mussel shell, which ideally is of the species Mytilus Edulis
DETAILED DESCRIPTION OF THE INVENTION
The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings in which:—
FIG. 1 is a schematic elevational view of a biofilter according to the invention,
FIG. 2 is a view similar to FIG. 1 of another biofilter according to the invention,
FIG. 3 is a view of portion of a filter bed incorporating a packing material,
FIGS. 4( a ) to ( c ) illustrate various other forms of packing material according to the invention, and
FIGS. 5 to 8 show results of tests carried out.
Referring to the drawings and initially to FIG. 1 , there is illustrated a biofilter, indicated generally by the reference numeral 1 . In this case, the biofilter 1 acts as a gas scrubber and should be more properly called a bioscrubber. The biofilter 1 comprises a biofilter housing 2 containing packing material 3 below a contaminant gas manifold 4 . The housing 2 has a water sump 5 and a water sprinkler bar 6 respectively below and above the packing material 3 . The sump 5 is connected by a water recirculation pump 7 and piping 8 to the sprinkler bar 6 . The sump 5 has a conventional overflow pipe 9 and a drain-off pipe 10 incorporating a drain-off valve 11 . A vent 12 is also provided in the overflow pipe 9 . A water make-up pipe 13 feeds the water sump 5 through a ball cock 14 . A gas outlet pipe 15 is mounted in the top of the housing 2 and in turn houses a valve 16 to which is connected a recirculation pipe 17 and recirculation fan 18 which feeds at 19 , a main contaminant gas inlet pipe 20 which then feeds the biofilter housing 2 through an inlet 21 below the packing material 3 . A gas sensor 34 is connected to a controller such as a programmed PC 35 which is used to control the valve 16 . An electromagnetic radiation device 36 is mounted in the water sump 5 and connected to the PC 35 .
Referring now to FIG. 2 , the biofilter 1 illustrated is a pure biofilter and parts similar to those described with reference to FIG. 1 are identified by the same reference numerals. In this embodiment, the sprinkler bar 6 is fed directly from a mains water supply line 25 or where there is a considerable amount of liquid effluent from a final liquid effluent supply. Essentially, it will be appreciated that, strictly speaking, the biofilter 1 operates only as a biofilter in FIG. 2 and as a bioscrubber in FIG. 1 , but the difference is relatively slight and it is convenient to refer to them both as biofilters.
The packing 3 comprises or at least contains a shell-like material having a bulk density of less than 900 g/liter, preferably less than 600 g/liter and typically approximately 500 g/liter. The shell-like material is in this case the spent shell of shell fish, particularly calcarous shell, especially mussel shells of the species Mytilus Edulis . The packing may include one or more additional packing materials. Additional packing materials may include one or more of peat nodules, activated carbon, alumina, or plastics media and the like. Indeed any similar packing material may be used.
Referring now specifically to FIG. 3 , there is illustrated portion of a packing of mussel shells, identified by the reference numeral 30 , and shows the random nature of the arrangement.
In use, the elements will be shovelled or thrown or otherwise roughly charged into the housing so that they will be randomly and not regularly arranged. Ideally these elements should not be broken. Broken elements can sometimes create areas within the filter media bed where the gas flow is increased compared to other areas. This creates a pressure differential across the filter media bed resulting in inefficient mass transfer of VOCs into the aqueous phase. The ideal situation is a uniform gas flow rate across the filter media bed.
Further, this random arrangement will ensure that some elements will fall one way and others another. For example, when the elements are of shell-like shape, whether of artificial construction or natural, they will nestle into each other, bridge each other, lie upright upside-down with the mouth facing downwards and not forming a liquid reservoir etc. Such a scattering of the elements will ensure packing that will be of a sufficiently open structure as to facilitate the passage of a gas stream therethrough.
The term shell-like, while particularly apt when considering shells or marine origin, does describe in general, if not very precise terms, the open-mouthed container-like construction of the individual elements constituting the packing, whether manmade or naturally occurring.
FIG. 4 illustrates various artificially formed shell-like elements, identified by the reference numerals 31 , 32 and 33 respectively. Each of these packing elements 31 , 32 and 33 can be formed of any suitable calcarous material and a binder and may be formed by any suitable moulding or other formation techniques. The packing element 31 is the simplest construction, being essentially a dish or shell-like structure, while the packing element 32 has a much narrower mouth, or opening as it where than the packing element 31 . The packing element 33 shows the provision of an irregular outer surface that will further promote the adherence of moisture and biologicals active material thereto as well as providing a greater available surface.
It is envisaged that many suitable binders could be used. It would be possible to provide a binder than would ensure there was sufficient free calcium available to allow the packing to be inoculated with bacteria mixed with sodium alginate, for example. A particularly suitable binder is Keratin. However, other suitable binders may be used.
In operation, the biofilter 1 can be operated in two ways with and without contaminate gas recirculation through the gas recirculation pipe 17 . How this operates will be described in more detail below. When the valve 16 is used to recirculate contaminate gases, it can be controlled by a gas sensor, such as gas sensor 30 , either at the inlet 21 further upstream or at the gas outlet pipe 15 . The operation will become apparent from the following examples.
There are a number of conditions that will dictate when contaminant gas recirculation will occur. These will be described in detail below. During operation, without recirculation, the biofilter will operate essentially as traditional biofilters such as that described in the applicant's Patent Application No. GB 2300824. In practice, the decontaminated gas passing through the outlet is continuously or intermittently monitored. If the VOC concentration in the gas outlet pipe 15 exceeds a preset limit such as that dictated by environmental regulation for exhaust gases, the recirculation process is switched on. During normal operation, gas is drawn through the biofilter at a rate within an optimal range. This will be between 100 to 300 m 3 gas/m 3 media/hour. In one embodiment, recirculation is effected by controlling the valve 16 and allowing a proportion of the gas to be recirculated and to re-enter the biofilter housing 2 via the connection 19 with the inlet pipe 20 . Recirculation is effected such that the volume of gas through the outlet pipe 15 is approximately equal to the volume of gas through the inlet pipe 20 . When the recirculated gas enters the inlet pipe 20 , a dilutory effect is achieved on the inlet gas as the recirculated gas has already had a percentage of the VOC removed. As mentioned previously, the dilutory effect helps to negate the previously problematic situation of variable VOC levels.
Described above is one situation, i.e. responding to variable VOC levels where recirculation is effected. Another situation is where the volume of exhaust gas from the plant varies over time. For example the volume of exhaust gases produced may peak at certain times of the week or indeed at certain times of the year. In this case, the volume of gas passing through the biofilter must be increased to accommodate with the increased volume of exhaust gases. Such an increase may take the biofilter throughput rate above the maximum optimum throughput rate for efficient and optimal VOC removal. Consequently, VOC removal efficiency will fall. However, when recirculation is carried out, as described above, even at this non-optimal throughput rate, the level of VOCs removed can still bring the levels in the outlet gases below the pre-set limit.
In short, it is envisaged that the recirculation process will allow the removal of VOCs from plants where firstly the VOC concentration can vary over time and secondly, where the volume of exhaust gases from the plants can also vary over time. Recirculation also allows the treatment of exhaust gases wherein the VOC concentrations are above those that could be handled by conventional biofilters. Recirculation causes the gases to come into contact with the filter media bed an increased number of times. A given volume of gas recirculated three times will have approximately 30 to 40% of the VOCs removed. This is equivalent to conventional biofilters at these VOC concentrations and air loadings and an actual residence time of 96 to 110 seconds during each pass. The accumulative effect is the achieval of approximately 80 to 95% removal efficiencies or VOC.
However, prior to describing the various examples, it should be appreciated that conventional biofilter wisdom would dictate that recirculating air would be of no advantage in the bio-treatment of VOCs. We have discovered certain unusual phenomena that we did not expect would happen with biofilters in accordance with the invention. When the biofilter was loaded in conventional manner at a range of air volumes between 100 to 300 m 3 air/m 3 media/hr representing a retention time of between 36 and 12 seconds with heavily contaminated air, that is to say, with VOC concentrations of the order of 500 mg/m 3 upwards, a removal efficiency of ˜30% was consistently attained. This is contrary to normal removal principles, since as the retention time was decreased, removal remained constant. Thus, whether the airflow was at 100 m 3 air/m 3 media/hr or at 300 m 3 , air/m 3 media/hr for these VOCs, the same removal efficiency was maintained. It is difficult to state with any certainty why this should be. Thus, much of the following is speculative and requires further analyses. It appears to be that with a packing material according to the present invention, there is a mass transfer of pollutants into an aqueous phase rather than a concentration gradient across the biofilter. Having discovered this, it was then decided to recirculate air through the biofilter. With an input air of 100 m 3 air/m 3 media/hr, by recirculating three times, effectively having a net loading of 300 m 3 /m 3 media/hr, greater removal efficiencies were achieved. These again were of the order of 30% at each pass of the air through the biofilter and thus with VOCs of the order of >500 mg/m 3 , the total VOC removal was at the rate of up to 90% efficiency. As far as can be ascertained, the recirculating gas appears to provide a net effective dilution of the inlet gas by a factor of the recirculation ratio, however, this is not a dilution in the normal sense of the word as the outlet and inlet volume flows of gas remain the same. In other words, the inlet and outlet rate is not effected. Secondly, the treatment of the gas a number of times appears to achieve removals each time equivalent to removal in conventional biofilters at these VOC concentrations and air loadings, thus significantly increasing removal capacity per cubic meter of media.
It appears that there is a radical changing of airflow dynamics, which promotes mass transfer of insoluble compounds and reiterative biological degradation. Mass transfer of relatively soluble VOCs is also promoted by an increased rate at which water passes through the filter media bed. At high VOC loadings this rate can be as high as 50 l/m 3 media per minute. It is important to realise that this rate is very high compared to traditional biofilter processes.
It is also envisaged that when VOC levels are low or nil for a sustained period, trace amounts of VOC's are added to the filter media bed 3 . In one embodiment the VOC's are separately dissolved in the liquid within the sump 5 and the liquid is recirculated via a recirculation pipe 8 so that the dissolved VOC's are delivered across the filter media bed 3 by the wetting means 6 . In an alternative embodiment where the liquid is not normally recirculated but rather is delivered to the biofilter housing 2 by a mains supply ( FIG. 2 ) the liquid can be recirculated.
A number of trials by the Applicant have shown the application of electromagnetic radiation to the recirculation liquid has a significant effect in preventing the build-up of biomass and increasing the dissolution properties of the recirculating liquid. The electromagnetic radiation appears to favour the growth of certain bacterial species while inhibiting the growth of others. The proliferation of filamentous bacteria i.e. those that may cause clogging of biofilters are inhibited by the electromagnetic radiation thus reducing an accumulation of biomass on the filter media which can lead to clogging, and thus a decrease in removal efficiency.
The first test carried out in accordance with the invention is given below where it will be seen that, quite clearly, because of the unique nature of the packing, increasing the airflow loading per cubic meter of media up to 3 times the loading on conventional biofilters, (and thus decreasing retention time) did not decrease removals of relatively high concentrations of VOCs. Thus, when recirculation took place, the efficiency increased enormously.
Test No. 1
The airflow through the columns was set primarily at 150 m 3 /hr/m 3 media
Total solvent load was set at: >500 mg/m 3 in a 1:1:1 ratio of Benzene:Xylene:Toluene (relatively insoluble VOCs)
Removal efficiencies of total solvent over a period of 2 weeks remained at 35-40%
The airflow to the column was increased to >300 m 3 /hr/m 3 media for 2 weeks Removal efficiency fell to below 25%
The airflow was subsequently pulled back to 280-300 m 3 /hr/m 3 media.
% Removal climbed back to 30-35%. This remained at this rate for one month.
Therefore the maximum optimum loading for a straight single pass throughput application was established of 280-300 m 3 /hr/m 3 media
At this time, the pH of the recirculation water remained above 6 pH units at all times
When scanned for organics, the recirculation water showed only trace amounts
Mass balance figures from solvent usage and removal efficiencies were consistent over this period.
The results of this test are shown in FIG. 5 .
Test No. 2 was carried out as listed below.
Test No. 2
A recirculation line was fitted.
The inlet air was set at 100-125 m 31 hr/m 3 media with an outlet flow of the same volume. The recirculation airline was controlled by a needle valve. The maximum recirculation possible through the system was found to be a 1:3 ratio 300-400 m 3 /hr/m 3 . Thus the inlet air was spinning around through the system 3 times with a nominal retention time of 36-28 seconds and an effective retention time of 108-85 seconds. Average removal was between 83-91% of total inlet solvent concentrations. Mass balance calculations of solvent usage versus inlet and outlet concentrations were within experimental error of <10%. The pressure difference across the shells remained under 500 Pascals showing no excessive build up of biomass. The recirculation water showed only trace organic species when scanned by GC-MS (Gas chromatography—mass spectrophotometry). Bacterial activity on the shell media remained high at 10 7 colony forming units per gramme media material.
The results of this test are shown in FIG. 6 .
Conclusion
With a through-put the equivalent of the optimum loading for maximum extraction when feeding highly contaminated air through the biofilter recirculation dramatically increased the extraction.
Test No. 3
In Test 3, (the graphical results of which are shown in FIG. 7 ), an 8 Colour Heated Printer, running 16 hours a day, 5 days a week, the air was recirculated three times and the removal rates as given on the Table below were achieved.
Inlet
Outlet
Elimination
Date
mg C/m 3
mg C/m 3
% Removal
g/hr
2/07
1259
309
75%
114
5/07
1752
336
81%
170
10/07
935
531
45%
48.5
19/07
2955
682
77%
272 5:1
20/07
2157
643
70%
182
21/07
1729
468
73%
151
22/07
1343
251
81%
131
04/08
1470
424
73%
105
21/08
1215
292
76%
111
24/08
1154
243
79%
109
24/08
1232
231
81%
120
Apparently, there is a 20-30% removal of high concentration VOCs of the order of 1,000 to 5,000 mg/m 3 on a single pass at high loading of up to 200-250 mg/m 3 media/hr. This appears to be the maximum VOC removal that can be achieved. However, by recirculating, effectively the removal is greatly increased. It appears that there must be some different kinetic removal involved such as first order kinetics in the sense that 20-30% removal is achieved at each cycle of air through the filter.
Referring now to FIG. 8 , the chromatogram once again shows a significant VOC removal efficiency of a biofilter according to this invention.
Test No 4
Lab scale pilot plants according to the invention were installed incorporating two columns treating up to 2,500 mg/m 3 VOC. One column incorporated a device for emitting electromagnetic radiation the other was a control. Such a device is described in PCT Patent Specification No. WO 96/22831 and the disclosure is incorporated herein by reference. Comparisons demonstrated some notable effects
the systems were reconfigured so that the inlet air was recirculated, air was recirculated at a ratio of 1:4 with a total retention time of approx. 25 seconds, xylene, benzene and toulene are introduced to the air stream at average total concentrations of 5000 mg/m 3 air, the removal efficiencies of the columns at a recirculation ratio of 1:4 are:
Control:
80%
Electromagnetic Stimulation:
87-91%
on microbial analysis of both the recirculation water and the shell media it is apparent that there are differing populations of bacteria present in the two biofilters,
the electromagnetic (EM) radiation device reduced sludging effects in the sump of the stimulated water,
after 3 months operation the air flow through the control biofilter reduced considerably whereas in the biofilter using the EM radiation it remained constant,
there were differing microbial populations present in the biofilters, this was evidenced by microbiological analysis of the water.
In the specification the terms “comprise, comprises, comprised and comprising” or any variation thereof and the terms “include, includes, included and including” or any variation thereof are considered to be totally interchangeable and they should all be afforded the widest possible interpretation.
The invention is not limited to the embodiments hereinbefore described but may be varied within the scope of the appended claims.
|
A process and system are disclosed for the biofiltration of volatile organic compounds. The process involved recirculating contaminated effluent gas through a biofilter ( 1 ), the biofilter ( 1 ) having an inlet ( 20 ), outlet ( 15 ) and micro-organism laden filter media bed ( 3 ). The filter media bed additionally having moisture retaining properties. This process has been effective in removing high levels of VOCs from effluent gas streams and also in removing VOCs from an effluent gas stream where the VOC levels and/or volumes of effluent gas vary over time.
| 1
|
CLAIM OF PRIORITY
[0001] This application claims priority under 35 USC §119(e) to U.S. Patent Application Ser. No. 61/184,493, filed on Jun. 5, 2009, the entire contents of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention relates to glycoproteins and glycoprotein preparations having reduced core fucosylation and methods related thereto, e.g., methods of making and using the glycoproteins and glycoprotein preparations.
BACKGROUND OF INVENTION
[0003] A typical glycoprotein consists not only of an amino acid backbone but also includes one or more glycan moieties. The glycan moieties attached to the amino acid backbone of a glycoprotein can vary structurally in many ways including, sequence, branching, sugar content, and heterogeneity. Glycosylation adds not only to the structural complexity of the molecules, but also affects or conditions many of a glycoprotein's biological and clinical attributes.
SUMMARY OF INVENTION
[0004] As is disclosed herein, the relationship between GDP-fucose levels in a cell and the level of fucosylation of proteins produced by a cell is not linear. A relatively modest reduction in GDP-fucose levels in the cell can result in a much lower level of fucosylation on proteins produced by the cell. Thus, when levels of GDP-fucose taught herein are used, the reduction of fucose on proteins produced by the cells can be maximized with minimal reduction in GDP-fucose levels and minimal disruption of other aspects of metabolism. E.g., one or more manipulations described herein can be used to achieve a minimal reduction of GDP-fucose levels but still provide a relatively great reduction in fucosylation. Thus, methods described herein allow optimization of the levels of GDP-fucose reduction with reduction in the fucosylation of proteins made by the cell.
[0005] The inventors have shown that the relationship between the level of GDP-fucose in a cell and the level of fucosylation on proteins made by the cell is non-linear. In embodiments the curve which describes the relationship between level of GDP-fucose in a cell and level of fucosylation of proteins made by the cell includes three phases. In embodiments the three phase are as follows: a first phase, beginning at relatively high concentrations of GDP-fucose, and continuing through declining levels of GDP-fucose, wherein the level of fucosylation on proteins made by the cell is, compared to the other two phases, relatively constant; a second phase, beginning at levels of GDP-fucose that are lower than the levels seen in the first phase, wherein the level of fucosylation on proteins made by the cell, compared to the other two phases, drops rapidly in response to a decrease in GDP-fucose level; and a third phase, beginning at levels of GDP-fucose that are lower than levels in the second phase, and continuing through declining levels of GDP-fucose, wherein the level of fucosylation on proteins made by the cell is, compared to the other two phases, relatively constant.
[0006] In embodiments the curve which describes the relationship between level of GDP-fucose in a cell and level of fucosylation of proteins made by the cell has three phases: a phase having a high relatively constant (relatively independent of the amount of GDP-fucose) level of fucosylation (points to the left of point A in FIG. 1 ), a phase of rapid decrease in fucosylation (points between A and B in FIG. 1 , wherein the level of fucosylation is relatively sensitive to the amount of GDP-fucose), and phase having a lower, relatively constant, level of fucosylation (relatively independent of the amount of GDP-fucose) (points to the right of point B in FIG. 1 ). ( FIG. 1 and the contents therein are typical. Of course analogous plots may also be used. In embodiments the curve plotting the relationship between level of GDP-fucose in a cell and level of fucosylation of proteins made by the cell may look different from that in FIG. 1 , but it will still have the three phases described.)
[0007] The appreciation of this relationship can be used to guide selection of the level of GDP-fucose, e.g., to allow minimization of the level of fucosylation with minimal reduction in the level of GDP-fucose in the cell. The balance between low fucose and undesirable contributions of low GDP-fucose levels can be optimized. This can allow minimizing the negative effects of very low concentrations of GDP-fucose.
[0008] For example, in some embodiments a decrease in GDP-mannose concentrations can be an undesirable side effect of very low GDP-fucose levels. In some instances a loss of GDP-fucose can lead to higher levels of conversion of GDP-mannose to GDP-fucose, leading to an undesirable decrease in intracellular levels of GDP-mannose. A decrease in GDP-mannose can result in a decrease in high mannose structures on proteins produced by the cell. High mannose structures mediate effector function, and particularly ADCC activity, of an antibody. Thus, if ADCC activity is a desirable property, a decrease in high mannose structures can be undesirable. Alternatively, if less ADCC activity is desired decreased GDP-mannose can be desirable.
[0000] Optimal levels can be determined by monitoring the levels of GDP-mannose in the cell; as needed the levels of GDP-fucose can be elevated if the levels of GDP-mannose begin to drop. In particular embodiments, GDP-fucose is increased, e.g., added, if GDP-mannose levels are less than about 90%, 80%, 70%, 60%, 50%, 40%, 30%, 25%, 20%, 15% or 10% of a reference GDP-mannose level, e.g., the level seen in an otherwise similar cell that does not have a reduction in GDP-mannose.
[0009] In other embodiments an increase in GDP-mannose concentrations is can be an undesirable side effect of very low GDP-fucose levels. In some instances a loss of GDP-fucose may lead to decreased conversion of GDP-mannose to GDP-fucose, leading to an undesirable increase in the levels of GDP-mannose (in some embodiments this might be observed when a cell is largely or completely deficient in the enzymes involved in the conversion of GDP-mannose to GDP-fucose). Optimal levels can be determined by monitoring the levels of GDP-mannose in the cell; as needed the levels of GDP-fucose or the level of the converting enzyme responsible for the GDP-fucose can be elevated if the levels of GDP-mannose begin to rise. In particular embodiments, GDP-fucose or the level of the converting enzyme is increased if GDP-mannose levels are more than about 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference GDP-mannose level, e.g. the level seen in an otherwise similar cell that does not have reduction ion the GDP-mannose.
[0010] The invention features glycoproteins, e.g., antibodies, and preparations thereof having reduced fucosylation, e.g., reduced core fucosylation. Exemplary proteins include a peptide which comprises a human IgG constant region, e.g., one made in cultured cells, e.g., CHO cells, and having a glycan component attached in the CH2 region, e.g., at residue Asn 297. Preparations, e.g., pharmaceutically acceptable preparations, of these, and other proteins having reduced levels of fucosylation, e.g., core fucosylation, are provided. The presence of core fucosylation on an antibody significantly attenuates its ADCC activity. Reduction of core fucosylation increases ADCC activity.
[0011] The invention provides methods in which cells having a manipulation (defined below) can be used to provide proteins having reduced fucosylation. E.g, one or both of a genetically engineered alteration and culture conditions can be used to provide an optimized level of GDP-fucose and an optimized level of fucosylation on proteins made by a cell.
[0012] Accordingly, in one aspect, the invention features, a method of reducing fucosylation of a glycoprotein (or a preparation of glycoproteins). The method comprises:
[0013] providing a cell having or subject to a manipulation that results in a level of GDP-fucose in said cell that is below a first preselected level and, in embodiments, above a second preselected level and optionally memorializing one or both levels;
[0014] culturing said cell, e.g., to provide a batch of cultured cells;
[0015] optionally, measuring the level of GDP-fucose in said cell or batch of cultured cells;
[0016] optionally, separating the glycoprotein from at least one component with which said cell or batch of cultured cells was cultured; and
[0017] optionally, evaluating the glycoprotein (or a glycoprotein on the surface of the cell) for a parameter related to fucosylation;
[0018] thereby providing a glycoprotein with reduced fucosylation, e.g., wherein the level of fucosylation is reduced by a predetermined level in comparison with a reference.
[0019] In an embodiment the manipulation is or was selected on the basis of providing a level of GDP fucose below a first preselected level and optionally above a second preselected level.
[0020] In one embodiment, the method further comprises evaluating a glycan on the surface of said cell or batch of cultured cells in order to determine if the glycoprotein produced by said cell or batch of cultured cells has reduced fucosylation. In another embodiment, said evaluation comprises evaluating a glycan on the surface of said cell or batch of cultured cells, to determine a property of said glycan, comparing the property to a reference, to thereby determine if said glycan structure is present on the product.
[0021] In one embodiment, said first preselected level of GDP-fucose is selected from a level that is:
[0022] i.a) approximately equal to or less than 80%, 70% or 60% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0023] ii.a) approximately equal to, or less than, the point of maximum curvature above the inflection point (e.g., the inflection point in the second phase) on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0024] ii.1.a) approximately equal to, or less than, the lowest level that results in a normal (e.g., that seen in an un-manipuated cell) level of fucosylation;
[0025] iii.a) approximately equal to or less than the point of maximum curvature below the inflection point on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0026] iii.1.a) approximately equal to, or less than, the highest level that results in no further reduction in fucosylation;
[0027] iv.a) approximately equal to or less than point A on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control;
[0028] v.a) approximately equal to or less than that corresponding to an amount between points A and B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control; or
[0029] vi.a) approximately equal to or less than point B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0030] In one embodiment, said second preselected level of GDP-fucose is selected from a level:
[0031] i.b) approximately equal to, or greater than, 10%, 15%, 20%, 25%, 30%, 35% or 40% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0032] ii.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in decrease of GDP-mannose, e.g., a decrease in GDP-mannose that is equal to, greater than, 10%, 20%, 30%, 40% or 50% than a reference levee, e.g., the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0033] iii.b) an amount that provides an unacceptable level of fucose deprivation, e.g. an amount that results in a level of high mannose structures that are less than or equal to 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of a reference level
[0034] iv.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of GDP-mannose, e.g. an increase in GDP-mannose that is equal to or greater than 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level, e.g. the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0035] v.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of high mannose structures that are more than or equal to 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level;
[0036] vi.b) approximately equal to or greater than point C on the curve in FIG. 1 , or greater than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0037] In an embodiment the first level is i.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0038] In an embodiment the first level is ii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0039] In an embodiment the first level is ii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0040] In an embodiment the first level is iii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0041] In an embodiment the first level is iii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0042] In an embodiment the first level is iv.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0043] In an embodiment the first level is v.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0044] In an embodiment the first level is vi.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0045] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is i.b.
[0046] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is ii.b.
[0047] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iii.b.
[0048] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iv.b.
[0049] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is v.b.
[0050] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is vi.b.
[0051] In an embodiment the level of GDP-fucose is between point B and C on the curve in FIG. 1 or in an analogous range on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0052] In an embodiment the level of GDP-fucose is between point A and C on the curve in FIG. 1 or in an analogous range on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0053] In one embodiment, the level of GDP-fucose is selected to be outside the range between A and B on the curve in FIG. 1 (as relatively small changes in GDP-fucose will result in relatively large changes in the amount of fucosylation. In an embodiment the level is also less than B.) In another embodiment, the level of GDP-fucose is reduced by a predetermined level, e.g., in comparison with a reference. In another embodiment, the reference is the amount present in a cell or batch of cultured cells, e.g., a CHO cell or batch of cultured cells, lacking the manipulation but otherwise the same or essentially the same as the cell having the manipulation. In another embodiment, the level of GDP-fucose is reduced by, as much as, or more than, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80 or 90%, as compared to the reference.
[0054] In one embodiment, the method further comprises evaluating the glycoprotein for a parameter related to fucosylation, e.g., the amount of fucosylation in the glycan complement, the amount or fucosylation on a component of the glycan complement, or the amount of fucosylation on a glycan component, e.g., in a preparation of glycoproteins.
[0055] In one embodiment, the method further comprises evaluating the glycoprotein for a parameter related to fucosylation, e.g., the proportion of a preselected glycan component which bears a fucosyl moiety, e.g., at a selected position on the glycan component, e.g., in a preparation of glycoproteins.
[0056] In one embodiment, the level of fucosylation at one, two, three, or more preselected amino acid residues is evaluated. In another embodiment, the level of fucosylation is reduced by a predetermined level in comparison with a reference. In another embodiment, the reference is the amount present in a cell or batch of cultured cells, e.g., a CHO cell or batch of cultured cells, lacking the manipulation but otherwise the same or essentially the same as the cell or batch of cultured cells having the manipulation. In another embodiment, the level of fucosylation is reduced by, as much as, or more than, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80 or 90%, as compared to the reference.
[0057] In one embodiment, X F is greater than X G ,
[0058] and wherein,
[0059] X F is the % or proportion of reduction in the level of fucosylation (e.g., as compared to the level of fucosylation in a cell or batch of cultured cells lacking the manipulation); and
[0060] X G is the % or proportion of reduction in the level of GDP fucose (as compared to the level of GDP fucose in a cell or batch of cultured cells lacking the manipulation).
[0061] In one embodiment, said manipulation is not a genetic lesion or the presence of an siRNA that reduces the level of an enzyme that promotes formation of GDP-fucose, or the attachment of a fucosyl moiety. For example, the manipulation is not a lesion that decreases the expression of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, the cell or batch of cultured cells is wild-type for one or all of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, the cell or batch of cultured cells does not include an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, absent the manipulation, the level of fucosylation is substantially the same as the level in a wild-type cell. In another embodiment, the manipulated cell carries no mutation that substantially lowers GDP-fucose levels. In another embodiment, the manipulated cell has no siRNA that substantially lowers GDP-fucose levels.
[0062] In one embodiment, the cell has a mutation (e.g., a genetically engineered change) that decreases the level of GDP-fucose. Exemplary mutations include those which alter the activity of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0000] The mutation can be in the structural gene which encodes GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. Such mutations can decrease the activity of the encoded protein. The decrease can be partial or complete. Such mutations can act, e.g., by altering the catalytic activity of the protein or by altering its half-life. Other exemplary mutations can be in a sequence that control expression of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. These can be mutations that completely, or partially, reduce the expression of the gene, at the RNA or protein level. Such mutations include deletion or other mutations in endogenous of control sequence. Such mutations also include the introduction of heterologous control sequence, e.g., the introduction of heterologous control regions, e.g., a sequence that will give a desired level of expression. (A heterologous control sequence is a sequence other than a sequence naturally associated with and operably linked to the structural gene.) In embodiments the manipulation comprises a mutation in the structural region or in a control sequence operably linked to the gene.
[0063] In an embodiment a cell having a mutation that that decreases the level of GDP-fucose, e.g., a mutation that decreases the activity of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter is cultured in the presence of a substance, e.g., fucose, that results in a GDP-fucose level and/or a fucosylation level described herein. In an embodiment the cell includes a mutation that, in the absence of fucose in the culture medium, would result in a cell having an unacceptably low level of GDP-fucose. When, however, cultured under the appropriate conditions, e.g., media supplemented, e.g., with fucose, that cell can exhibit a desired level of GDP-fucose, e.g., a level of GDP-fucose described herein. Thus, fucose or another substance is present in the culture medium at a level that results in a level of GDP-fucose recited above.
[0064] In another embodiment, the manipulation is the presence of an siRNA that reduces the level of an enzyme that promotes formation of GDP-fucose, or the attachment of a fucosyl moiety, e.g., an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter, and fucose or another substance is present in the culture medium at a level that results in a level of GDP-fucose recited above.
[0065] In one embodiment, said culturing comprises culturing the cell in a medium that results in said level of GDP-fucose.
[0066] In one embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0067] In one embodiment, the cell is a Chinese Hamster Ovary (CHO) cell. In another embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0068] In one embodiment, the glycoprotein is selected from Table 1.
[0069] In one embodiment, the method further comprises culturing a plurality of the cells and separating as much as, or at least, 1, 10, 100, 1,000, or 10,000 grams of the glycoprotein from the cells. In another embodiment, the method further comprises combining the glycoprotein having reduced fucosylation with a pharmaceutically acceptable component and, e.g., formulating the glycoprotein having reduced fucosylation into a pharmaceutically acceptable formulation.
[0070] In one embodiment, the glycoprotein is analyzed by one or more of HPLC, CE, MALDI-MS and NMR.
[0071] In one embodiment, the method further comprises memorializing the result of the evaluation.
[0072] In one embodiment, the manipulation is, or is the product of, a selection for reduced levels of GDP-fucose. In another embodiment, the manipulation is, or is the product of, a selection for reduced fucosylation of a glycoprotein. In another embodiment, the manipulation comprises contact with, or inclusion in or on the cell or batch of cultured cells, of an exogenous inhibitor of an enzyme involved in GDP-fucose biosynthesis, e.g., a specific or non-specific inhibitor.
[0073] In one embodiment, the level of fucosylation at one, two, three, or more preselected amino acid residues is evaluated.
[0074] In one embodiment, one or more of said cell or said batch of cultured cells, said manipulation, and said glycoprotein, is selected on the basis that it or the combination will provide a glycoprotein having reduced fucosylation.
[0075] In one embodiment, one or more of said cell or said batch of cultured cells, said manipulation (or manipulations), and said glycoprotein, is selected on the basis that it or the combination will provide a level of GDP-fucose described herein, e.g., a level which gives a minimal level of fucosylation (e.g., with reference to a curve analogous to that in FIG. 1 , the level is to the right of point B) but which is above a preselected level In some embodiments the level is above a level that gives an unwanted decrease in the level of GDP-mannose, e.g., a decrease in GDP-mannose that is equal to, or more than, 10%, 20%, 30%, 40% or 50% as compared to a reference level, e.g., the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation.
[0076] In some embodiments the level is above a level that gives an unwanted increase in the level of GDP-mannose, e.g., an increase in GDP-mannose that is equal to, or more than, about 2×, 3×, 4×, 5×, ×, 7×, 8×, 9×, or 10× of a reference level, e.g., the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation.
[0077] In one embodiment, the method further comprises providing a value for a parameter associated with a compound other than GDP-fucose, wherein a parameter for the compound, e.g., the level of the compound, is correlated to the level of GDP-fucose.
[0000] In another embodiment, the method further comprises providing a comparison of the value with a reference value, wherein optionally, a preselected relationship of the value to the reference value, e.g., greater than, equal to, or less than, is indicative of whether the level of GDP fucose is above, at or below the second level. In another embodiment, the method further comprises, responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture without intervening to change the level of GDP-fucose. In one embodiment, the compound other than GDP-fucose is GDP-mannose. In one embodiment, the compound other than GDP-fucose is GDP-mannose and the parameter is the level of GDP-mannose.
[0078] In one embodiment, the method further comprises providing a value for the level of GDP-mannose, providing a comparison of the value with a reference value, and responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture at without intervening to change the level of GDP-fucose. In one embodiment, the method comprises continuing to culture said cells, and repeating the steps above.
[0079] In an embodiment, an inhibitor, e.g., an inhibitor of GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, or enzymes involved in the biosynthesis of GDP-mannose, is used, e.g., in the culture medium, to lower the levels of the GDP-fucose. In an embodiment the inhibitor can be guanosine-5′-O-(2-thiodiphosphate)-fucose, guanosine-5′-O-(2-thiodiphosphate)-mannose, pyridoxal-5′-phosphate, GDP-4-dehydro-6-L-deoxygalactose, GDP-L-fucose, guanosine diphosphate (GDP), guanosine monophosphate (GMP), GDP-D-glucose, or p-chloromercuriphenylsulfonate EDTA. The inhibitor can be used with a cell which is mutant or wildtype for one or more GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0080] In an embodiment the media contains a substance that can increase the level of GDP-fucose, e.g., butyrate or fucose. Such media can be used, e.g., with a cell having a mutation that eliminates or decreased the activity of one or more of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0081] While some methods described herein rely at least in part on mutations in a gene that conditions the level of GDP-fucose other methods described herein do not. Thus, cells that are not mutant at key genes involved in maintaining GDP-fucose levels can be used to provide proteins having reduced fucosylation. Levels of GDP-fucose can, e.g., be manipulated by culture conditions.
[0082] Thus, in another aspect, the invention features, a method of reducing fucosylation of a glycoprotein or a preparation of glycoproteins, the method comprising:
[0083] providing a cell that expresses said glycoprotein and that is wild-type for one or more (or all) of GMD, FX, fucokinase, GFPP, GDP-Fucose synthetase, a fucosyltransferase or a GDP-Fucose transporter;
[0084] culturing said cell under conditions that result in a level of GDP-fucose in said cell that is below a first preselected level and, in embodiments, above a second preselected level, and results in a preselected level of fucosylation, which is less than in a reference cell cultured under reference conditions, e.g., to provide a batch of cultured cells;
[0085] optionally, measuring the level of GDP-fucose in said cell or batch of cultured cells; and
[0086] optionally, separating the glycoprotein from at least one component with which said cell or batch of cultured cells was cultured,
[0087] optionally, evaluating the glycoprotein (or a glycoprotein on the surface of the cell or batch of cultured cells) for a parameter related to fucosylation;
[0088] thereby providing a glycoprotein with reduced fucosylation, e.g., wherein the level of fucosylation is reduced by a predetermined level in comparison with a reference.
[0089] In one embodiment, the method further comprises evaluating a glycan on the surface of said cell or batch of cultured cells in order to determine if the glycoprotein produced by said cell or batch of cultured cells has reduced fucosylation. In another embodiment, said evaluation comprises evaluating a glycan on the surface of said cell or batch of cultured cells, to determine a property of said glycan, comparing the property to a reference, to thereby determine if said glycan structure is present on the product.
[0090] In one embodiment, said first preselected level of GDP-fucose is selected from a level that is:
[0091] i.a) approximately equal to or less than 80%, 70% or 60% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0092] ii.a) approximately equal to, or less than, the point of maximum curvature above the inflection point (e.g., the inflection point in the second phase) on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0093] ii.1.a) approximately equal to, or less than, the lowest level that results in a normal (e.g., that seen in an un-manipuated cell) level of fucosylation;
[0094] iii.a) approximately equal to or less than the point of maximum curvature below the inflection point on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0095] iii.1.a) approximately equal to, or less than, the highest level that results in no further reduction in fucosylation;
[0096] iv.a) approximately equal to or less than point A on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control;
[0097] v.a) approximately equal to or less than that corresponding to an amount between points A and B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control; or
[0098] vi.a) approximately equal to or less than point B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0099] In one embodiment, said second preselected level of GDP-fucose is selected from a level:
[0100] i.b) approximately equal to, or greater than, 10%, 15%, 20%, 25%, 30%, 35% or 40% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0101] ii.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in decrease of GDP-mannose, e.g., a decrease in GDP-mannose that is equal to, greater than, 10%, 20%, 30%, 40% or 50% than a reference levee, e.g., the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0102] iii.b) an amount that provides an unacceptable level of fucose deprivation, e.g. an amount that results in a level of high mannose structures that are less than or equal to 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of a reference level;
[0103] iv.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of GDP-mannose, e.g. an increase in GDP-mannose that is equal to or greater than 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level, e.g. the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0104] v.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of high mannose structures that are more than or equal to 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level; or
[0105] vi.b) approximately equal to or greater than point C on the curve in FIG. 1 , or greater than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0106] In an embodiment the first level is i.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0107] In an embodiment the first level is ii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0108] In an embodiment the first level is ii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0109] In an embodiment the first level is iii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0110] In an embodiment the first level is iii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0111] In an embodiment the first level is iv.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0112] In an embodiment the first level is v.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0113] In an embodiment the first level is vi.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0114] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is i.b.
[0115] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is ii.b.
[0116] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iii.b.
[0117] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iv.b.
[0118] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is v.b.
[0119] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is vi.b.
[0120] In an embodiment the level of GDP-fucose is between point B and C on the curve in FIG. 1 or in an analogous range on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0121] In an embodiment the level of GDP-fucose is between point A and C on the curve in FIG. 1 or in an analogous range on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0122] In one embodiment, the level of GDP-fucose is selected to be outside the range between A and B on the curve in FIG. 1 (as relatively small changes in GDP-fucose will result in relatively large changes in the amount of fucosylation. In an embodiment the level is also less than B.). In another embodiment, the level of GDP-fucose is reduced by a predetermined level, e.g., in comparison with a reference. In another embodiment, the reference is the amount present in a cell or batch of cultured cells, e.g., a CHO cell or batch of cultured cells, cultured under reference conditions but otherwise the same or essentially the same as the cell cultured under conditions that result in said level of GDP-fucose. In another embodiment, the level of GDP-fucose is reduced by, as much as, or more than, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80 or 90%, as compared to the reference.
[0123] In one embodiment, the method further comprises evaluating the glycoprotein for a parameter related to fucosylation, e.g., the amount of fucosylation in the glycan complement, the amount or fucosylation on a component of the glycan complement, or the amount of fucosylation on a glycan component, e.g., in a preparation of glycoproteins.
[0124] In one embodiment, the method further comprises evaluating the glycoprotein for a parameter related to fucosylation, e.g., the proportion of a preselected glycan component which bears a fucosyl moiety, e.g., at a selected position on the glycan component, e.g., in a preparation of glycoproteins.
[0125] In one embodiment, the level of fucosylation at one, two, three, or more preselected amino acid residues is evaluated. In another embodiment, the level of fucosylation is reduced by a predetermined level in comparison with a reference. In another embodiment, the reference is the amount present in a cell or batch of cultured cells, e.g., a CHO cell or batch of cultured cells, cultured under reference conditions but otherwise the same or essentially the same as the cell cultured under conditions that result in said level of GDP-fucose. In another embodiment, the level of fucosylation is reduced by, as much as, or more than, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80 or 90%, as compared to the reference.
[0126] In one embodiment, wherein X F is greater than X G ,
[0127] and wherein,
[0128] X F is the % or proportion of reduction in the level of fucosylation (e.g., as compared to the level of fucosylation in a cell or batch of cultured cells cultured under reference conditions); and
[0129] X G is the % or proportion of reduction in the level of GDP fucose (as compared to the level of GDP fucose in a cell or batch of cultured cells cultured under reference conditions).
[0130] In one embodiment, the cell or batch of cultured cells does not include an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0131] In one embodiment, the cell or batch of cultured cells does includes an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0132] In an embodiments, an inhibitor, e.g., an inhibitor of GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, or enzymes involved in the biosynthesis of GDP-mannose, is used, e.g., in the culture medium, to lower the levels of the GDP-fucose.
[0133] In an embodiment the inhibitor can be guanosine-5′-O-(2-thiodiphosphate)-fucose, guanosine-5′-O-(2-thiodiphosphate)-mannose, pyridoxal-5′-phosphate, GDP-4-dehydro-6-L-deoxygalactose, GDP-L-fucose, guanosine diphosphate (GDP), guanosine monophosphate (GMP), GDP-D-glucose, or p-chloromercuriphenylsulfonate EDTA.
[0134] In an embodiment the media contains a substance that can increase the level of GDP-fucose, e.g., butyrate or fucose.
[0135] In one embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0136] In one embodiment, the cell is a Chinese Hamster Ovary (CHO) cell. In another embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0137] In one embodiment, the glycoprotein is selected from Table 1.
[0138] In one embodiment, the method further comprises culturing a plurality of the cells and separating as much as, or at least, 1, 10, 100, 1,000, or 10,000 grams of the glycoprotein from the cells. In another embodiment, the method further comprises combining the glycoprotein having reduced fucosylation with a pharmaceutically acceptable component and, e.g., formulating the glycoprotein having reduced fucosylation into a pharmaceutically acceptable formulation.
[0139] In one embodiment, the glycoprotein is analyzed by one or more of HPLC, CE, MALDI-MS and NMR.
[0140] In one embodiment, the method further comprises memorializing the result of the evaluation.
[0141] In one embodiment, the level of fucosylation at one, two, three, or more preselected amino acid residues is evaluated.
[0142] In one embodiment, the method further comprises providing a value for a parameter associated with a compound other than GDP-fucose, wherein a parameter for the compound, e.g., the level of the compound, is correlated to the level of GDP-fucose.
[0000] In another embodiment, the method further comprises providing a comparison of the value with a reference value, wherein optionally, a preselected relationship of the value to the reference value, e.g., greater than, equal to, or less than, is indicative of whether the level of GDP fucose is above, at or below the second level. In another embodiment, the method further comprises, responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture without intervening to change the level of GDP-fucose. In one embodiment, the compound other than GDP-fucose is GDP-mannose. In one embodiment, the compound other than GDP-fucose is GDP-mannose and the parameter is the level of GDP-mannose.
[0143] In one embodiment, the method further comprises providing a value for the level of GDP-mannose, providing a comparison of the value with a reference value, and responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture at without intervening to change the level of GDP-fucose. In one embodiment, the method comprises continuing to culture said cells, and repeating the steps above.
[0144] Methods described herein allow the production of proteins having reduced fucosylation from a cell line that is not genetically altered to reduce fucosylation. Such methods allow the use of a cell line that produces a reference glycoprotein, e.g., an approved product, by culturing that cell line to provide the reference glycoprotein with optimized levels of fucosylation. E.g., a cell line that has been optimized or otherwise selected for use in producing a protein, e.g., an FDA approved therapeutic protein, can be used to produce a protein having reduced fucosylation according to the invention, without genetically engineering the production line cell.
[0145] Accordingly, in another aspect, the invention features, a method of providing a glycoprotein (or preparation thereof) having fucosylation that is reduced compared to a reference glycoprotein, e.g., an FDA approved glycoprotein. The method comprises:
[0146] providing a cell that expresses said reference glycoprotein, which optionally, is wild-type for one or more (or all) of GMD, FX, fucokinase, GFPP, GDP-Fucose synthetase, a fucosyltransferase or a GDP-Fucose transporter;
[0147] culturing said cell (without inducing a mutation in, or adding an siRNA that targets one or more of GMD, FX, fucokinase, GFPP, GDP-Fuc synthetase, a fucosyltransferase or a GDP-Fucose transporter) under culture conditions that result in a level of GDP-fucose in said cell that is below a first preselected level and, in embodiments, above a second preselected level, and results in a preselected level of fucosylation, which is less than in a reference cell cultured under reference conditions, e.g., to provide a batch of cultured cells;
[0148] optionally, measuring the level of GDP-fucose in said cell or batch of cultured cells; and
[0149] optionally, separating the glycoprotein from at least one component with which said cell or batch of cultured cells was cultured;
[0150] optionally, evaluating the glycoprotein (or a glycoprotein on the surface of the cell or batch of cultured cells) for a parameter related to fucosylation;
[0151] thereby providing a glycoprotein having fucosylation that is reduced compared to a reference glycoprotein, e.g., an FDA approved glycoprotein.
[0152] In one embodiment, the method further comprises evaluating a glycan on the surface of said cell or batch of cultured cells in order to determine if the glycoprotein produced by said cell or batch of cultured cells has reduced fucosylation. In another embodiment, said evaluation comprises evaluating a glycan on the surface of said cell or batch of cultured cells, to determine a property of said glycan, comparing the property to a reference, to thereby determine if said glycan structure is present on the product.
[0153] In one embodiment, the method further comprises evaluating a glycan on the surface of said cell or batch of cultured cells in order to determine if the glycoprotein produced by said cell or batch of cultured cells has reduced fucosylation. In another embodiment, said evaluation comprises evaluating a glycan on the surface of said cell or batch of cultured cells, to determine a property of said glycan, comparing the property to a reference, to thereby determine if said glycan structure is present on the product.
[0154] In one embodiment, said first preselected level of GDP-fucose is selected from a level that is:
[0155] i.a) approximately equal to or less than 80%, 70% or 60% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0156] ii.a) approximately equal to, or less than, the point of maximum curvature above the inflection point (e.g., the inflection point in the second phase) on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0157] ii.1.a) approximately equal to, or less than, the lowest level that results in a normal (e.g., that seen in an un-manipuated cell) level of fucosylation;
[0158] iii.a) approximately equal to or less than the point of maximum curvature below the inflection point on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0159] iii.1.a) approximately equal to, or less than, the highest level that results in no further reduction in fucosylation;
[0160] iv.a) approximately equal to or less than point A on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control;
[0161] v.a) approximately equal to or less than that corresponding to an amount between points A and B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control; or
[0162] vi.a) approximately equal to or less than point B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0163] In one embodiment, said second preselected level of GDP-fucose is selected from a level:
[0164] i.b) approximately equal to, or greater than, 10%, 15%, 20%, 25%, 30%, 35% or 40% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0165] ii.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in decrease of GDP-mannose, e.g., a decrease in GDP-mannose that is equal to, greater than, 10%, 20%, 30%, 40% or 50% than a reference levee, e.g., the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0166] iii.b) an amount that provides an unacceptable level of fucose deprivation, e.g. an amount that results in a level of high mannose structures that are less than or equal to 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of a reference level;
[0167] iv.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of GDP-mannose, e.g. an increase in GDP-mannose that is equal to or greater than 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level, e.g. the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0168] v.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of high mannose structures that are more than or equal to 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level; or
[0169] vi.b) approximately equal to or greater than point C on the curve in FIG. 1 , or greater than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0170] In an embodiment the first level is i.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0171] In an embodiment the first level is ii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0172] In an embodiment the first level is ii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0173] In an embodiment the first level is iii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0174] In an embodiment the first level is iii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0175] In an embodiment the first level is iv.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0176] In an embodiment the first level is v.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0177] In an embodiment the first level is vi.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0178] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is i.b.
[0179] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is ii.b.
[0180] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iii.b.
[0181] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iv.b.
[0182] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is v.b.
[0183] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is vi.b.
[0184] In one embodiment, the level of GDP-fucose is selected to be outside the range between A and B on the curve in FIG. 1 (as relatively small changes in GDP-fucose will result in relatively large changes in the amount of fucosylation. In an embodiment the level is also less than B.). In another embodiment, the level of GDP-fucose is reduced by a predetermined level, e.g., in comparison with a reference. In another embodiment, the reference is the amount present in a cell or batch of cultured cells, e.g., a CHO cell or batch of cultured cells, cultured under reference conditions but otherwise the same or essentially the same as the cell cultured under conditions that result in said level of GDP-fucose. In another embodiment, the level of GDP-fucose is reduced by, as much as, or more than, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80 or 90%, as compared to the reference.
[0185] In one embodiment, the method further comprises evaluating the glycoprotein for a parameter related to fucosylation, e.g., the amount of fucosylation in the glycan complement, the amount or fucosylation on a component of the glycan complement, or the amount of fucosylation on a glycan component, e.g., in a preparation of glycoproteins.
[0186] In one embodiment, the method further comprises evaluating the glycoprotein for a parameter related to fucosylation, e.g., the proportion of a preselected glycan component which bears a fucosyl moiety, e.g., at a selected position on the glycan component, e.g., in a preparation of glycoproteins.
[0000] In one embodiment, the level of fucosylation at one, two, three, or more preselected amino acid residues is evaluated. In another embodiment, the level of fucosylation is reduced by a predetermined level in comparison with a reference. In another embodiment, the reference is the amount present in a cell or batch of cultured cells, e e.g., a CHO cell or batch of cultured cells, cultured under reference conditions but otherwise the same or essentially the same as the cell cultured under conditions that result in said level of GDP-fucose. In another embodiment, the level of fucosylation is reduced by, as much as, or more than, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80 or 90%, as compared to the reference.
[0187] In one embodiment, wherein X F is greater than X G ,
[0188] and wherein,
[0189] X F is the % or proportion of reduction in the level of fucosylation (e.g., as compared to the level of fucosylation in a cell or batch of cultured cells cultured under reference conditions); and
[0190] X G is the % or proportion of reduction in the level of GDP fucose (as compared to the level of GDP fucose in a cell or batch of cultured cells cultured under reference conditions).
[0191] In an embodiments, an inhibitor, e.g., an inhibitor of GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, or enzymes involved in the biosynthesis of GDP-mannose, is used, e.g., in the culture medium, to lower the levels of the GDP-fucose. In an embodiment the inhibitor can be guanosine-5′-O-(2-thiodiphosphate)-fucose, guanosine-5′-O-(2-thiodiphosphate)-mannose, pyridoxal-5′-phosphate, GDP-4-dehydro-6-L-deoxygalactose, GDP-L-fucose, guanosine diphosphate (GDP), guanosine monophosphate (GMP), GDP-D-glucose, or p-chloromercuriphenylsulfonate EDTA.
[0192] In an embodiment the media contains a substance that can increase the level of GDP-fucose, e.g., butyrate or fucose.
[0193] In one embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0194] In one embodiment, the cell is a Chinese Hamster Ovary (CHO) cell. In another embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0195] In one embodiment, the glycoprotein is selected from Table 1.
[0196] In one embodiment, the method further comprises culturing a plurality of the cells and separating as much as, or at least, 1, 10, 100, 1,000, or 10,000 grams of the glycoprotein from the cells. In another embodiment, the method further comprises combining the glycoprotein having reduced fucosylation with a pharmaceutically acceptable component and, e.g., formulating the glycoprotein having reduced fucosylation into a pharmaceutically acceptable formulation.
[0197] In one embodiment, the glycoprotein is analyzed by one or more of HPLC, CE, MALDI-MS and NMR.
[0198] In one embodiment, the method further comprises memorializing the result of the evaluation.
[0199] In one embodiment, the level of fucosylation at one, two, three, or more preselected amino acid residues is evaluated.
[0200] In one embodiment, the method further comprises providing a value for a parameter associated with a compound other than GDP-fucose, wherein a parameter for the compound, e.g., the level of the compound, is correlated to the level of GDP-fucose.
[0000] In another embodiment, the method further comprises providing a comparison of the value with a reference value, wherein optionally, a preselected relationship of the value to the reference value, e.g., greater than, equal to, or less than, is indicative of whether the level of GDP fucose is above, at or below the second level. In another embodiment, the method further comprises, responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture without intervening to change the level of GDP-fucose. In one embodiment, the compound other than GDP-fucose is GDP-mannose. In one embodiment, the compound other than GDP-fucose is GDP-mannose and the parameter is the level of GDP-mannose.
[0201] In one embodiment, the method further comprises providing a value for the level of GDP-mannose, providing a comparison of the value with a reference value, and responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture at without intervening to change the level of GDP-fucose. In one embodiment, the method comprises continuing to culture said cells, and repeating the steps above.
[0202] In another aspect, the invention features, a reaction mixture containing one or more of a cell or batch of cultured cells having a manipulation, culture medium, and a glycoprotein having reduced fucosylation produced by the cell.
[0203] In another aspect, the invention features, a device for the culture of cells comprising one or more of a cell having a manipulation, culture medium, and a glycoprotein having reduced fucosylation produced by the cell.
[0204] When reduced fucosylation is desired, methods described herein allow selecting a cell which makes a desired protein, selecting a manipulation(s) that gives reduced fucosylation according to the invention, providing the manipulations to a cell, and optionally, using the cell for making the protein. Although useful in other applications, this method can be used to use and/or further modify an existing cell line that has been used to make a protein not having reduced fucosylation.
[0205] Accordingly, in another aspect, the invention features, a method of making, or providing, a glycoprotein, or preparation thereof, having a glycan structure having reduced fucosylation, comprising:
[0206] optionally, selecting a glycan structure having reduced fucosylation, e.g., from a list comprising a plurality of glycan structures having reduced fucosylation (in embodiments the list is provided), and optionally memorializing said selected glycan structure;
[0207] selecting a cell, preferably on the basis that it produces a protein having the primary amino acid sequence of said glycoprotein but which protein lacks said glycan structure having reduced fucosylation;
[0208] optionally, selecting a manipulation, e.g., selecting the manipulation on the basis that the manipulation decreases fucosylation and which manipulation thereby promotes the formation of said glycan structure having reduced fucosylation (in embodiments the manipulation is from a list comprising a plurality of manipulations, and in embodiments the list is provided);
[0209] providing said manipulation to said cell to provide a cell having or subject to a manipulation that decreases the level of fucosylation and which manipulation thereby promotes the formation of said glycan structure having reduced fucosylation;
[0210] culturing said selected cell, e.g., to provide a batch of cultured cells;
[0211] optionally, separating the glycoprotein having a glycan structure from at least one component with which the cell or batch of cultured cells was cultured;
[0212] optionally, analyzing said glycoprotein to confirm the presence of the glycan structure having reduced fucosylation;
[0213] thereby making, or providing, a glycoprotein having a glycan structure having reduced fucosylation, e.g., by inhibiting or promoting the addition of a fucose moiety to a protein or glycoprotein.
[0214] In one embodiment, the method further comprises evaluating a glycan on the surface of said cell or batch of cultured cells in order to determine if the glycoprotein produced by said cell or batch of cultured cells has reduced fucosylation. In another embodiment, said evaluation comprises evaluating a glycan on the surface of said cell or batch of cultured cells, to determine a property of said glycan, comparing the property to a reference, to thereby determine if said glycan structure is present on the product.
[0215] In one embodiment, the manipulation results in a level of GDP-fucose in said cell that is below a first preselected level and, in embodiments, above a second preselected level. In embodiment said first preselected level of GDP-fucose is selected from a level that is:
[0216] i.a) approximately equal to or less than 80%, 70% or 60% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0217] ii.a) approximately equal to, or less than, the point of maximum curvature above the inflection point (e.g., the inflection point in the second phase) on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0218] ii.1.a) approximately equal to, or less than, the lowest level that results in a normal (e.g., that seen in an un-manipuated cell) level of fucosylation;
[0219] iii.a) approximately equal to or less than the point of maximum curvature below the inflection point on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0220] iii.1.a) approximately equal to, or less than, the highest level that results in no further reduction in fucosylation;
[0221] iv.a) approximately equal to or less than point A on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control;
[0222] v.a) approximately equal to or less than that corresponding to an amount between points A and B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control; or
[0223] vi.a) approximately equal to or less than point B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0224] In one embodiment, said second preselected level of GDP-fucose is selected from a level:
[0225] i.b) approximately equal to, or greater than, 10%, 15%, 20%, 25%, 30%, 35% or 40% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0226] ii.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in decrease of GDP-mannose, e.g., a decrease in GDP-mannose that is equal to, greater than, 10%, 20%, 30%, 40% or 50% than a reference levee, e.g., the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0227] iii.b) an amount that provides an unacceptable level of fucose deprivation, e.g. an amount that results in a level of high mannose structures that are less than or equal to 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of a reference level;
[0228] iv.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of GDP-mannose, e.g. an increase in GDP-mannose that is equal to or greater than 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level, e.g. the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0229] v.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of high mannose structures that are more than or equal to 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level; or
[0230] vi.b) approximately equal to or greater than point C on the curve in FIG. 1 , or greater than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0231] In an embodiment the first level is i.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0232] In an embodiment the first level is ii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0233] In an embodiment the first level is ii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0234] In an embodiment the first level is iii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0235] In an embodiment the first level is iii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0236] In an embodiment the first level is iv.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0237] In an embodiment the first level is v.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0238] In an embodiment the first level is vi.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0239] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is i.b.
[0240] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is ii.b.
[0241] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iii.b.
[0242] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iv.b.
[0243] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is v.b.
[0244] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is vi.b.
[0245] In an embodiment the level of GDP-fucose is between point B and C on the curve in FIG. 1 or in an analogous range on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0246] In an embodiment the level of GDP-fucose is between point A and C on the curve in FIG. 1 or in an analogous range on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0247] In one embodiment, the level of GDP-fucose is selected to be outside the range between A and B on the curve in FIG. 1 (as relatively small changes in GDP-fucose will result in relatively large changes in the amount of fucosylation. In an embodiment the level is also less than B.) In another embodiment, the level of GDP-fucose is reduced by a predetermined level, e.g., in comparison with a reference. In another embodiment, the reference is the amount present in a cell or batch of cultured cells, e.g., a CHO cell or batch of cultured cells, lacking the manipulation but otherwise the same or essentially the same as the cell having the manipulation. In another embodiment, the level of GDP-fucose is reduced by, as much as, or more than, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80 or 90%, as compared to the reference.
[0248] In one embodiment, the method further comprises evaluating the glycoprotein for a parameter related to fucosylation, e.g., the amount of fucosylation in the glycan complement, the amount or fucosylation on a component of the glycan complement, or the amount of fucosylation on a glycan component, e.g., in a preparation of glycoproteins.
[0249] In one embodiment, the method further comprises evaluating the glycoprotein for a parameter related to fucosylation, e.g., the proportion of a preselected glycan component which bears a fucosyl moiety, e.g., at a selected position on the glycan component, e.g., in a preparation of glycoproteins.
[0250] In one embodiment, the level of fucosylation at one, two, three, or more preselected amino acid residues is evaluated. In another embodiment, the level of fucosylation is reduced by a predetermined level in comparison with a reference. In another embodiment, the reference is the amount present in a cell or batch of cultured cells, e.g., a CHO cell or batch of cultured cells, lacking the manipulation but otherwise the same or essentially the same as the cell or batch of cultured cells having the manipulation. In another embodiment, the level of fucosylation is reduced by, as much as, or more than, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80 or 90%, as compared to the reference.
[0251] In one embodiment, X F is greater than X G ,
[0252] and wherein,
[0253] X F is the % or proportion of reduction in the level of fucosylation (e.g., as compared to the level of fucosylation in a cell or batch of cultured cells lacking the manipulation); and
[0254] X G is the % or proportion of reduction in the level of GDP fucose (as compared to the level of GDP fucose in a cell or batch of cultured cells lacking the manipulation).
[0255] In one embodiment, said manipulation is not a genetic lesion or the presence of an siRNA that reduces the level of an enzyme that promotes formation of GDP-fucose, or the attachment of a fucosyl moiety. For example, the manipulation is not a lesion that decreases the expression of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, the cell or batch of cultured cells is wild-type for one or all of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, the cell or batch of cultured cells does not include an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, absent the manipulation, the level of fucosylation is substantially the same as the level in a wild-type cell. In another embodiment, the manipulated cell carries no mutation that substantially lowers GDP-fucose levels. In another embodiment, the manipulated cell has no siRNA that substantially lowers GDP-fucose levels.
[0256] In one embodiment, the cell has a mutation (e.g., a genetically engineered change) that decreases the level of GDP-fucose. Exemplary mutations include those which alter the activity of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. The mutation can be in the structural gene which encodes GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. Such mutations can decrease the activity of the encoded protein. The decrease can be partial or complete. Such mutations can act, e.g., by altering the catalytic activity of the protein or by altering its half-life. Other exemplary mutations can be in a sequence that control expression of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. These can be mutations that completely, or partially, reduce the expression of the gene, at the RNA or protein level. Such mutations include deletion or other mutations in endogenous of control sequence. Such mutations also include the introduction of heterologous control sequence, e.g., the introduction of heterologous control regions, e.g., a sequence that will give a desired level of expression. (A heterologous control sequence is a sequence other than a sequence naturally associated with and operably linked to the structural gene.) In embodiments the manipulation comprises a mutation in the structural region or in a control sequence operably linked to the gene.
[0257] In an embodiment a cell having a mutation that that decreases the level of GDP-fucose, e.g., a mutation that decreases the activity of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter is cultured in the presence of a substance, e.g., fucose, that results in a GDP-fucose level and/or a fucosylation level described herein. In an embodiment the cell includes a mutation that, in the absence of fucose in the culture medium, would result in a cell having an unacceptably low level of GDP-fucose. When, however, cultured under the appropriate conditions, e.g., media supplemented, e.g., with fucose, that cell can exhibit a desired level of GDP-fucose, e.g., a level of GDP-fucose described herein. Thus, fucose or another substance is present in the culture medium at a level that results in a level of GDP-fucose recited above.
[0258] In another embodiment, the manipulation is the presence of an siRNA that reduces the level of an enzyme that promotes formation of GDP-fucose, or the attachment of a fucosyl moiety, e.g., an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter, and fucose or another substance is present in the culture medium at a level that results in formation of said glycoprotein having a glycan structure having reduced fucosylation.
[0259] In one embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0260] In one embodiment, the cell is a Chinese Hamster Ovary (CHO) cell. In another embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0261] In one embodiment, the glycoprotein is selected from Table 1.
[0262] In one embodiment, the method further comprises culturing a plurality of the cells and separating as much as, or at least, 1, 10, 100, 1,000, or 10,000 grams of the glycoprotein from the cells. In another embodiment, the method further comprises combining the glycoprotein having reduced fucosylation with a pharmaceutically acceptable component and, e.g., formulating the glycoprotein having reduced fucosylation into a pharmaceutically acceptable formulation.
[0263] In one embodiment, the glycoprotein is analyzed by one or more of HPLC, CE, MALDI-MS and NMR.
[0264] In one embodiment, the method further comprises memorializing the result of the evaluation.
[0265] In one embodiment, the manipulation is, or is the product of, a selection for reduced levels of GDP-fucose. In another embodiment, the manipulation is, or is the product of, a selection for reduced fucosylation of a glycoprotein. In another embodiment, the manipulation comprises contact with, or inclusion in or on the cell or batch of cultured cells, of an exogenous inhibitor of an enzyme involved in GDP-fucose biosynthesis, e.g., a specific or non-specific inhibitor.
[0266] In one embodiment, the level of fucosylation at one, two, three, or more preselected amino acid residues is evaluated.
[0267] In one embodiment, one or more of said cell or said batch of cultured cells, said manipulation, and said glycoprotein, is selected on the basis that it or the combination will provide a glycoprotein having reduced fucosylation.
[0268] In one embodiment, one or more of said cell or said batch of cultured cells, said manipulation (or manipulations), and said glycoprotein, is selected on the basis that it or the combination will provide a level of GDP-fucose described herein, e.g., a level which gives a minimal level of fucosylation (e.g., with reference to a curve analogous to that in FIG. 1 , the level is to the right of point B) but which is above a preselected level. E.g., in a an embodiment the level is above a level that gives an unwanted decrease in the level of GDP-mannose, e.g., a decrease in GDP-mannose that is equal to, or more than, 10%, 20%, 30%, 40% or 50% as compared to a reference level, e.g., the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation.
[0269] In some embodiments the level is above a level that gives an unwanted increase in the level of GDP-mannose, e.g., an increase in GDP-mannose that is equal to, or more than, about 2×, 3×, 4×, 5×, ×, 7×, 8×, 9×, or 10× of a reference level, e.g., the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation.
[0270] In one embodiment, the method further comprises providing a value for a parameter associated with a compound other than GDP-fucose, wherein a parameter for the compound, e.g., the level of the compound, is correlated to the level of GDP-fucose.
[0000] In another embodiment, the method further comprises providing a comparison of the value with a reference value, wherein optionally, a preselected relationship of the value to the reference value, e.g., greater than, equal to, or less than, is indicative of whether the level of GDP fucose is above, at or below the second level. In another embodiment, the method further comprises, responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture without intervening to change the level of GDP-fucose. In one embodiment, the compound other than GDP-fucose is GDP-mannose. In one embodiment, the compound other than GDP-fucose is GDP-mannose and the parameter is the level of GDP-mannose.
[0271] In one embodiment, the method further comprises providing a value for the level of GDP-mannose, providing a comparison of the value with a reference value, and responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture at without intervening to change the level of GDP-fucose. In one embodiment, the method comprises continuing to culture said cells, and repeating the steps above.
[0272] In an embodiments, an inhibitor, e.g., an inhibitor of GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, or enzymes involved in the biosynthesis of GDP-mannose, is used, e.g., in the culture medium, to lower the levels of the GDP-fucose. In an embodiment the inhibitor can be guanosine-5′-O-(2-thiodiphosphate)-fucose, guanosine-5′-O-(2-thiodiphosphate)-mannose, pyridoxal-5′-phosphate, GDP-4-dehydro-6-L-deoxygalactose, GDP-L-fucose, guanosine diphosphate (GDP), guanosine monophosphate (GMP), GDP-D-glucose, or p-chloromercuriphenylsulfonate EDTA. The inhibitor can be used with a cell which is mutant or wildtype for one or more GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0273] In an embodiment the media contains a substance that can increase the level of GDP-fucose, e.g., butyrate or fucose. Such media can be used, e.g., with a cell having a mutation that eliminates or decreased the activity of one or more of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0274] When reduced fucosylation is desired, methods described herein allow selecting a cell which makes the desired protein. Although useful in other applications, this method can be used to use and/or further modify an existing cell line that has been used to make a protein not having reduced fucosylation.
[0275] In one aspect, the invention features a method of providing a cell that makes a glycoprotein having a glycan structure having reduced fucosylation, comprising:
[0276] optionally, selecting a glycan structure having reduced fucosylation, e.g., from a list comprising a plurality of glycan structures having reduced fucosylation (in embodiments the list is provided), and optionally memorializing said selected glycan structure;
[0277] selecting a cell, preferably on the basis that it produces a protein having the primary amino acid sequence of said glycoprotein but which protein lacks said glycan structure having reduced fucosylation;
[0278] optionally, selecting a manipulation, e.g., selecting the manipulation on the basis that the manipulation decreases the level of fucosylation, and which manipulation thereby promotes the formation of said glycan structure having reduced fucosylation (in embodiments the manipulation is from a list comprising a plurality of manipulations, and in embodiments the list is provided);
[0279] providing said manipulation to said cell to provide a cell having or subject to a manipulation that decreases fucosylation, and which manipulation thereby promotes the formation of said glycan structure having reduced fucosylation;
[0280] optionally producing glycoprotein from said cell and determining if said glycoprotein has said glycan structure having reduced fucosylation, thereby providing a cell that makes a glycoprotein having a glycan structure.
[0281] In one embodiment, the method further comprises evaluating a glycan on the surface of said cell or batch of cultured cells in order to determine if the glycoprotein produced by said cell or batch of cultured cells has reduced fucosylation. In another embodiment, said evaluation comprises evaluating a glycan on the surface of said cell or batch of cultured cells, to determine a property of said glycan, comparing the property to a reference, to thereby determine if said glycan structure is present on the product.
[0282] In one embodiment, the manipulation results in a level of GDP-fucose in said cell that is below a first preselected level and, in embodiments, above a second preselected level. In one embodiment, said first preselected level of GDP-fucose is selected from a level that is:
[0283] i.a) approximately equal to or less than 80%, 70% or 60% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0284] ii.a) approximately equal to, or less than, the point of maximum curvature above the inflection point (e.g., the inflection point in the second phase) on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0285] ii.1.a) approximately equal to, or less than, the lowest level that results in a normal (e.g., that seen in an un-manipuated cell) level of fucosylation;
[0286] iii.a) approximately equal to or less than the point of maximum curvature below the inflection point on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0287] iii.1.a) approximately equal to, or less than, the highest level that results in no further reduction in fucosylation;
[0288] iv.a) approximately equal to or less than point A on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control;
[0289] v.a) approximately equal to or less than that corresponding to an amount between points A and B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control; or
[0290] vi.a) approximately equal to or less than point B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0291] In one embodiment, said second preselected level of GDP-fucose is selected from a level:
[0292] i.b) approximately equal to, or greater than, 10%, 15%, 20%, 25%, 30%, 35% or 40% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0293] ii.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in decrease of GDP-mannose, e.g., a decrease in GDP-mannose that is equal to, greater than, 10%, 20%, 30%, 40% or 50% than a reference levee, e.g., the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0294] iii.b) an amount that provides an unacceptable level of fucose deprivation, e.g. an amount that results in a level of high mannose structures that are less than or equal to 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of a reference level;
[0295] iv.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of GDP-mannose, e.g. an increase in GDP-mannose that is equal to or greater than 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level, e.g. the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0296] v.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of high mannose structures that are more than or equal to 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level; or
[0297] vi.b) approximately equal to or greater than point C on the curve in FIG. 1 , or greater than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0298] In an embodiment the first level is i.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0299] In an embodiment the first level is ii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0300] In an embodiment the first level is ii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0301] In an embodiment the first level is iii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0302] In an embodiment the first level is iii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0303] In an embodiment the first level is iv.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0304] In an embodiment the first level is v.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0305] In an embodiment the first level is vi.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0306] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is i.b.
[0307] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is ii.b.
[0308] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iii.b.
[0309] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iv.b.
[0310] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is v.b.
[0311] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is vi.b.
[0312] In an embodiment the level of GDP-fucose is between point B and C on the curve in FIG. 1 or in an analogous range on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0313] In an embodiment the level of GDP-fucose is between point A and C on the curve in FIG. 1 or in an analogous range on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0314] In one embodiment, the level of GDP-fucose is selected to be outside the range between A and B on the curve in FIG. 1 (as relatively small changes in GDP-fucose will result in relatively large changes in the amount of fucosylation. In an embodiment the level is also less than B.) In another embodiment, the level of GDP-fucose is reduced by a predetermined level, e.g., in comparison with a reference. In another embodiment, the reference is the amount present in a cell or batch of cultured cells, e.g., a CHO cell or batch of cultured cells, lacking the manipulation but otherwise the same or essentially the same as the cell having the manipulation. In another embodiment, the level of GDP-fucose is reduced by, as much as, or more than, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80 or 90%, as compared to the reference.
[0000] In one embodiment, the method further comprises evaluating the glycoprotein for a parameter related to fucosylation, e.g., the amount of fucosylation in the glycan complement, the amount or fucosylation on a component of the glycan complement, or the amount of fucosylation on a glycan component, e.g., in a preparation of glycoproteins.
[0315] In one embodiment, the method further comprises evaluating the glycoprotein for a parameter related to fucosylation, e.g., the proportion of a preselected glycan component which bears a fucosyl moiety, e.g., at a selected position on the glycan component, e.g., in a preparation of glycoproteins.
[0316] In one embodiment, the level of fucosylation at one, two, three, or more preselected amino acid residues is evaluated. In another embodiment, the level of fucosylation is reduced by a predetermined level in comparison with a reference. In another embodiment, the reference is the amount present in a cell or batch of cultured cells, e.g., a CHO cell or batch of cultured cells, lacking the manipulation but otherwise the same or essentially the same as the cell or batch of cultured cells having the manipulation. In another embodiment, the level of fucosylation is reduced by, as much as, or more than, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80 or 90%, as compared to the reference.
[0317] In one embodiment, X F is greater than X G ,
[0318] and wherein,
[0319] X F is the % or proportion of reduction in the level of fucosylation (e.g., as compared to the level of fucosylation in a cell or batch of cultured cells lacking the manipulation); and
[0320] X G is the % or proportion of reduction in the level of GDP fucose (as compared to the level of GDP fucose in a cell or batch of cultured cells lacking the manipulation).
[0321] In one embodiment, said manipulation is not a genetic lesion or the presence of an siRNA that reduces the level of an enzyme that promotes formation of GDP-fucose, or the attachment of a fucosyl moiety. For example, the manipulation is not a lesion that decreases the expression of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, the cell or batch of cultured cells is wild-type for one or all of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, the cell or batch of cultured cells does not include an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, absent the manipulation, the level of fucosylation is substantially the same as the level in a wild-type cell. In another embodiment, the manipulated cell carries no mutation that substantially lowers GDP-fucose levels. In another embodiment, the manipulated cell has no siRNA that substantially lowers GDP-fucose levels.
[0322] In one embodiment, the cell has a mutation (e.g., a genetically engineered change) that decreases the level of GDP-fucose. Exemplary mutations include those which alter the activity of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0000] The mutation can be in the structural gene which encodes GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. Such mutations can decrease the activity of the encoded protein. The decrease can be partial or complete. Such mutations can act, e.g., by altering the catalytic activity of the protein or by altering its half-life. Other exemplary mutations can be in a sequence that control expression of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. These can be mutations that completely, or partially, reduce the expression of the gene, at the RNA or protein level. Such mutations include deletion or other mutations in endogenous of control sequence. Such mutations also include the introduction of heterologous control sequence, e.g., the introduction of heterologous control regions, e.g., a sequence that will give a desired level of expression. (A heterologous control sequence is a sequence other than a sequence naturally associated with and operably linked to the structural gene.) In embodiments the manipulation comprises a mutation in the structural region or in a control sequence operably linked to the gene.
[0323] In an embodiment a cell having a mutation that that decreases the level of GDP-fucose, e.g., a mutation that decreases the activity of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter is cultured in the presence of a substance, e.g., fucose, that results in a GDP-fucose level and/or a fucosylation level described herein. In an embodiment the cell includes a mutation that, in the absence of fucose in the culture medium, would result in a cell having an unacceptably low level of GDP-fucose. When, however, cultured under the appropriate conditions, e.g., media supplemented, e.g., with fucose, that cell can exhibit a desired level of GDP-fucose, e.g., a level of GDP-fucose described herein. Thus, fucose or another substance is present in the culture medium at a level that results in a level of GDP-fucose recited above.
[0324] In another embodiment, the manipulation is the presence of an siRNA that reduces the level of an enzyme that promotes formation of GDP-fucose, or the attachment of a fucosyl moiety, e.g., an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter, and fucose or another substance is present in the culture medium at a level that results in formation of said glycoprotein having a glycan structure having reduced fucosylation.
[0325] In one embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0326] In one embodiment, the cell is a Chinese Hamster Ovary (CHO) cell. In another embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0327] In one embodiment, the glycoprotein is selected from Table 1.
[0328] In one embodiment, the method further comprises culturing a plurality of the cells and separating as much as, or at least, 1, 10, 100, 1,000, or 10,000 grams of the glycoprotein from the cells. In another embodiment, the method further comprises combining the glycoprotein having reduced fucosylation with a pharmaceutically acceptable component and, e.g., formulating the glycoprotein having reduced fucosylation into a pharmaceutically acceptable formulation.
[0329] In one embodiment, the glycoprotein is analyzed by one or more of HPLC, CE, MALDI-MS and NMR.
[0330] In one embodiment, the method further comprises memorializing the result of the evaluation.
[0331] In one embodiment, the manipulation is, or is the product of, a selection for reduced levels of GDP-fucose. In another embodiment, the manipulation is, or is the product of, a selection for reduced fucosylation of a glycoprotein. In another embodiment, the manipulation comprises contact with, or inclusion in or on the cell or batch of cultured cells, of an exogenous inhibitor of an enzyme involved in GDP-fucose biosynthesis, e.g., a specific or non-specific inhibitor.
[0332] In one embodiment, the level of fucosylation at one, two, three, or more preselected amino acid residues is evaluated.
[0333] In one embodiment, one or more of said cell or said batch of cultured cells, said manipulation, and said glycoprotein, is selected on the basis that it or the combination will provide a glycoprotein having reduced fucosylation.
[0334] In one embodiment, one or more of said cell or said batch of cultured cells, said manipulation (or manipulations), and said glycoprotein, is selected on the basis that it or the combination will provide a level of GDP-fucose described herein, e.g., a level which gives a minimal level of fucosylation (e.g., with reference to a curve analogous to that in FIG. 1 , the level is to the right of point B) but which is above a preselected level, e.g., above a level that gives an unwanted decrease in the level of GDP-mannose. E.g., the level is above a level that gives a decrease in GDP-mannose that is equal to, or more than, 10%, 20%, 30%, 40% or 50% as compared to a reference level, e.g., the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation.
[0335] In some embodiments the level is above a level that gives an unwanted increase in the level of GDP-mannose, e.g., an increase in GDP-mannose that is equal to, or more than, about 2×, 3×, 4×, 5×, ×, 7×, 8×, 9×, or 10× of a reference level, e.g., the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation.
[0336] In one embodiment, the method further comprises providing a value for a parameter associated with a compound other than GDP-fucose, wherein a parameter for the compound, e.g., the level of the compound, is correlated to the level of GDP-fucose.
[0000] In another embodiment, the method further comprises providing a comparison of the value with a reference value, wherein optionally, a preselected relationship of the value to the reference value, e.g., greater than, equal to, or less than, is indicative of whether the level of GDP fucose is above, at or below the second level. In another embodiment, the method further comprises, responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture without intervening to change the level of GDP-fucose. In one embodiment, the compound other than GDP-fucose is GDP-mannose. In one embodiment, the compound other than GDP-fucose is GDP-mannose and the parameter is the level of GDP-mannose.
[0337] In one embodiment, the method further comprises providing a value for the level of GDP-mannose, providing a comparison of the value with a reference value, and responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture at without intervening to change the level of GDP-fucose. In one embodiment, the method comprises continuing to culture said cells, and repeating the steps above.
[0338] In an embodiments, an inhibitor, e.g., an inhibitor of GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, or enzymes involved in the biosynthesis of GDP-mannose, is used, e.g., in the culture medium, to lower the levels of the GDP-fucose. In an embodiment the inhibitor can be guanosine-5′-O-(2-thiodiphosphate)-fucose, guanosine-5′-O-(2-thiodiphosphate)-mannose, pyridoxal-5′-phosphate, GDP-4-dehydro-6-L-deoxygalactose, GDP-L-fucose, guanosine diphosphate (GDP), guanosine monophosphate (GMP), GDP-D-glucose, or p-chloromercuriphenylsulfonate EDTA. The inhibitor can be used with a cell which is mutant or wildtype for one or more GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0339] In an embodiment the media contains a substance that can increase the level of GDP-fucose, e.g., butyrate or fucose. Such media can be used, e.g., with a cell having a mutation that eliminates or decreased the activity of one or more of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0340] Methods described herein allow monitoring a process of making a protein, e.g., to insure that the process is in compliance with parameters set out herein.
[0341] Thus, in another aspect, the invention features, a method of monitoring a process, e.g., a process of culturing cells, e.g., of a selected type, to produce a product, comprising:
[0342] optionally, selecting a glycan structure having reduced fucosylation, e.g., from a list comprising a plurality of glycan structures having reduced fucosylation (in embodiments the list is provided), and optionally memorializing said selected glycan structure;
[0343] optionally, selecting a cell on the basis of the cell having or subject to a manipulation that decreases the level of fucosylation or GDP-fucose, and which manipulation decreases the level of fucosylation or GDP-fucose (in embodiments the manipulation is from a list comprising a plurality of manipulations, and in embodiments the list is provided);
[0344] providing a cell having or subject to a manipulation that decreases the level of fucosylation or GDP-fucose, e.g., a cell having a manipulation described herein or a cell a cell selected by a method described herein;
[0345] culturing said cell, e.g., to provide a batch of cultured cells; and
[0346] evaluating (directly or indirectly) the level of GDP-fucose of, or a glycan complement, glycan component or glycan structure produced by, the cell or the batch of cultured cells,
[0000] to thereby monitor the process.
[0347] In one embodiment, the evaluating step comprises any of:
[0348] (a) isolating glycoproteins produced from the cell or the batch of cultured cells and evaluating the glycans containing on the glycoproteins,
[0349] (b) isolating a specific glycoprotein composition produced from the cell or the batch of cultured cells and evaluating the glycans from the isolated glycoprotein composition,
[0350] (c) obtaining a glycan preparation from a glycoprotein preparation or isolated glycoprotein produced from the cell or the batch of cultured cells and evaluating the glycans in the glycan preparation,
[0351] (d) cleaving monosaccharides from glycans present on a glycoprotein produced from the cell or the batch of cultured cells or from glycans on the surface of the cell or the batch of cultured cells, and detecting the cleaved monosaccharides,
[0352] (e) providing at least one peptide from a glycoprotein preparation produced from the cell or the batch of cultured cells, and evaluating the glycans on the at least one peptide, and
[0353] (f) evaluating glycans from glycans on the cell surface of the cell or the batch of cultured cells.
[0354] In another embodiment, the evaluating step comprises isolating glycoproteins produced from the cell or the batch of cultured cells and evaluating the glycans containing on the glycoproteins. In another embodiment, the evaluating step comprises isolating a specific glycoprotein composition produced from the cell or the batch of cultured cells and evaluating the glycans from the isolated glycoprotein composition. In another embodiment, the evaluating step comprises obtaining a glycan preparation from a glycoprotein preparation or isolated glycoprotein produced from the cell or the batch of cultured cells and evaluating the glycans in the glycan preparation. In another embodiment, the evaluating step comprises cleaving monosaccharides from glycans present on a glycoprotein produced from the cell or the batch of cultured cells or from glycans on the surface of the cell or the batch of cultured cells, and detecting the cleaved monosaccharides. In another embodiment, the evaluating step comprises providing at least one peptide from a glycoprotein preparation produced from the cell or the batch of cultured cells, and evaluating the glycans on the at least one peptide. In another embodiment, the evaluating step comprises evaluating glycans from glycans on the cell surface of the cell or the batch of cultured cells.
[0355] In another embodiment, the method further comprises, if an observed value from an evaluation step does not meet a reference value, discarding said cell, continuing culture of said cell, or altering a culture condition and further culturing said cell. In another embodiment, the method further comprises, if an observed value from an evaluation step meets said reference value, continuing culture of said cell or said batch of cultured cells, altering a culture condition and further culturing said cell or said batch of cultured cells, or discarding said cell or said batch of cultured cells. In another embodiment, the method further comprises continuing culture of the cell or the batch of cultured cells. In another embodiment, the method further comprises altering a culture condition and further culturing said cell or said batch of cultured cells and optionally repeating the evaluation.
[0356] In one embodiment, the evaluation comprises determining if the level of GDP-fucose in said cell that is below a first preselected level and, in embodiments, above a second preselected level. In one embodiment, said first preselected level of GDP-fucose is selected from a level that is:
[0357] i.a) approximately equal to or less than 80%, 70% or 60% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0358] ii.a) approximately equal to, or less than, the point of maximum curvature above the inflection point (e.g., the inflection point in the second phase) on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0359] ii.1.a) approximately equal to, or less than, the lowest level that results in a normal (e.g., that seen in an un-manipuated cell) level of fucosylation;
[0360] iii.a) approximately equal to or less than the point of maximum curvature below the inflection point on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0361] iii.1.a) approximately equal to, or less than, the highest level that results in no further reduction in fucosylation;
[0362] iv.a) approximately equal to or less than point A on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control;
[0363] v.a) approximately equal to or less than that corresponding to an amount between points A and B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control; or
[0364] vi.a) approximately equal to or less than point B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0365] In one embodiment, said second preselected level of GDP-fucose is selected from a level:
[0366] i.b) approximately equal to, or greater than, 10%, 15%, 20%, 25%, 30%, 35% or 40% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0367] ii.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in decrease of GDP-mannose, e.g., a decrease in GDP-mannose that is equal to, greater than, 10%, 20%, 30%, 40% or 50% than a reference levee, e.g., the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0368] iii.b) an amount that provides an unacceptable level of fucose deprivation, e.g. an amount that results in a level of high mannose structures that are less than or equal to 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of a reference level;
[0369] iv.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of GDP-mannose, e.g. an increase in GDP-mannose that is equal to or greater than 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level, e.g. the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0370] v.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of high mannose structures that are more than or equal to 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level; or
[0371] vi.b) approximately equal to or greater than point C on the curve in FIG. 1 , or greater than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0372] In an embodiment the first level is i.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0373] In an embodiment the first level is ii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0374] In an embodiment the first level is ii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0375] In an embodiment the first level is iii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0376] In an embodiment the first level is iii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0377] In an embodiment the first level is iv.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0378] In an embodiment the first level is v.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0379] In an embodiment the first level is vi.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0380] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is i.b.
[0381] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is ii.b.
[0382] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iii.b.
[0383] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iv.b.
[0384] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is v.b.
[0385] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is vi.b.
[0386] In an embodiment the level of GDP-fucose is between point B and C on the curve in FIG. 1 or in an analogous range on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0387] In an embodiment the level of GDP-fucose is between point A and C on the curve in FIG. 1 or in an analogous range on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0388] In one embodiment, the level of GDP-fucose is selected to be outside the range between A and B on the curve in FIG. 1 (as relatively small changes in GDP-fucose will result in relatively large changes in the amount of fucosylation. In an embodiment the level is also less than B.) In another embodiment, the level of GDP-fucose is reduced by a predetermined level, e.g., in comparison with a reference. In another embodiment, the reference is the amount present in a cell or batch of cultured cells, e.g., a CHO cell or batch of cultured cells, lacking the manipulation but otherwise the same or essentially the same as the cell having the manipulation. In another embodiment, the level of GDP-fucose is reduced by, as much as, or more than, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80 or 90%, as compared to the reference.
[0389] In one embodiment, said manipulation is not a genetic lesion or the presence of an siRNA that reduces the level of an enzyme that promotes formation of GDP-fucose, or the attachment of a fucosyl moiety. For example, the manipulation is not a lesion that decreases the expression of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, the cell or batch of cultured cells is wild-type for one or all of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, the cell or batch of cultured cells does not include an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, absent the manipulation, the level of fucosylation is substantially the same as the level in a wild-type cell. In another embodiment, the manipulated cell carries no mutation that substantially lowers GDP-fucose levels. In another embodiment, the manipulated cell has no siRNA that substantially lowers GDP-fucose levels.
[0390] In one embodiment, the cell has a mutation (e.g., a genetically engineered change) that decreases the level of GDP-fucose. Exemplary mutations include those which alter the activity of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. The mutation can be in the structural gene which encodes GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. Such mutations can decrease the activity of the encoded protein. The decrease can be partial or complete. Such mutations can act, e.g., by altering the catalytic activity of the protein or by altering its half-life. Other exemplary mutations can be in a sequences that control expression of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. These can be mutations that completely, or partially, reduce the expression of the gene, at the RNA or protein level. Such mutations include deletion or other mutations in endogenous of control sequence. Such mutations also include the introduction of heterologous control sequence, e.g., the introduction of heterologous control regions, e.g., a sequence that will give a desired level of expression. (A heterologous control sequence is a sequence other than a sequence naturally associated with and operably linked to the structural gene.) In embodiments the manipulation comprises a mutation in the structural region or in a control sequence operably linked to the gene.
[0391] In an embodiment a cell having a mutation that that decreases the level of GDP-fucose, e.g., a mutation that decreases the activity of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter is cultured in the presence of a substance, e.g., fucose, that results in a GDP-fucose level and/or a fucosylation level described herein. In an embodiment the cell includes a mutation that, in the absence of fucose in the culture medium, would result in a cell having an unacceptably low level of GDP-fucose. When, however, cultured under the appropriate conditions, e.g., media supplemented, e.g., with fucose, that cell can exhibit a desired level of GDP-fucose, e.g., a level of GDP-fucose described herein. Thus, fucose or another substance is present in the culture medium at a level that results in a level of GDP-fucose recited above.
[0392] In another embodiment, the manipulation is the presence of an siRNA that reduces the level of an enzyme that promotes formation of GDP-fucose, or the attachment of a fucosyl moiety, e.g., an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter, and fucose or another substance is present in the culture medium at a level that results in formation of said glycan structure having reduced fucosylation.
[0393] In one embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0394] In one embodiment, the cell is a Chinese Hamster Ovary (CHO) cell. In another embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0395] In one embodiment, the glycoprotein is selected from Table 1.
[0396] In one embodiment, the method further comprises culturing a plurality of the cells and separating as much as, or at least, 1, 10, 100, 1,000, or 10,000 grams of the glycoprotein from the cells. In another embodiment, the method further comprises combining the glycoprotein having reduced fucosylation with a pharmaceutically acceptable component and, e.g., formulating the glycoprotein having reduced fucosylation into a pharmaceutically acceptable formulation.
[0397] In one embodiment, the glycoprotein is analyzed by one or more of HPLC, CE, MALDI-MS and NMR.
[0398] In one embodiment, the method further comprises memorializing the result of the evaluation.
[0399] In one embodiment, the manipulation is, or is the product of, a selection for reduced levels of GDP-fucose. In another embodiment, the manipulation is, or is the product of, a selection for reduced fucosylation of a glycoprotein. In another embodiment, the manipulation comprises contact with, or inclusion in or on the cell or batch of cultured cells, of an exogenous inhibitor of an enzyme involved in GDP-fucose biosynthesis, e.g., a specific or non-specific inhibitor.
[0400] In one embodiment, the level of fucosylation at one, two, three, or more preselected amino acid residues is evaluated.
[0401] In one embodiment, the method further comprises providing a value for a parameter associated with a compound other than GDP-fucose, wherein a parameter for the compound, e.g., the level of the compound, is correlated to the level of GDP-fucose.
[0000] In another embodiment, the method further comprises providing a comparison of the value with a reference value, wherein optionally, a preselected relationship of the value to the reference value, e.g., greater than, equal to, or less than, is indicative of whether the level of GDP fucose is above, at or below the second level. In another embodiment, the method further comprises, responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture without intervening to change the level of GDP-fucose. In one embodiment, the compound other than GDP-fucose is GDP-mannose. In one embodiment, the compound other than GDP-fucose is GDP-mannose and the parameter is the level of GDP-mannose.
[0402] In one embodiment, the method further comprises providing a value for the level of GDP-mannose, providing a comparison of the value with a reference value, and responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture at without intervening to change the level of GDP-fucose. In one embodiment, the method comprises continuing to culture said cells, and repeating the steps above.
[0403] In an embodiments, an inhibitor, e.g., an inhibitor of GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, or enzymes involved in the biosynthesis of GDP-mannose, is used, e.g., in the culture medium, to lower the levels of the GDP-fucose. In an embodiment the inhibitor can be guanosine-5′-O-(2-thiodiphosphate)-fucose, guanosine-5′-O-(2-thiodiphosphate)-mannose, pyridoxal-5′-phosphate, GDP-4-dehydro-6-L-deoxygalactose, GDP-L-fucose, guanosine diphosphate (GDP), guanosine monophosphate (GMP), GDP-D-glucose, or p-chloromercuriphenylsulfonate EDTA. The inhibitor can be used with a cell which is mutant or wildtype for one or more GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0404] In an embodiment the media contains a substance that can increase the level of GDP-fucose, e.g., butyrate or fucose. Such media can be used, e.g., with a cell having a mutation that eliminates or decreased the activity of one or more of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0405] Methods described herein allow monitoring a process of making a protein, e.g., to insure that the process is in compliance with parameters set out herein.
[0406] In one aspect, the invention features a method of controlling a process for making a glycoprotein having a glycan structure with reduced fucosylation, comprising:
(1) providing a glycoprotein made by the process of
[0408] optionally, selecting a glycan structure having reduced fucosylation, e.g., from a list comprising a plurality of glycan structures having reduced fucosylation (in embodiments the list is provided);
[0409] optionally, selecting a cell on the basis of the cell having or subject to a manipulation that decreases the level of fucosylation or GDP-fucose, and which manipulation decreases the level of fucosylation or GDP-fucose (in embodiments the manipulation is from a list comprising a plurality of manipulations, and in embodiments the list is provided);
[0410] providing a cell having or subject to a manipulation that decreases the level of decreases the level of fucosylation or GDP-fucose; and
[0411] culturing the cell to provide a glycoprotein and, e.g., form a batch of cultured cells;
(2) evaluating (directly or indirectly) the level of GDP-fucose in the cells or the glycan structure of the glycoprotein, (3) responsive to said evaluation, selecting a production parameter, e.g., a culture
condition, e.g., a level of a nutrient or other component in the culture medium, e.g., to provide a selected level of GDP-fucose in the cells or the selected glycan structure of the glycoprotein,
[0414] to thereby control the process for making a glycoprotein having a glycan structure.
[0415] In one embodiment, the method comprises continuing culture of the cell or batch of cultured cells under conditions that differ from those used prior to the evaluation. In another embodiment, the method comprises continuing culture of the cell or batch of cultured cells under the same conditions used prior to the evaluation.
[0416] In one embodiment, the evaluation comprises determining if the level of GDP-fucose in said cell that is below a first preselected level and, in embodiments, above a second preselected level. In one embodiment, said first preselected level of GDP-fucose is selected from a level that is:
[0417] i.a) approximately equal to or less than 80%, 70% or 60% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0418] ii.a) approximately equal to, or less than, the point of maximum curvature above the inflection point (e.g., the inflection point in the second phase) on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0419] ii.1.a) approximately equal to, or less than, the lowest level that results in a normal (e.g., that seen in an un-manipuated cell) level of fucosylation;
[0420] iii.a) approximately equal to or less than the point of maximum curvature below the inflection point on a graph of the amount of fucosylation vs. decrease in GDP-fucose;
[0421] iii.1.a) approximately equal to, or less than, the highest level that results in no further reduction in fucosylation;
[0422] iv.a) approximately equal to or less than point A on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control;
[0423] v.a) approximately equal to or less than that corresponding to an amount between points A and B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control; or
[0424] vi.a) approximately equal to or less than point B on the curve in FIG. 1 , or less than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0425] In one embodiment, said second preselected level of GDP-fucose is selected from a level:
[0426] i.b) approximately equal to, or greater than, 10%, 15%, 20%, 25%, 30%, 35% or 40% of a reference level, e.g., the level in said cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0427] ii.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in decrease of GDP-mannose, e.g., a decrease in GDP-mannose that is equal to, greater than, 10%, 20%, 30%, 40% or 50% than a reference levee, e.g., the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0428] iii.b) an amount that provides an unacceptable level of fucose deprivation, e.g. an amount that results in a level of high mannose structures that are less than or equal to 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of a reference level;
[0429] iv.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of GDP-mannose, e.g. an increase in GDP-mannose that is equal to or greater than 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level, e.g. the level of GDP-mannose in a cell or batch of cultured cells, e.g., a cell or batch of cultured cells which is otherwise similar, without the manipulation;
[0430] v.b) an amount that provides an unacceptable level of fucose deprivation, e.g., an amount that results in accumulation of high mannose structures that are more than or equal to 2×, 3×, 4×, 5×, 6×, 7×, 8×, 9×, or 10× of a reference level; or
[0431] vi.b) approximately equal to or greater than point C on the curve in FIG. 1 , or greater than or equal to an analogous point on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0432] In an embodiment the first level is i.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0433] In an embodiment the first level is ii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0434] In an embodiment the first level is ii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0435] In an embodiment the first level is iii.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0436] In an embodiment the first level is iii.1.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0437] In an embodiment the first level is iv.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0438] In an embodiment the first level is v.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0439] In an embodiment the first level is vi.a and the second level is selected from i.b, ii.b, iii.b, iv.b, v.b, and vi.b.
[0440] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is i.b.
[0441] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is ii.b.
[0442] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iii.b.
[0443] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is iv.b.
[0444] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is v.b.
[0445] In an embodiment the first level is selected from i.a, ii.a, ii.1.a, iii.a, iii.1.a, iv.a, v.a, and vi.a and the second level is vi.b.
[0446] In an embodiment the level of GDP-fucose is between point B and C on the curve in FIG. 1 or in an analogous range on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0447] In an embodiment the level of GDP-fucose is between point A and C on the curve in FIG. 1 or in an analogous range on a plot of the amount of fucosylation (%) vs. the amount of GDP fucose as a % of control.
[0448] In one embodiment, the level of GDP-fucose is selected to be outside the range between A and B on the curve in FIG. 1 (as relatively small changes in GDP-fucose will result in relatively large changes in the amount of fucosylation. In an embodiment the level is also less than B.) In another embodiment, the level of GDP-fucose is reduced by a predetermined level, e.g., in comparison with a reference. In another embodiment, the reference is the amount present in a cell or batch of cultured cells, e.g., a CHO cell or batch of cultured cells, lacking the manipulation but otherwise the same or essentially the same as the cell having the manipulation. In another embodiment, the level of GDP-fucose is reduced by, as much as, or more than, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80 or 90%, as compared to the reference.
[0449] In one embodiment, said evaluation step comprises comparing the structure of said glycan structure having reduced fucosylation present on a glycoprotein from said cultured cell or batch of cultured cells to a reference, and determining if said glycan structure having reduced fucosylation present on a glycoprotein from said cultured cell or batch of cultured cells differs from the corresponding glycan structure formed by a cell or batch of cultured cells that lacks the manipulation.
[0450] In one embodiment, the method further comprises evaluating the glycoprotein for a parameter related to fucosylation, e.g., the amount of fucosylation in the glycan complement, the amount or fucosylation on a component of the glycan complement, or the amount of fucosylation on a glycan component, e.g., in a preparation of glycoproteins. In another embodiment, the method further comprises evaluating the glycoprotein for a parameter related to fucosylation, e.g., the proportion of a preselected glycan component which bears a fucosyl moiety, e.g., at a selected position on the glycan component, e.g., in a preparation of glycoproteins.
[0451] In one embodiment, the level of fucosylation at one, two, three, or more preselected amino acid residues is evaluated. In another embodiment, the level of fucosylation is reduced by a predetermined level in comparison with a reference. In another embodiment, the reference is the amount present in a cell or batch of cultured cells, e.g., a CHO cell or batch of cultured cells, lacking the manipulation but otherwise the same or essentially the same as the cell or batch of cultured cells having the manipulation. In another embodiment, the level of fucosylation is reduced by, as much as, or more than, 10, 20, 30, 40, 50, 60, 70, 80 or 90%, as compared to the reference.
[0452] In one embodiment, said manipulation is not a genetic lesion or the presence of an siRNA that reduces the level of an enzyme that promotes formation of GDP-fucose, or the attachment of a fucosyl moiety. For example, the manipulation is not a lesion that decreases the expression of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, the cell or batch of cultured cells is wild-type for one or all of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, the cell or batch of cultured cells does not include an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, absent the manipulation, the level of fucosylation is substantially the same as the level in a wild-type cell. In another embodiment, the manipulated cell carries no mutation that substantially lowers GDP-fucose levels. In another embodiment, the manipulated cell has no siRNA that substantially lowers GDP-fucose levels.
[0453] In one embodiment, the cell has a mutation (e.g., a genetically engineered change) that decreases the level of GDP-fucose. Exemplary mutations include those which alter the activity of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0000] The mutation can be in the structural gene which encodes GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. Such mutations can decrease the activity of the encoded protein. The decrease can be partial or complete. Such mutations can act, e.g., by altering the catalytic activity of the protein or by altering its half-life. Other exemplary mutations can be in a sequences that control expression of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. These can be mutations that completely, or partially, reduce the expression of the gene, at the RNA or protein level. Such mutations include deletion or other mutations in endogenous of control sequence. Such mutations also include the introduction of heterologous control sequence, e.g., the introduction of heterologous control regions, e.g., a sequence that will give a desired level of expression. (A heterologous control sequence is a sequence other than a sequence naturally associated with and operably linked to the structural gene.) In embodiments the manipulation comprises a mutation in the structural region or in a control sequence operably linked to the gene.
[0454] In an embodiment a cell having a mutation that that decreases the level of GDP-fucose, e.g., a mutation that decreases the activity of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter is cultured in the presence of a substance, e.g., fucose, that results in a GDP-fucose level and/or a fucosylation level described herein. In an embodiment the cell includes a mutation that, in the absence of fucose in the culture medium, would result in a cell having an unacceptably low level of GDP-fucose. When, however, cultured under the appropriate conditions, e.g., media supplemented, e.g., with fucose, that cell can exhibit a desired level of GDP-fucose, e.g., a level of GDP-fucose described herein. Thus, fucose or another substance is present in the culture medium at a level that results in a level of GDP-fucose recited above.
[0455] In another embodiment, the manipulation is the presence of an siRNA that reduces the level of an enzyme that promotes formation of GDP-fucose, or the attachment of a fucosyl moiety, e.g., an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter, and fucose or another substance is present in the culture medium at a level that results in formation of said glycan structure having reduced fucosylation.
[0456] In one embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0457] In one embodiment, the cell is a Chinese Hamster Ovary (CHO) cell. In another embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0458] In one embodiment, the glycoprotein is selected from Table 1.
[0459] In one embodiment, the method further comprises culturing a plurality of the cells and separating as much as, or at least, 1, 10, 100, 1,000, or 10,000 grams of the glycoprotein from the cells. In another embodiment, the method further comprises combining the glycoprotein having reduced fucosylation with a pharmaceutically acceptable component and, e.g., formulating the glycoprotein having reduced fucosylation into a pharmaceutically acceptable formulation.
[0460] In one embodiment, the glycoprotein is analyzed by one or more of HPLC, CE, MALDI-MS and NMR.
[0461] In one embodiment, the method further comprises memorializing the result of the evaluation.
[0462] In one embodiment, the manipulation is, or is the product of, a selection for reduced levels of GDP-fucose. In another embodiment, the manipulation is, or is the product of, a selection for reduced fucosylation of a glycoprotein. In another embodiment, the manipulation comprises contact with, or inclusion in or on the cell or batch of cultured cells, of an exogenous inhibitor of an enzyme involved in GDP-fucose biosynthesis, e.g., a specific or non-specific inhibitor.
[0463] In one embodiment, the level of fucosylation at one, two, three, or more preselected amino acid residues is evaluated.
[0464] In one embodiment, one or more of said cell or said batch of cultured cells, said manipulation, and said glycoprotein, is selected on the basis that it or the combination will provide a glycoprotein having reduced fucosylation.
[0465] In one embodiment, the method further comprises providing a value for a parameter associated with a compound other than GDP-fucose, wherein a parameter for the compound, e.g., the level of the compound, is correlated to the level of GDP-fucose.
[0000] In another embodiment, the method further comprises providing a comparison of the value with a reference value, wherein optionally, a preselected relationship of the value to the reference value, e.g., greater than, equal to, or less than, is indicative of whether the level of GDP fucose is above, at or below the second level. In another embodiment, the method further comprises, responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture without intervening to change the level of GDP-fucose. In one embodiment, the compound other than GDP-fucose is GDP-mannose. In one embodiment, the compound other than GDP-fucose is GDP-mannose and the parameter is the level of GDP-mannose.
[0466] In one embodiment, the method further comprises providing a value for the level of GDP-mannose, providing a comparison of the value with a reference value, and responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture at without intervening to change the level of GDP-fucose. In one embodiment, the method comprises continuing to culture said cells, and repeating the steps above.
[0467] In an embodiments, an inhibitor, e.g., an inhibitor of GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, or enzymes involved in the biosynthesis of GDP-mannose, is used, e.g., in the culture medium, to lower the levels of the GDP-fucose. In an embodiment the inhibitor can be guanosine-5′-O-(2-thiodiphosphate)-fucose, guanosine-5′-O-(2-thiodiphosphate)-mannose, pyridoxal-5′-phosphate, GDP-4-dehydro-6-L-deoxygalactose, GDP-L-fucose, guanosine diphosphate (GDP), guanosine monophosphate (GMP), GDP-D-glucose, or p-chloromercuriphenylsulfonate EDTA. The inhibitor can be used with a cell which is mutant or wildtype for one or more GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0468] In an embodiment the media contains a substance that can increase the level of GDP-fucose, e.g., butyrate or fucose. Such media can be used, e.g., with a cell having a mutation that eliminates or decreased the activity of one or more of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0469] Methods described herein allow monitoring a process of making a protein, e.g., to insure that the process is in compliance with parameters set out herein.
[0470] In one aspect, the invention features method of controlling a process for making a glycoprotein having a glycan structure with reduced fucosylation, comprising:
[0471] (1) providing a glycoprotein made by the process of:
[0472] optionally, selecting a glycan structure having reduced fucosylation, e.g., from a list comprising a plurality of glycan structures having reduced fucosylation (in embodiments the list is provided);
[0473] optionally, selecting a cell on the basis of the cell having or subject to a manipulation that decreases the level of fucosylation or GDP-fucose, and which manipulation decreases the level of fucosylation or GDP-fucose (in embodiments the manipulation is from a list comprising a plurality of manipulations, and in embodiments the list is provided);
[0474] providing a cell having or subject to a manipulation that decreases the level of decreases the level of fucosylation or GDP-fucose; and
[0475] culturing the cell to provide a glycoprotein and, e.g., form a batch of cultured cells;
[0476] (2) providing a value for a parameter associated with a compound other than GDP-fucose, wherein a parameter for the compound, e.g., the level of the compound, is correlated to the level of GDP-fucose,
[0477] (3) providing a comparison of the value with a reference value, wherein optionally, a preselected relationship of the value to the reference value, e.g., greater than, equal to, or less than, is indicative of whether the level of GDP fucose is above, at or below a preselected level
[0478] (4) responsive to said comparison, selecting a production parameter, e.g., a culture condition, e.g., a level of a nutrient or other component in the culture medium, to thereby control the process for making a glycoprotein having a glycan structure.
[0479] In one embodiment, the method further comprises, responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture without intervening to change the level of GDP-fucose. In another embodiment, the compound other than GDP-fucose is GDP-mannose. In another embodiment, the compound other than GDP-fucose is GDP-mannose and the parameter is the level of GDP-mannose.
[0480] In one embodiment, the method further comprises providing a value for the level of GDP-mannose, providing a comparison of the value with a reference value, and responsive to the result of the comparison, increasing the level of GDP-fucose, decreasing the level of GDP-fucose or continuing cell culture at without intervening to change the level of GDP-fucose. In another embodiment, the method comprises continuing to culture said cells, and repeating the steps above.
[0481] In one embodiment, said manipulation is not a genetic lesion or the presence of an siRNA that reduces the level of an enzyme that promotes formation of GDP-fucose, or the attachment of a fucosyl moiety. For example, the manipulation is not a lesion that decreases the expression of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, the cell or batch of cultured cells is wild-type for one or all of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, the cell or batch of cultured cells does not include an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. In another embodiment, absent the manipulation, the level of fucosylation is substantially the same as the level in a wild-type cell. In another embodiment, the manipulated cell carries no mutation that substantially lowers GDP-fucose levels. In another embodiment, the manipulated cell has no siRNA that substantially lowers GDP-fucose levels.
[0482] In one embodiment, the cell has a mutation (e.g., a genetically engineered change) that decreases the level of GDP-fucose. Exemplary mutations include those which alter the activity of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. The mutation can be in the structural gene which encodes GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. Such mutations can decrease the activity of the encoded protein. The decrease can be partial or complete. Such mutations can act, e.g., by altering the catalytic activity of the protein or by altering its half-life. Other exemplary mutations can be in a sequences that control expression of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter. These can be mutations that completely, or partially, reduce the expression of the gene, at the RNA or protein level. Such mutations include deletion or other mutations in endogenous of control sequence. Such mutations also include the introduction of heterologous control sequence, e.g., the introduction of heterologous control regions, e.g., a sequence that will give a desired level of expression. (A heterologous control sequence is a sequence other than a sequence naturally associated with and operably linked to the structural gene.) In embodiments the manipulation comprises a mutation in the structural region or in a control sequence operably linked to the gene.
[0483] In an embodiment a cell having a mutation that that decreases the level of GDP-fucose, e.g., a mutation that decreases the activity of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter is cultured in the presence of a substance, e.g., fucose, that results in a GDP-fucose level and/or a fucosylation level described herein. In an embodiment the cell includes a mutation that, in the absence of fucose in the culture medium, would result in a cell having an unacceptably low level of GDP-fucose. When, however, cultured under the appropriate conditions, e.g., media supplemented, e.g., with fucose, that cell can exhibit a desired level of GDP-fucose, e.g., a level of GDP-fucose described herein. Thus, fucose or another substance is present in the culture medium at a level that results in a level of GDP-fucose recited above.
[0484] In another embodiment, the manipulation is the presence of an siRNA that reduces the level of an enzyme that promotes formation of GDP-fucose, or the attachment of a fucosyl moiety, e.g., an siRNA that targets GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter, and fucose or another substance is present in the culture medium at a level that results in formation of said glycan structure having reduced fucosylation.
[0485] In one embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0486] In one embodiment, the cell is a Chinese Hamster Ovary (CHO) cell. In another embodiment, the glycoprotein is an antibody. In another embodiment, the antibody has reduced core fucosylation. In another embodiment, the antibody is selected from the group consisting of Rituximab, Trastuzamab, Bevacizumab, Tositumomab, Alemtuzumab, Arcitumomab, Cetuximab, Trastuzumab, Adalimumab, Ranibizumab, Gemtuzumab [ozogamicin], Fanolesomab, Efalizumab, Infliximab, Abciximab, Rituximab, Basiliximab, Eculizumab, Palivizumab, Natalizumab, Omalizumab, Daclizumab, and Ibritumomab.
[0487] In one embodiment, the glycoprotein is selected from Table 1.
[0488] In one embodiment, the method further comprises culturing a plurality of the cells and separating as much as, or at least, 1, 10, 100, 1,000, or 10,000 grams of the glycoprotein from the cells. In another embodiment, the method further comprises combining the glycoprotein having reduced fucosylation with a pharmaceutically acceptable component and, e.g., formulating the glycoprotein having reduced fucosylation into a pharmaceutically acceptable formulation.
[0489] In one embodiment, the glycoprotein is analyzed by one or more of HPLC, CE, MALDI-MS and NMR.
[0490] In one embodiment, the method further comprises memorializing the result of the evaluation.
[0491] In one embodiment, the manipulation is, or is the product of, a selection for reduced levels of GDP-fucose. In another embodiment, the manipulation is, or is the product of, a selection for reduced fucosylation of a glycoprotein. In another embodiment, the manipulation comprises contact with, or inclusion in or on the cell or batch of cultured cells, of an exogenous inhibitor of an enzyme involved in GDP-fucose biosynthesis, e.g., a specific or non-specific inhibitor.
[0492] In an embodiments, an inhibitor, e.g., an inhibitor of GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, or enzymes involved in the biosynthesis of GDP-mannose, is used, e.g., in the culture medium, to lower the levels of the GDP-fucose. In an embodiment the inhibitor can be guanosine-5′-O-(2-thiodiphosphate)-fucose, guanosine-5′-O-(2-thiodiphosphate)-mannose, pyridoxal-5′-phosphate, GDP-4-dehydro-6-L-deoxygalactose, GDP-L-fucose, guanosine diphosphate (GDP), guanosine monophosphate (GMP), GDP-D-glucose, or p-chloromercuriphenylsulfonate EDTA. The inhibitor can be used with a cell which is mutant or wildtype for one or more GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0493] In an embodiment the media contains a substance that can increase the level of GDP-fucose, e.g., butyrate or fucose. Such media can be used, e.g., with a cell having a mutation that eliminates or decreased the activity of one or more of GMD, FX, fucokinase, GFPP, GDP-synthetase, a fucosyltransferase or a GDP-Fucose transporter.
[0494] In one aspect, the invention features a method of making a glycoprotein having reduced fucosylation, comprising:
(a) providing, acknowledging, selecting, accepting, or memorializing a defined, desired or preselected glycan structure having reduced fucosylation for the glycoprotein, (b) optionally providing a cell manipulated to decrease the level of fucosylation or fucose-GDP, (c) culturing a cell manipulated to decrease the level of fucosylation or fucose-GDP, e.g., to form a batch of cultured cells, and (d) isolating from the cell or batch of cultured cells a glycoprotein having the desired glycan structure,
thereby making a glycoprotein.
[0499] In one aspect, the invention features method of making a glycoprotein, comprising:
[0500] providing, acknowledging, selecting, accepting, or memorializing a defined, desired or preselected glycan structure having reduced fucosylation for the glycoprotein, chosen, e.g., from Table 1;
[0501] optionally, providing, acknowledging, selecting, accepting, or memorializing a manipulation described herein;
[0502] culturing a cell having the manipulation, e.g., to form a batch of cultured cells;
isolating from the cell or batch of cultured cells a glycoprotein having the desired glycan structure,
thereby making a glycoprotein.
[0504] In one aspect, the invention features method of formulating a pharmaceutical composition comprising:
[0505] contacting a glycoprotein made by a method described herein with a pharmaceutically acceptable substance, e.g., an excipient or diluent.
[0506] In one aspect, the invention features pharmaceutical preparation of a glycoprotein described herein or made by a method described herein, wherein the glycoprotein is selected from Table 1.
[0507] Any step that generates information in a method described herein, e.g., a selection, analysis, comparison with a reference, or other evaluation or determination, can be memorialized, for example, by entry into a computer database. Such information can further be compared to a reference, or itself serve as a reference, for an evaluation made in the process.
DETAILED DESCRIPTION
[0508] The drawings are first described.
[0509] FIG. 1 is a plot of increasing amount of fucosylation on a glycoprotein produced by a cell (as a percentage of a cell without manipulation) (Y axis) against decreasing cellular GDP-fucose in the cell (as a percentage of a cell without manipulation). The plot shows a non-linear relationship indicative of a threshold relationship. E.g., reducing parental GDP-fucose levels by 20% gives little reduction in the amount of fucosylation. Reduction of more than 20% in GDP-fucose levels produced significant further reduction in glycosylation. Point A on the plot shows the point at which reduction in GDP-fucose begins to result in a significant reduction in fucosylation. Point B on the plot shows the point at which further reduction in GDP-fucose fails to result in further significant reduction in fucosylation. The region between points B and C is an optimal range. [>20% and <80% of parental GDP-fucose levels, e.g., >40% and <65% of parental GDP-fucose levels.]
[0510] FIG. 2 is a depiction of glycan profiles from glycoproteins expressed from wild type CHO cells (top) and Lec 13.6 A cells (bottom). Data are negative mode MALDI spectra with the most abundant glycans indicated by structure. As indicated, glycans from the Lec 13.6 A cells have very low levels of fucosylation.
DEFINITIONS
[0511] “Branched fucose” as used herein refers to a fucose moiety that is attached via an cd-3 or cd-4 linkage to an N-acetylglucosamine sugar of an N-linked or O-linked glycan component.
[0512] “Core fucose” as used herein refers to a fucose moiety that is attached via an cd-6 linkage to the N-acetylglucosamine sugar that is directly attached to the asparagine amino acid in an N-linked glycan component.
[0513] “Culturing” as used herein refers to placing a cell, e.g., a vertebrate, mammalian or rodent cell, under conditions that allow for at least some of the steps for the production of a glycoprotein to proceed. In embodiments, the conditions are sufficient to allow the glycosylation process to be completed. In embodiments, the conditions are sufficient to allow all of the steps, e.g., through secretion, to occur. Culturing refers to cultures of cells, cell lines, and populations of cells. The cells can be eukaryotic or a prokaryotic cells, e.g., animal, plant, yeast, fungal, insect or bacterial cells. In embodiments, culturing refers to in vitro culture of cells, e.g., primary or secondary cell lines.
[0514] “Glycan complement” as used herein refers to all of the glycan components of a glycoprotein. In the case of a protein having a single glycosylation site, the glycan component attached thereto forms the glycan complement. In the case of a protein having more than one glycosylation site, the glycan complement is made up of the glycan components attached at all of the sites. The N-linked glycan complement refers to all of the N-linked glycan components of a protein. The O-linked glycan complement refers to all of the O-linked glycan components of a protein. A “component of the glycan complement” refers to a subset of the glycan components making up the glycan complement, e.g., one or more glycan components attached to its or their respective glycosylation site or sites.
[0515] “Glycan component” as used herein refers to a sugar moiety, e.g., a monosaccharide, oligosaccharide or polysaccharide (e.g., a disaccharide, trisaccharide, tetrasaccharide, etc.) attached to a protein at one site. In embodiments the attachment is covalent and the glycan component is N- or O-linked to the protein. Glycan components can be chains of monosaccharides attached to one another via glycosidic linkages. Glycan components can be linear or branched. Fucose moieties are typically attached to an N-acetylglucosamine sugar of an N-linked or O-linked glycan component via an cd-3, cd-4 or cd-6 linkage.
[0516] “Glycan structure” as used herein refers to the structure of a glycan complement, component of a glycan complement, or glycan component. In embodiments it refers to one or more of the placement and number of fucosyl moieties.
[0517] A glycan structure can be described in terms of a comparison of the presence, absence or amount of a first glycan structure to a second glycan structure, for example, the presence, absence or amount of fucose relative to the presence, absence or amount of some other component. In other examples, the presence, absence or amount of fucose can be compared, e.g., to the presence, absence or amount of a sialic acid derivative such as N-glycolylneuraminic acid.
[0518] Glycan structures can be described, identified or assayed in a number of ways. A glycan structure can be described, e.g., in defined structural terms, e.g., by chemical name, or by a functional or physical property, e.g., by molecular weight or by a parameter related to purification or separation, e.g., retention time of a peak in a column or other separation device. In embodiments a glycan structure can, by way of example, be a peak or other fraction (representing one or more species) from glycan structures derived from a glycoprotein, e.g., from an enzymatic digest.
[0519] “Manipulation” as used herein can be any of a cell/activity-based manipulation, an envirocultural manipulation, or a selected functional manipulation. In general a manipulation is induced, selected, isolated, engineered, or is otherwise the product of the “hand of man.”
[0520] A “cell/activity-based manipulation” as used herein refers to a property of a cell that decreases the level of GDP-fucose activity in a cell, e.g., which decreases the level of activity of an enzyme involved in GDP-fucose biosynthesis. Decreased means by comparison with a cell that is not subject to the cell/activity-based manipulation.
[0521] Examples of cell/activity-based manipulations include:
[0522] the presence in or on the cell of an exogenous inhibitor (e.g., an siRNA or a chemical inhibitor) of the activity of an enzyme involved in GDP-fucose biosynthesis; or
[0523] a mutation or other genetic event that inhibits the activity of an enzyme involved in GDP-fucose biosynthesis. In some embodiments a cell/activity-based manipulation excludes genetic lesions, e.g., genetic knock-outs, discussed elsewhere herein.
[0524] An “envirocultural manipulation” as used herein refers to a property of the culture conditions, e.g., of the culture medium, that lowers GDP-fucose level and results in a decrease in transfer of a fucose moiety to a glycoprotein. Examples include the modulation of salt or ion concentrations in the culture medium. Specific examples of media conditions that will lead to altered levels of GDP-fucose include but are not limited to altering the levels of cobalt, butyrate, fucose, guanosine, and manganese.
[0525] A selected functional manipulation is a physical characteristic or property characterized, e.g., by the process that gave rise to it, e.g., a cell that was placed under selective conditions that result in the cell being able to produce a glycoprotein having a glycan structure characterized by a reduced GDP-fucose level, wherein the underlying basis for the ability to produce said glycoprotein having a glycan structure may or may not be known or characterized.
[0526] “Reduced fucosylation” relates to the amount or frequency of fucosylation. With regard to a single molecule, it means fewer fucose moieties, e.g., as compared to a reference, e.g., a protein made by a cell without the manipulation that gave rise to reduced fucosylation. With regard to a plurality of molecules, e.g., a pharmaceutically acceptable preparation, it can mean fewer fucose moieties on the molecules of the plurality (e.g., as compared to a reference, e.g., the plurality made by cells without the manipulation that gave rise to reduced fucosylation). The comparison can be with regard to all fucosylation sites on the subject molecule or with regard to the fucosylation at one or more specific sites. Reduced fucosylation can mean reduced occupancy by, or presence of, a fucosyl moiety at a selected site, e.g., as compared to a reference preparation, e.g., a reference preparation made by cells without the manipulation that gave rise to reduced fucosylation.
Regulation of Glycosylation
[0527] Glycosylation is a nonlinear non-template driven process. To this end, regulation of a particular glycan structure may be due to a number of orthogonal inputs such as precursor levels, donor levels, and transferase levels to name a few. Glycosylation of proteins can have dramatic effect on their activities, such as regulating receptor affinity, regulating bioavailability, or altering immunogenicity. For example, the presence of core fucosylation on an antibody may significantly attenuate antibody-dependent cell-mediated cytotoxicity (ADCC).
[0528] Eukaryotic glycosylation occurs in the endoplasmic reticulum (ER) and Golgi through a stepwise process in which one monosaccharide is added through the activity of a glycosyltransferase, utilizing an activated sugar nucleotide as the donor molecule. The graphic below illustrates this with GDP-fucose.
[0000]
[0529] It should be noted that fucose can be added to a glycan structure at various points during the diversification process. This is one example of a glycan structure that may be fucosylated.
GDP-Fucose Biosynthesis
[0530] Two pathways have been described for synthesis of GDP-fucose in the cytosol of essentially all mammalian cells, the de novo pathway and the salvage pathway. The de novo pathway transforms GDP-mannose to GDP-fucose via three enzymatic reactions carried out by two proteins, GDP-mannose 4,6-dehydratase (GMD) and GDP-keto-6-deoxymannose-3,5-epimerase-4-reductase (also known as the FX protein or tissue specific transplantation antigen P35B) (Scheme 1). The salvage pathway synthesizes GDP-fucose from free fucose derived from extracellular or lysosomal sources via the reactions of two proteins, a fucose kinase (fucokinase) followed by either GDP-fucose pyrophosphorylase (GFPP) (also known as fucose-1-phosphate guanylyltransferase) or GDP-fucose synthetase (Scheme 2). Quantitative studies of fucose metabolism in HeLa cells indicate that greater than 90% of GDP-fucose is derived from the de novo pathway (Yurchenco and Atkinson, Biochemistry 14(14):3107-14, 1975; Yurchenco and Atkinson, Biochemistry 16(5):944-53, 1977).
[0000]
[0531] Methods of regulating fucosylation by modulating levels of GDP-fucose, e.g., lowering GDP-fucose levels below a threshold level, are disclosed herein. In some embodiments this may involve the use of inhibitors of enzymes critical for GDP-fucose biosynthesis, such as GMD, FX, fucose kinase, GFPP and/or GDP-fucose synthetase.
[0532] Exemplary proteins involved in GDP-fucose biosynthesis include the following:
[0000]
Protein sequence of human GDP-mannose 4,6-
dehydratase
(SEQ ID NO: 1)
MAHAPARCPSARGSGDGEMGKPRNVALITGITGQDGSYLAEFLLEKGYEV
HGIVRRSSSFNTGRIEHLYKNPQAHIEGNMKLHYGDLTDSTCLVKIINEV
KPTEIYNLGAQSHVKISFDLAEYTADVDGVGTLRLLDAVKTCGLINSVKF
YQASTSELYGKVQEIPQKETTPFYPRSPYGAAKLYAYWIVVNFREAYNLF
AVNGILFNHESPRRGANFVTRKISRSVAKIYLGQLECFSLGNLDAKRDWG
HAKDYVEAMWLMLQNDEPEDFVIATGEVHSVREFVEKSFLHIGKTIVWEG
KNENEVGRCKETGKVHVTVDLKYYRPTEVDFLQGDCTKAKQKLNWKPRVA
FDELVREMVHADVELMRTNPNA
GenBank Accession No. NP_001491 (GenBank version
dated 10-DEC-2008)
mRNA sequence of human GDP-mannose 4,6-dehydratase
(SEQ ID NO: 2)
ATGGCACACGCACCGGCACGCTGCCCCAGCGCCCGGGGCTCCGGGGACGG
CGAGATGGGCAAGCCCAGGAACGTGGCGCTCATCACCGGTATCACAGGCC
AGGATGGTTCCTACCTGGCTGAGTTCCTGCTGGAGAAAGGCTATGAGGTC
CATGGAATTGTACGGCGGTCCAGTTCATTTAATACGGGTCGAATTGAGCA
TCTGTATAAGAATCCCCAGGCTCACATTGAAGGAAACATGAAGTTGCACT
ATGGCGATCTCACTGACAGTACCTGCCTTGTGAAGATCATTAATGAAGTA
AAGCCCACAGAGATCTACAACCTTGGAGCCCAGAGCCACGTCAAAATTTC
CTTTGACCTCGCTGAGTACACTGCGGACGTTGACGGAGTTGGCACTCTAC
GACTTCTAGATGCAGTTAAGACTTGTGGCCTTATCAACTCTGTGAAGTTC
TACCAAGCCTCAACAAGTGAACTTTATGGGAAAGTGCAGGAAATACCCCA
GAAGGAGACCACCCCTTTCTATCCCCGGTCACCCTATGGGGCAGCAAAAC
TCTATGCCTATTGGATTGTGGTGAACTTCCGTGAGGCGTATAATCTCTTT
GCAGTGAACGGCATTCTCTTCAATCATGAGAGTCCCAGAAGAGGAGCTAA
TTTCGTTACTCGAAAAATTAGCCGGTCAGTAGCTAAGATTTACCTTGGAC
AACTGGAATGTTTCAGTTTGGGAAATCTGGATGCCAAACGAGATTGGGGC
CATGCCAAGGACTATGTGGAGGCTATGTGGTTGATGTTGCAGAATGATGA
GCCGGAGGACTTCGTTATAGCTACTGGGGAGGTCCATAGTGTCCGGGAAT
TTGTCGAGAAATCATTCTTGCACATTGGAAAAACCATTGTGTGGGAAGGA
AAGAATGAAAATGAAGTGGGCAGATGTAAAGAGACCGGCAAAGTTCACGT
GACTGTGGATCTCAAGTACTACCGGCCAACTGAAGTGGACTTTCTGCAGG
GCGACTGCACCAAAGCGAAACAGAAGCTGAACTGGAAGCCCCGGGTCGCT
TTCGATGAGCTGGTGAGGGAGATGGTGCACGCCGACGTGGAGCTCATGAG
GACAAACCCCAATGCCTGA
GenBank Accession No. NM_001500 (GenBank version
dated 10-DEC-2008)
Protein sequence of mouse GDP-mannose 4,6-
dehydratase
(SEQ ID NO: 3)
MAQAPAKCPSYPGSGDGEMGKLRKVALITGITGQDGSYLAEFLLEKGYEV
HGIVRRSSSFNTGRIEHLYKNPQAHIEGNMKLHYGDLTDSTCLVKIINEV
KPTEIYNLGAQSHVKISFDLAEYTADVDGVGTLRLLDAIKTCGLINSVKF
YQASTSELYGKVQEIPQKETTPFYPRSPYGAAKLYAYWIVVNFREAYNLF
AVNGILFNHESPRRGANFVTRKISRSVAKIYLGQLECFSLGNLDAKRDWG
HAKDYVEAMWLMLQNDEPEDFVIATGEVHSVREFVEKSFMHIGKTIVWEG
KNENEVGRCKETGKVHVTVDLKYYRPTEVDFLQGDCSKAQQKLNWKPRVA
FDELVREMVQADVELMRTNPNA
GenBank Accession No. NP_666153 (GenBank version
dated 18-APR-2009)
mRNA sequence of mouse GDP-mannose 4,6-dehydratase
(SEQ ID NO: 4)
ATGGCTCAAGCTCCCGCTAAGTGCCCGAGCTACCCGGGCTCCGGGGATGG
CGAGATGGGCAAGCTCAGGAAGGTGGCTCTCATCACTGGCATCACCGGAC
AGGATGGTTCGTACTTGGCAGAATTCCTGTTGGAGAAAGGGTACGAGGTC
CATGGAATAGTACGGCGATCTAGTTCATTTAATACAGGTCGAATTGAACA
TTTATATAAGAATCCTCAGGCTCATATTGAAGGAAACATGAAGTTGCACT
ATGGTGACCTCACTGACAGCACCTGCCTAGTGAAAATCATCAATGAAGTC
AAGCCTACAGAGATCTATAATCTTGGAGCCCAGAGCCATGTCAAGATCTC
CTTTGACTTAGCTGAGTACACCGCAGATGTTGATGGCGTTGGCACCTTGC
GGCTTCTGGATGCAATTAAAACTTGTGGCCTTATAAATTCTGTGAAGTTC
TACCAGGCCTCAACAAGTGAACTTTATGGAAAAGTGCAGGAAATACCCCA
GAAGGAGACCACACCTTTCTATCCGAGGTCACCCTATGGAGCAGCCAAAC
TCTATGCCTATTGGATTGTGGTGAATTTCCGTGAAGCTTATAATCTCTTT
GCAGTGAATGGAATTCTCTTCAATCATGAGAGTCCCAGAAGAGGAGCTAA
TTTTGTTACTCGAAAAATTAGCCGGTCAGTAGCTAAGATTTACCTTGGAC
AACTGGAATGTTTCAGCTTGGGAAATCTGGATGCCAAACGAGACTGGGGC
CATGCCAAGGACTATGTAGAGGCTATGTGGCTCATGTTGCAGAATGATGA
GCCAGAGGACTTTGTCATAGCTACTGGGGAAGTTCACAGTGTCCGTGAAT
TTGTTGAAAAGTCATTCATGCACATCGGAAAAACCATTGTGTGGGAAGGA
AAGAATGAAAATGAAGTGGGCAGATGTAAAGAGACCGGCAAAGTTCACGT
GACTGTGGATCTGAAATACTACCGACCGACTGAAGTGGACTTTCTGCAGG
GAGACTGCTCCAAGGCTCAGCAGAAGCTAAACTGGAAGCCCCGCGTTGCC
TTTGACGAGCTGGTGAGGGAGATGGTGCAGGCCGACGTGGAGCTCATGAG
GACCAACCCCAACGCTTGA
GenBank Accession No. NM_146041 (GenBank version
dated 18-APR-2009)
Protein sequence of rat GDP-mannose 4,6-
dehydratase
(SEQ ID NO: 5)
MAHAPASCRRYPGSGDGEMGKLRKVALITGITGQDGSYLAEFLLEKGYEV
HGIVRRSSSFNTGRIEHLYKNPQAHIEGNMKLHYGDLTDSTCLVKIINEV
KPTEIYNLGAQSHVKISFDLAEYTADVDGVGTLRLLDAIKTCGLINSVKF
YQASTSELYGKVQEIPQKETTPFYPRSPYGAAKLYAYWIVVNFREAYNLF
AVNGILFNHESPRRGANFVTRKISRSVAKIYLGQLECFSLGNLDAKRDWG
HAKDYVEAMWLMLQNDEPEDFVIATGEVHSVREFVEKSFMHIGKTIVWEG
KNENEVGRCKETGKIHVTVDLKYYRPTEVDFLQGDCSKAQQKLNWKPRVA
FDELVREMVQADVELMRTNPNA
GenBank Accession No. NP_001034695 (GenBank
version dated 18-APR-2009)
mRNA sequence of rat GDP-mannose 4,6-dehydratase
(SEQ ID NO: 6)
ATGGCCCACGCTCCCGCTAGCTGCCGGAGATACCCGGGCTCCGGGGATGG
CGAGATGGGCAAGCTCAGGAAGGTAGCTCTCATCACCGGCATCACTGGCC
AGGATGGTTCATACTTGGCAGAATTCCTGCTGGAGAAAGGATACGAGGTC
CATGGAATAGTACGGCGATCTAGTTCATTTAATACAGGTCGAATTGAACA
TTTATATAAGAATCCTCAGGCTCATATTGAAGGAAACATGAAGTTGCACT
ATGGCGACCTGACTGACAGCACCTGCCTGGTGAAAATCATCAATGAAGTG
AAGCCTACAGAGATCTACAATCTTGGCGCTCAGAGCCATGTCAAGATCTC
CTTTGACTTAGCTGAATACACCGCAGACGTTGATGGAGTTGGCACCTTGC
GGCTTCTGGATGCAATTAAAACTTGCGGCCTTATAAATTCTGTGAAGTTC
TACCAGGCCTCGACAAGTGAACTTTATGGAAAAGTTCAGGAAATACCCCA
GAAAGAGACCACACCTTTCTATCCGAGGTCACCCTATGGAGCCGCCAAGC
TCTATGCCTATTGGATTGTGGTGAATTTCCGTGAAGCTTATAATCTCTTT
GCAGTGAATGGCATTCTCTTCAATCACGAGAGCCCCAGAAGAGGAGCTAA
TTTTGTTACTCGAAAAATTAGCCGGTCAGTAGCTAAGATTTACCTTGGAC
AACTGGAATGTTTCAGTTTGGGAAATCTGGATGCCAAACGAGACTGGGGC
CATGCCAAGGACTATGTAGAGGCTATGTGGCTGATGTTGCAAAATGATGA
GCCGGAGGACTTTGTCATAGCTACTGGGGAAGTTCACAGTGTCCGTGAAT
TTGTTGAAAAATCATTCATGCACATTGGAAAAACCATTGTGTGGGAAGGA
AAGAATGAAAATGAAGTAGGCAGATGTAAGGAGACCGGCAAAATTCACGT
GACTGTGGATCTGAAATACTACCGACCGACTGAAGTGGACTTTCTACAGG
GAGACTGCTCCAAGGCTCAGCAGAAACTGAACTGGAAACCCCGCGTTGCC
TTCGATGAGCTGGTGAGAGAGATGGTGCAGGCCGACGTGGAGCTCATGAG
GACCAACCCCAACGCTTGA
GenBank Accession No. NM_001039606 (GenBank
version dated 18-APR-2009)
Protein sequence of Chinese hamster GDP-mannose
4,6-dehydratase
(SEQ ID NO: 7)
MAHAPARCPSARGSGDGEMGKPRNVALITGITGQDGSYLAEFLLEKGYEV
HGIVRRSSSFNTGRIEHLYKNPQAHIEGNMKLHYGDLTDSTCLVKIINEV
KPTEIYNLGAQSHVKISFDLAEYTADVDGVGTLRLLDAVKTCGLINSVKF
YQASTSELYGKVQEIPQKETTPFYPRSPYGAAKLYAYWIVVNFREAYNLF
AVNGILFNHESPRRGANFVTRKISRSVAKIYLGQLECFSLGNLDAKRDWG
HAKDYVEAMWLMLQNDEPEDFVIATGEVHSVREFVEKSFLHIGKTIVWEG
KNENEVGRCKETGKVHVTVDLKYYRPTEVDFLQGDCTKAKQKLNWKPRVA
FDELVREMVHADVELMRTNPNA
GenBank Accession No. Q8K3X3 (GenBank version
dated 20-JAN-2009)
mRNA sequence of Chinese hamster GDP-mannose
4,6-dehydratase
(SEQ ID NO: 8)
agactgtggcggccgctgcagctccgtgaggcgactggcgcgcgcaccca
cgtctctgtcggcccgctgccggttccacggttccactcctccttccact
cggctgcacgctcacccgcccgcggcgacATGGCTCACGCTCCCGCTAGC
TGCCCGAGCTCCAGGAACTCTGGGGACGGCGATAAGGGCAAGCCCAGGAA
GGTGGCGCTCATCACGGGCATCACCGGCCAGGATGGCTCATACTTGGCAG
AATTCCTGCTGGAGAAAGGATACGAGGTTCATGGAATTGTACGGCGATCC
AGTTCATTTAATACAGGTCGAATTGAACATTTATATAAGAATCCACAGGC
TCATATTGAAGGAAACATGAAGTTGCACTATGGTGACCTCACCGACAGCA
CCTGCCTAGTAAAAATCATCAATGAAGTCAAACCTACAGAGATCTACAAT
CTTGGTGCCCAGAGCCATGTCAAGATTTCCTTTGACTTAGCAGAGTACAC
TGCAGATGTTGATGGAGTTGGCACCTTGCGGCTTCTGGATGCAATTAAGA
CTTGTGGCCTTATAAATTCTGTGAAGTTCTACCAGGCCTCAACTAGTGAA
CTGTATGGAAAAGTGCAAGAAATACCCCAGAAAGAGACCACCCCTTTCTA
TCCAAGGTCGCCCTATGGAGCAGCCAAACTTTATGCCTATTGGATTGTAG
TGAACTTTCGAGAGGCTTATAATCTCTTTGCGGTGAACGGCATTCTCTTC
AATCATGAGAGTCCTAGAAGAGGAGCTAATTTTGTTACTCGAAAAATTAG
CCGGTCAGTAGCTAAGATTTACCTTGGACAACTGGAATGTTTCAGTTTGG
GAAATCTGGACGCCAAACGAGACTGGGGCCATGCCAAGGACTATGTCGAG
GCTATGTGGCTGATGTTACAAAATGATGAACCAGAGGACTTTGTCATAGC
TACTGGGGAAGTTCATAGTGTCCGTGAATTTGTTGAGAAATCATTCATGC
ACATTGGAAAGACCATTGTGTGGGAAGGAAAGAATGAAAATGAAGTGGGC
AGATGTAAAGAGACCGGCAAAATTCATGTGACTGTGGATCTGAAATACTA
CCGACCAACTGAAGTGGACTTCCTGCAGGGAGACTGCTCCAAGGCGCAGC
AGAAACTGAACTGGAAGCCCCGCGTTGCCTTTGACGAGCTGGTGAGGGAG
ATGGTGCAAGCCGATGTGGAGCTCATGAGAACCAACCCCAACGCCTGAgc
acctctacaaaaaattcgcgagacatggactatggtgcagagccagccaa
ccagagtccagccactcctgagaccatcgaccataaaccctcgactgcct
gtgtcgtccccacagctaagagctgggccacaggtttgtgggcaccagga
cggggacactccagagctaaggccacttcgcttttgtcaaaggctcctct
gaatgattttgggaaatcaagaagtttaaaatcacatactcattttactt
gaaattatgtcactagacaacttaaatttttgagtcttgagattgttttt
ctcttttcttattaaatgatctttctatgaaccagcaaaaaaaaaaaaaa
aaaaaa
GenBank Accession No. AF525364 (GenBank version
dated 04-AUG-2002)
Protein sequence of human GDP-keto-6-deoxymannose
3,5-epimerase, 4-reductase (FX protein, tissue
specific transplantation antigen P35B)
(SEQ ID NO: 9)
MGEPQGSMRILVTGGSGLVGKAIQKVVADGAGLPGEDWVFVSSKDADLTD
TAQTRALFEKVQPTHVIHLAAMVGGLFRNIKYNLDFWRKNVHMNDNVLHS
AFEVGARKVVSCLSTCIFPDKTTYPIDETMIHNGPPHNSNFGYSYAKRMI
DVQNRAYFQQYGCTFTAVIPTNVFGPHDNFNIEDGHVLPGLIHKVHLAKS
SGSALTVWGTGNPRRQFIYSLDLAQLFIWVLREYNEVEPIILSVGEEDEV
SIKEAAEAVVEAMDFHGEVTFDTTKSDGQFKKTASNSKLRTYLPDFRFTP
FKQAVKETCAWFTDNYEQARK
GenBank Accession No. NP_003304 (GenBank version
dated 10-DEC-2008)
mRNA sequence of human GDP-keto-6-deoxymannose
3,5-epimerase, 4-reductase (FX protein, tissue
specific transplantation antigen P35B)
(SEQ ID NO: 10)
ATGGGTGAACCCCAGGGATCCATGCGGATTCTAGTGACAGGGGGCTCTGG
GCTGGTAGGCAAAGCCATCCAGAAGGTGGTAGCAGATGGAGCTGGACTTC
CTGGAGAGGACTGGGTGTTTGTCTCCTCTAAAGACGCCGATCTCACGGAT
ACAGCACAGACCCGCGCCCTGTTTGAGAAGGTCCAACCCACACACGTCAT
CCATCTTGCTGCAATGGTGGGGGGCCTGTTCCGGAATATCAAATACAATT
TGGACTTCTGGAGGAAAAACGTGCACATGAACGACAACGTCCTGCACTCG
GCCTTTGAGGTGGGCGCCCGCAAGGTGGTGTCCTGCCTGTCCACCTGTAT
CTTCCCTGACAAGACGACCTACCCGATAGATGAGACCATGATCCACAATG
GGCCTCCCCACAACAGCAATTTTGGGTACTCGTATGCCAAGAGGATGATC
GACGTGCAGAACAGGGCCTACTTCCAGCAGTACGGCTGCACCTTCACCGC
TGTCATCCCCACCAACGTCTTCGGGCCCCACGACAACTTCAACATCGAGG
ATGGCCACGTGCTGCCTGGCCTCATCCACAAGGTGCACCTGGCCAAGAGC
AGCGGCTCGGCCCTGACGGTGTGGGGTACAGGGAATCCGCGGAGGCAGTT
CATATACTCGCTGGACCTGGCCCAGCTCTTTATCTGGGTCCTGCGGGAGT
ACAATGAAGTGGAGCCCATCATCCTCTCCGTGGGCGAGGAAGATGAGGTC
TCCATCAAGGAGGCAGCCGAGGCGGTGGTGGAGGCCATGGACTTCCATGG
GGAAGTCACCTTTGATACAACCAAGTCGGATGGGCAGTTTAAGAAGACAG
CCAGTAACAGCAAGCTGAGGACCTACCTGCCCGACTTCCGGTTCACACCC
TTCAAGCAGGCGGTGAAGGAGACCTGTGCTTGGTTCACTGACAACTACGA
GCAGGCCCGGAAGTGA
GenBank Accession No. NM_003313 (GenBank version
dated 10-DEC-2008)
Protein sequence of mouse GDP-keto-6-deoxymannose
3,5-epimerase, 4-reductase (FX protein, tissue
specific transplantation antigen P35B)
(SEQ ID NO: 11)
MGEPHGSMRILVTGGSGLVGRAIQKVVADGAGLPGEEWVFVSSKDADLTD
AAQTQALFQKVQPTHVIHLAAMVGGLFRNIKYNLDFWRKNVHINDNVLHS
AFEVGARKVVSCLSTCIFPDKTTYPIDETMIHNGPPHSSNFGYSYAKRMI
DVQNRAYFQQHGCTFTAVIPTNVFGPYDNFNIEDGHVLPGLIHKVHLAKS
SDSALTVWGTGKPRRQFIYSLDLARLFIWVLREYSEVEPIILSVGEEDEV
SIKEAAEAVVEAMDFNGEVTFDSTKSDGQYKKTASNGKLRSYLPDFRFTP
FKQAVKETCTWFTDNYEQARK
GenBank Accession No. NP_112478 (GenBank version
dated 10-MAY-2009)
mRNA sequence of mouse GDP-keto-6-deoxymannose
3,5-epimerase, 4-reductase (FX protein, tissue
specific transplantation antigen P35B)
(SEQ ID NO: 12)
ATGGGCGAACCCCATGGATCCATGAGGATCCTAGTGACAGGGGGCTCTGG
ACTGGTGGGTAGAGCCATCCAGAAGGTGGTTGCAGATGGGGCCGGCTTAC
CTGGAGAGGAATGGGTGTTTGTCTCCTCCAAAGATGCAGATCTGACGGAT
GCAGCCCAAACCCAAGCACTCTTCCAGAAAGTACAGCCCACCCACGTCAT
CCATCTCGCTGCAATGGTAGGCGGCCTTTTCCGGAATATCAAATACAACT
TGGATTTCTGGCGGAAAAACGTGCACATCAATGACAACGTCCTGCATTCG
GCCTTCGAGGTGGGCGCTCGCAAGGTGGTCTCCTGCCTGTCCACCTGCAT
CTTCCCTGACAAGACCACCTATCCTATTGACGAGACAATGATCCACAACG
GGCCGCCTCACAGCAGCAATTTCGGGTACTCATACGCCAAGAGGATGATT
GACGTGCAGAACAGAGCCTACTTCCAGCAGCACGGCTGTACCTTCACCGC
CGTCATCCCTACCAATGTCTTTGGGCCTTATGACAACTTCAACATCGAAG
ATGGCCACGTGCTACCCGGCCTCATCCATAAGGTGCACCTGGCCAAGAGT
AGTGACTCGGCCCTGACGGTGTGGGGTACAGGGAAGCCGCGGAGGCAGTT
CATCTACTCACTGGACCTCGCCCGGCTCTTCATCTGGGTCCTACGGGAGT
ACAGTGAGGTGGAGCCCATCATCCTCTCAGTGGGTGAGGAAGATGAAGTG
TCCATCAAGGAGGCAGCTGAGGCTGTAGTGGAGGCCATGGACTTCAATGG
GGAAGTCACTTTTGATTCAACAAAGTCAGATGGGCAATATAAGAAGACAG
CCAGCAATGGCAAGTTGCGGTCCTACTTGCCCGACTTCCGTTTCACACCC
TTCAAGCAGGCTGTGAAGGAAACCTGCACTTGGTTCACCGACAACTATGA
GCAGGCCCGGAAGTAA
GenBank Accession No. NM_031201 (GenBank version
dated 10-MAY-2009)
Protein sequence of rat GDP-keto-6-deoxymannose
3,5-epimerase, 4-reductase (FX protein, tissue
specific transplantation antigen P35B)
(SEQ ID NO: 13)
MGEPHGSMRILVTGGSGLVGRAIQKVVADGAGLPGEEWVFVSSKDADLTD
AAQTQALFQKVQPTHVIHLAAMVGGLFRNIKYNLDFWRKNVHINDNVLHS
AFEVGTRKVVSCLSTCIFPDKTTYPIDETMIHNGPPHSSNFGYSYAKRMI
DVQNRAYFQQHGCTFTSVIPTNVFGPYDNFNIEDGHVLPGLIHKVHLAKS
SGSALTVWGTGKPRRQFIYSLDLARLFIWVLREYNEVEPIILSVGEEDEV
SIKEAAEAVVEAMDFSGEVTFDSTKSDGQYKKTASNGKLRSYLPDFCFTP
FKQAVKETCAWFTENYEQARK
GenBank Accession No. NP_001120927 (GenBank
version dated 24-AUG-2008)
mRNA sequence of rat GDP-keto-6-deoxymannose 3,5-
epimerase, 4-reductase (FX protein, tissue
specific transplantation antigen P35B)
(SEQ ID NO: 14)
ATGGGTGAACCCCACGGATCCATGAGGATCCTAGTAACAGGGGGCTCTGG
ACTGGTGGGCAGAGCCATCCAGAAGGTGGTCGCAGATGGGGCCGGCTTGC
CTGGAGAGGAATGGGTGTTTGTCTCCTCCAAAGATGCAGATCTGACGGAT
GCAGCGCAAACCCAAGCTCTGTTCCAGAAGGTACAGCCCACCCACGTCAT
CCATCTTGCTGCAATGGTAGGCGGCCTTTTCCGGAATATTAAATACAACT
TGGATTTCTGGAGGAAGAACGTGCACATCAATGACAACGTCCTACATTCA
GCCTTCGAGGTGGGCACACGCAAGGTGGTCTCCTGCCTGTCCACCTGCAT
CTTCCCTGACAAGACCACCTATCCTATTGATGAGACCATGATCCACAACG
GGCCGCCTCACAGCAGCAATTTTGGGTACTCATATGCCAAGAGGATGATT
GACGTGCAGAACAGGGCCTACTTCCAGCAGCATGGCTGTACCTTCACCTC
TGTCATCCCTACCAATGTCTTTGGGCCTTACGACAACTTCAACATCGAAG
ATGGCCACGTGCTGCCGGGCCTCATCCATAAGGTGCACCTGGCCAAGAGC
AGTGGTTCAGCCTTGACTGTGTGGGGTACGGGGAAGCCGCGGAGACAGTT
CATCTACTCACTGGACCTAGCCCGGCTCTTCATCTGGGTCCTTCGGGAGT
ACAATGAGGTGGAGCCCATCATCCTCTCAGTGGGCGAGGAAGATGAAGTG
TCTATCAAGGAGGCAGCTGAGGCTGTGGTGGAGGCCATGGACTTCTCTGG
GGAAGTCACTTTTGATTCAACAAAGTCAGATGGGCAGTATAAGAAGACAG
CCAGCAATGGCAAGTTGCGGTCCTACTTGCCTGACTTCTGTTTCACACCC
TTCAAGCAGGCTGTGAAGGAAACTTGTGCTTGGTTCACTGAAAACTACGA
GCAGGCCCGGAAGTAA
GenBank Accession No. NM_001127455 (GenBank
version dated 24-AUG-2008)
Protein sequence of Chinese hamster GDP-keto-6-
deoxymannose 3,5-epimerase, 4-reductase
(SEQ ID NO: 15)
MGEPQGSRRILVTGGSGLVGRAIQKVVADGAGLPGEEWVFVSSKDADLTD
AAQTQALFQKVQPTHVIHLAAMVGGLFRNIKYNLDFWRKNVHINDNVLHS
AFEVGTRKVVSCLSTCIFPDKTTYPIDETMIHNGPPHSSNFGYSYAKRMI
DVQNRAYFQQHGCTFTAVIPTNVFGPHDNFNIEDGHVLPGLIHKVHLAKS
NGSALTVWGTGKPRRQFIYSLDLARLFIWVLREYNEVEPIILSVGEEDEV
SIKEAAEAVVEAMDFCGEVTFDSTKSDGQYKKTASNGKLRAYLPDFRFTP
FKQAVKETCAWFTDNYEQARK
GenBank Accession No. Q8K3X2 (GenBank version
dated 20-JAN-2009)
mRNA sequence of Chinese hamster GDP-keto-6-
deoxymannose 3,5-epimerase, 4-reductase (FX
protein)
(SEQ ID NO: 16)
ccggaagtagctcttggactggtggaaccctgcgcaggtgcagcaacaAT
GGGTGAGCCCCAGGGATCCAGGAGGATCCTAGTGACAGGGGGCTCTGGAC
TGGTGGGCAGAGCTATCCAGAAGGTGGTCGCAGATGGCGCTGGCTTACCC
GGAGAGGAATGGGTGTTTGTCTCCTCCAAAGATGCAGATCTGACGGATGC
AGCACAAACCCAAGCCCTGTTCCAGAAGGTACAGCCCACCCATGTCATCC
ATCTTGCTGCAATGGTAGGAGGCCTTTTCCGGAATATCAAATACAACTTG
GATTTCTGGAGGAAGAATGTGCACATCAATGACAACGTCCTGCACTCAGC
TTTCGAGGTGGGCACTCGCAAGGTGGTCTCCTGCCTGTCCACCTGTATCT
TCCCTGACAAGACCACCTATCCTATTGATGAAACAATGATCCACAATGGT
CCACCCCACAGCAGCAATTTTGGGTACTCGTATGCCAAGAGGATGATTGA
CGTGCAGAACAGGGCCTACTTCCAGCAGCATGGCTGCACCTTCACTGCTG
TCATCCCTACCAATGTCTTTGGACCTCATGACAACTTCAACATTGAAGAT
GGCCATGTGCTGCCTGGCCTCATCCATAAGGTGCATCTGGCCAAGAGTAA
TGGTTCAGCCTTGACTGTTTGGGGTACAGGGAAACCACGGAGGCAGTTCA
TCTACTCACTGGACCTAGCCCGGCTCTTCATCTGGGTCCTGCGGGAGTAC
AATGAAGTTGAGCCCATCATCCTCTCAGTGGGCGAGGAAGATGAAGTCTC
CATTAAGGAGGCAGCTGAGGCTGTAGTGGAGGCCATGGACTTCTGTGGGG
AAGTCACTTTTGATTCAACAAAGTCAGATGGGCAGTATAAGAAGACAGCC
AGCAATGGCAAGCTTCGGGCCTACTTGCCTGATTTCCGTTTCACACCCTT
CAAGCAGGCTGTGAAGGAGACCTGTGCCTGGTTCACCGACAACTATGAGC
AGGCCCGGAAGTGAagcatgggacaagcgggtgctcagctggcaatgccc
agtcagtaggctgcagtctcatcatttgcttgtcaagaactgaggacagt
atccagcaacctgagccacatgctggtctctctgccagggggcttcatgc
agccatccagtagggcccatgtttgtccatcctcgggggaaggccagacc
aacaccttgtttgtctgcttctgccccaacctcagtgcatccatgctggt
cctgctgtcccttgtctagaaaccaataaaatggattttcataaaaaaaa
aaaaaaaaaaa
GenBank Accession No. AF525365 (GenBank version
dated 04-AUG-2002)
Protein sequence of human GDP fucose pyrophos-
phorylase
(SEQ ID NO: 17)
MAAARDPPEVSLREATQRKLRRFSELRGKLVARGEFWDIVAITAADEKQE
LAYNQQLSEKLKRKELPLGVQYHVFVDPAGAKIGNGGSTLCALQCLEKLY
GDKWNSFTILLIHSGGYSQRLPNASALGKIFTALPLGNPIYQMLELKLAM
YIDFPLNMNPGILVTCADDIELYSIGEFEFIRFDKPGFTALAHPSSLTIG
TTHGVFVLDPFDDLKHRDLEYRSCHRFLHKPSIEKMYQFNAVCRPGNFCQ
QDFAGGDIADLKLDSDYVYTDSLFYMDHKSAKMLLAFYEKIGTLSCEIDA
YGDFLQALGPGATVEYTRNTSHVIKEESELVEMRQRIFHLLKGTSLNVVV
LNNSKFYHIGTTEEYLFYFTSDNSLKSELGLQSITFSIFPDIPECSGKTS
CIIQSILDSRCSVAPGSVVEYSRLGPDVSVGENCIISGSYILTKAALPAH
SFVCSLSLKMNRCLKYATMAFGVQDNLKKSVKTLSDIKLLQFFGVCFLSC
LDVWNLKVTEELFSGNKTCLSLWTARIFPVCSSLSDSVITSLKMLNAVKN
KSAFSLNSYKLLSIEEMLIYKDVEDMITYREQIFLEISLKSSLM
GenBank Accession No. AAC73005 (GenBank version
dated 12-NOV-1998)
mRNA sequence of human GDP fucose pyrophos-
phorylase
(SEQ ID NO: 18)
ATGGCAGCTGCTAGGGACCCTCCGGAAGTATCGCTGCGAGAAGCCACCCA
GCGAAAATTGCGGAGGTTTTCCGAGCTAAGAGGCAAACTTGTAGCACGTG
GAGAATTCTGGGACATAGTTGCAATAACAGCGGCTGATGAAAAACAGGA
ACTTGCTTACAACCAACAGCTGTCAGAAAAGCTGAAAAGAAAGGAGTTAC
CCCTTGGAGTTCAATATCACGTTTTTGTGGATCCTGCTGGAGCCAAAATT
GGAAATGGAGGATCAACACTTTGTGCCCTTCAATGTTTGGAAAAGCTATA
TGGAGATAAATGGAATTCTTTTACCATCTTATTAATTCACTCTGGTGGCT
ACAGTCAACGACTTCCAAATGCAAGTGCTCTGGGAAAAATTTTCACTGCT
TTACCTCTTGGTAACCCCATTTATCAGATGCTAGAATTAAAGCTAGCCAT
GTACATTGATTTCCCCTTAAATATGAATCCTGGAATTCTGGTTACCTGTG
CAGATGATATTGAACTTTATAGTATTGGAGAATTTGAGTTTATTAGGTTT
GACAAACCTGGCTTTACTGCTTTAGCTCATCCTTCTAGTTTGACGATAGG
TACCACACATGGAGTATTTGTCTTAGATCCTTTTGATGATTTAAAACATA
GAGACCTTGAATACAGGTCTTGCCATCGTTTCCTTCATAAGCCCAGCATA
GAAAAGATGTATCAGTTTAATGCTGTGTGTAGACCTGGAAATTTTTGTCA
ACAGGACTTTGCTGGGGGTGACATTGCCGATCTTAAATTAGACTCTGACT
ATGTCTACACAGATAGCCTATTTTATATGGATCATAAATCAGCAAAAATG
TTACTTGCTTTTTATGAAAAAATAGGCACACTGAGCTGTGAAATAGATGC
CTATGGTGACTTTCTGCAGGCTTTGGGACCTGGAGCAACTGTGGAGTACA
CCAGAAACACATCACATGTCATTAAAGAAGAGTCAGAGTTGGTAGAAATG
AGGCAGAGAATATTTCATCTTCTTAAAGGAACATCACTAAATGTTGTTGT
TCTTAATAACTCCAAATTTTATCACATTGGAACAACCGAAGAATATTTGT
TTTACTTTACCTCAGATAACAGTTTAAAGTCAGAGCTCGGCTTACAGTCC
ATAACTTTTAGTATCTTTCCAGATATACCAGAATGCTCTGGCAAAACATC
CTGTATCATTCAAAGCATACTGGATTCAAGATGTTCTGTGGCACCTGGCT
CAGTTGTGGAGTATTCCAGATTGGGGCCTGATGTTTCAGTTGGGGAAAAC
TGCATTATTAGTGGTTCTTACATCCTAACAAAAGCTGCCCTCCCCGCACA
TTCTTTTGTATGTTCCTTAAGCTTAAAGATGAATAGATGCTTAAAGTATG
CAACTATGGCATTTGGAGTGCAAGACAACTTGAAAAAGAGTGTGAAAACA
TTGTCAGATATAAAGTTACTTCAATTCTTTGGAGTCTGTTTCCTGTCATG
CTTAGATGTTTGGAATCTTAAAGTTACAGAGGAACTGTTCTCTGGTAACA
AGACATGTCTGAGTTTGTGGACTGCACGCATTTTCCCAGTTTGTTCTTCT
TTGAGTGACTCAGTTATAACATCCCTAAAGATGTTAAATGCTGTTAAGAA
CAAGTCAGCATTCAGCCTGAATAGCTATAAGTTGCTGTCCATTGAAGAAA
TGCTTATCTACAAAGATGTAGAAGATATGATAACTTACAGGGAACAAATT
TTTCTAGAAATCAGTTTAAAAAGCAGTTTGATGTAG
GenBank Accession No. AF017445 (GenBank version
dated 12-NOV-1998)
Protein sequence of mouse GDP fucose pyrophos-
phorylase (fucose-1-phosphate guanylyltransferase)
(SEQ ID NO: 19)
MASLREATLRKLRRFSELRGKPVAAGEFWDVVAITAADEKQELAYKQQLS
EKLKKRELPLGVQYHVFPDPAGTKIGNGGSTLCSLECLESLCGDKWNSLK
VLLIHSGGYSQRLPNASALGKIFTALPLGEPIYQMLELKLAMYVDFPSNM
RPGVLVTCADDIELYSVGDSEYIAFDQPGFTALAHPSSLAVGTTHGVFVL
HSDSSLQHGDLEYRQCYQFLHKPTIENMHRFNAVHRQRSFGQQNLSGGDT
DCLPLHTEYVYTDSLFYMDHKSAKKLLDFYKSEGPLNCEIDAYGDFLQAL
GPGATAEYTRNTSHVTKEESQLLDMRQKIFHLLKGTPLNVVVLNNSRFYH
IGTLQEYLLHFTSDSALKTELGLQSIAFSVSPSVPERSSGTACVIHSIVD
SGCCVAPGSVVEYSRLGPEVSIGENCIISSSVIAKTVVPAYSFLCSLSVK
INGHLKYSTMVFGMQDNLKNSVKTLEDIKALQFFGVCFLSCLDIWNLKAT
EKLFSGNKMNLSLWTACIFPVCSSLSESATASLGMLSAVRNHSPFNLSDF
NLLSIQEMLVYKDVQDMLAYREHIFLEISSNKNQSDLEKS
GenBank Accession No. NP_083606 (GenBank version
dated 10-FEB-2008)
mRNA sequence of mouse GDP fucose pyrophos-
phorylase (fucose-1-phosphate guanylyltransferase)
(SEQ ID NO: 20)
agtgtgctcccggaagtcggccATGGCGTCTCTCCGCGAAGCCACCCTGC
GGAAACTGCGCAGATTTTCTGAGCTGAGAGGCAAACCCGTGGCAGCTGGA
GAATTCTGGGATGTGGTTGCAATAACAGCAGCTGATGAAAAGCAGGAGCT
CGCTTACAAGCAACAGTTGTCCGAGAAGCTGAAGAAAAGGGAATTGCCTC
TTGGAGTTCAATACCATGTTTTTCCAGATCCTGCTGGGACCAAAATTGGA
AATGGAGGATCAACACTTTGTTCCCTTGAGTGTTTGGAAAGCCTCTGTGG
AGACAAATGGAATTCTCTGAAGGTCCTGCTAATCCACTCTGGTGGCTACA
GCCAACGCCTTCCCAATGCGAGTGCTTTAGGAAAGATCTTCACAGCCTTA
CCACTTGGTGAACCCATTTATCAGATGTTGGAGTTAAAACTAGCCATGTA
CGTGGATTTCCCCTCAAACATGAGGCCTGGAGTCTTGGTCACCTGTGCAG
ATGATATCGAACTCTACAGTGTTGGGGACAGTGAGTACATTGCCTTTGAC
CAGCCTGGCTTTACTGCCTTAGCCCATCCGTCTAGTCTGGCTGTAGGCAC
TACTCATGGAGTATTTGTCTTGCACTCTGACAGTTCCTTACAACATGGTG
ACCTTGAGTACAGGCAATGCTACCAATTCCTCCACAAGCCCACCATTGAA
AACATGCACCGCTTTAATGCTGTGCATAGACAACGAAGCTTTGGTCAACA
GAACTTGTCTGGAGGTGACACTGACTGTCTTCCATTGCACACTGAGTATG
TCTACACAGATAGCCTGTTTTACATGGATCACAAATCAGCCAAAAAGTTA
CTTGATTTCTATAAAAGTGAAGGCCCACTGAACTGTGAAATAGATGCCTA
TGGAGACTTTCTTCAGGCACTGGGGCCTGGAGCAACTGCAGAGTACACCA
GGAACACATCTCATGTCACTAAAGAAGAGTCCCAGTTGTTGGACATGAGG
CAGAAAATATTCCACCTCCTCAAGGGAACACCACTGAATGTTGTTGTTCT
TAATAACTCCAGATTTTATCACATTGGAACACTGCAAGAGTATCTGCTTC
ATTTCACCTCTGATAGTGCATTAAAGACGGAGCTGGGCTTACAATCCATA
GCTTTCAGTGTCTCTCCAAGTGTTCCTGAGCGCTCCAGTGGAACAGCCTG
TGTCATTCACAGTATAGTGGATTCAGGATGCTGTGTGGCCCCTGGCTCAG
TGGTAGAGTATTCTAGATTGGGGCCTGAGGTGTCCATCGGGGAAAACTGC
ATTATCAGCAGTTCTGTCATAGCAAAAACTGTTGTGCCAGCATATTCTTT
TTTGTGTTCTTTAAGTGTGAAGATAAATGGACACTTAAAATATTCTACTA
TGGTGTTTGGCATGCAAGACAACTTGAAGAACAGTGTTAAAACACTGGAA
GACATAAAGGCACTTCAGTTCTTTGGAGTCTGTTTTCTGTCTTGTTTAGA
CATTTGGAATCTTAAAGCTACAGAGAAACTATTCTCTGGAAATAAGATGA
ATCTGAGCCTGTGGACTGCATGCATTTTCCCTGTCTGTTCATCTCTGAGT
GAGTCGGCTACAGCATCCCTTGGGATGTTAAGCGCTGTAAGGAACCATTC
ACCATTCAACCTAAGTGACTTTAACCTTTTGTCCATCCAGGAAATGCTTG
TCTACAAAGATGTACAAGACATGCTAGCTTATAGGGAACACATTTTTCTA
GAAATTAGTTCAAATAAAAATCAATCTGATTTAGAGAAATCTTGAatata
ttttggccataaacaaaattgcaaatacaggcattttctatagacctctg
acatttttgtttgttttaataaagtaatataataaaaattatgttaatat
aactgttgtagcttggtaatgagaatggtacaactgaccacttctgctag
aagtacgttccaggactagagtcaggaaaggtcggctgttttagatgttt
acaccatcttacaattgtgctctttggtaaagatccatttatgggacact
gtttcattcacaaaataaatatttctgttttataggatgattttctaaac
ataacatatctttaaagcttttctatcttcttttgaaatttggaccaata
aaattctaggtgatatggaggattgtattgctcaacttctcatagtgaga
caacacgtaacaaaacattgttataaattcttagaagaaatgtcattatt
tgaggttttctttgaggactttgttctagttttattttatgtgtataaat
gtgttacctgcatgtatgcatgtgcaccacttgcctgcggcacccataga
ggctagaacagctgttctcaacatttgggttgggaccttttgtgggctca
aacaatcctttgaggggtaacctaagtccattggaaaacaaaatatttac
attatgattcataacagtagggaaattacagttaagtagcaacaaaaata
attttatatttggggtcactacagcatggggactgtattgaaaggatagc
agcatcaggaaggttaaaaactgccggtctagaagaaagcattgggtctc
ttggaactagagttatagatgcttagaacctccgtgttgcttctgtaagt
caacctccttagtcctatgaaagtgctatataatgatgtttgtgcctcat
tggtcttgccaaaatgatataaaagtatgtatggatgattttgttcttat
acactagaacatgtgttgccatatcttataaactatgtctactgatatat
tacactggtagctatgtacacacagaactcagttgtctgctcaggaggtg
gtagggatagttgagagccagtactcactcactatggaccttacttaatc
ctctcctagttaatccttctccaaatctcttaacttgacagtggacattt
gccttgcatcattggtggtagtgatgctgtgaacaaacaataggcccaaa
gagaggaaattcaaataggcaatctgaagaactactcaaatcataaacaa
ctgcagggaaatgaaatgggtggaattcctggttatgcgtacctattatg
aaataaacacattagtggaatgtccttaggttgaactgtaatagagttaa
attttatcatacttgtgtttaaaataccttaagtacattgtaatatctgc
tgtggcaactttaattctgtgtaagttttcataaaaatatatgataaaca
agatatctgtcaaaactcctttatattatttatataagaatatttgcctt
tttgaggtactagataataaagcaaagaatgtacgatactatatgacaat
tattggtaaagttacagagaattcaatggatgttaaatgttattaaatac
tcaagactaaagtcctatcaacgatgagaattatgatttcatgttccaag
aaaaaaatatcattaataaagaataccatcacttccttgtaaaaaaaaaa
aaaaaaaaaaaaaaaaaaaaaaaaaa
GenBank Accession No. NM_029330 (GenBank version
dated 10-FEB-2008)
Protein sequence of rat GDP fucose pyrophos-
phorylase (fucose-1-phosphate guanylyltransferase)
(SEQ ID NO: 21)
METLREATLRKLRRFSELRGKPVAAGEFWDVVAITAADEKQELAYKQQLS
EKLRRKELPLGVQYHVFPDPAGTKIGNGGSTLCSLQCLKSLYGDEWNSFK
VLLIHSGGYSQRLPNASALGKIFTALPLGEPIYQMLELKLAMYVDFPSHM
KPGVLVTCADDIELYSVGDCQYIAFDQPGFTALAHPSSLAVGTTHGVFVL
HSASSLQHGDLQYRQCHRFLHKPTIENMHQFNAVQRQGSFAQQDFPGGDT
ACLPLHTEYVYTDSLFYMDHKSAKKLLDFYKNVNQLNCEIDAYGDFLQAL
GPGATAEYTRNTSHVTKEDSQLLDMRQKIFHLLKGTPLNVVVLNNSRFYH
IGTTQEYLLHFTSDSTLRSRARLTVHSFQVSLQVSLNPPMKQPVSFTVYW
DSGCCVAPGSVVEYSRLGPEVSIGENCIVSSSVLANTAVPAYSFVCSLSV
RTNGLLEYSTMVFSVQDNLKGSVKTLEDIKALQFFGVCFLSCLDIWNLKA
TEKLFSGSKRNLSLWTARIFPVCPSLSESVTASLGMLSAVRSHSPFSLSN
FKLMSIQEMLVYKDVQDMLAYREQIFLEINSNKKQSDLEKS
GenBank Accession No. NP_955788 (GenBank version
dated 11-FEB-2008)
Protein sequence of rat GDP fucose pyrophos-
phorylase (fucose-1-phosphate guanylyltransferase)
(SEQ ID NO: 22)
ATGGAGACTCTCCGGGAAGCCACCCTGCGGAAACTGCGCAGATTTTCGGA
GCTGAGAGGCAAACCTGTGGCAGCTGGAGAATTCTGGGATGTGGTTGCGA
TAACAGCAGCCGATGAAAAGCAGGAGCTCGCTTACAAGCAGCAGTTGTCA
GAAAAGCTGAGAAGAAAGGAATTGCCTCTTGGAGTTCAATACCATGTTTT
TCCTGATCCTGCTGGGACCAAAATTGGAAATGGAGGATCGACACTTTGTT
CCCTTCAGTGCCTAAAAAGCCTCTATGGAGATGAATGGAATTCTTTCAAG
GTCCTGTTAATTCACTCCGGTGGCTACAGTCAACGCCTTCCCAATGCAAG
TGCTTTAGGAAAGATCTTCACAGCCTTACCACTTGGTGAACCCATCTATC
AGATGTTGGAGTTAAAACTAGCCATGTACGTGGATTTCCCCTCACACATG
AAGCCTGGAGTCTTGGTCACCTGTGCAGATGACATTGAACTGTACAGTGT
TGGGGACTGTCAGTACATTGCCTTTGACCAGCCTGGCTTTACTGCCTTAG
CCCATCCTTCCAGTCTGGCTGTAGGCACCACACACGGAGTATTTGTCTTG
CACTCTGCCAGTTCCTTACAACATGGTGACCTTCAGTACAGACAATGCCA
CCGTTTCCTCCACAAGCCCACCATTGAAAACATGCATCAGTTTAATGCTG
TGCAAAGACAAGGAAGCTTTGCTCAACAGGACTTCCCTGGAGGTGACACC
GCGTGTCTTCCATTGCACACTGAGTATGTCTACACAGATAGCCTGTTTTA
CATGGACCACAAATCGGCCAAAAAGTTACTTGATTTCTATAAAAATGTAA
ACCAACTGAACTGTGAAATAGATGCCTATGGTGACTTTCTGCAGGCACTG
GGGCCTGGAGCAACTGCAGAGTATACCAGGAACACATCACATGTCACTAA
AGAAGACTCCCAGTTGTTGGACATGAGGCAGAAAATATTCCACCTCCTCA
AGGGGACACCACTGAATGTTGTTGTTCTTAATAACTCCAGATTTTATCAC
ATTGGAACAACACAAGAATATCTGCTTCATTTCACGTCTGATAGTACGTT
AAGGTCAAGAGCTAGGCTTACAGTCCATAGCTTTCAAGTGTCTCTCCAAG
TATCCCTGAATCCTCCAATGAAACAGCCTGTATCATTCACAGTATACTGG
GATTCAGGATGCTGTGTGGCACCTGGCTCAGTTGTAGAGTATTCTAGACT
GGGGCCTGAGGTGTCCATTGGGGAAAACTGCATTGTCAGCAGCTCTGTCC
TAGCAAACACTGCTGTGCCGGCATATTCTTTTGTGTGTTCTCTAAGTGTG
AGGACAAATGGACTCTTGGAATATTCTACCATGGTGTTTAGTGTGCAGGA
CAACTTGAAAGGCAGTGTTAAAACCCTGGAAGATATAAAGGCACTTCAGT
TCTTTGGAGTCTGTTTCTTGTCTTGTTTAGACATCTGGAACCTTAAAGCT
ACAGAGAAACTGTTCTCTGGAAGTAAGAGGAACCTGAGCCTGTGGACTGC
ACGGATTTTCCCTGTCTGTCCTTCTCTGAGTGAGTCAGTTACAGCATCCC
TTGGGATGTTAAGTGCTGTAAGGAGCCATTCACCATTCAGCCTAAGCAAC
TTTAAGCTGATGTCCATCCAGGAAATGCTTGTCTACAAAGATGTACAAGA
CATGCTAGCTTATAGGGAGCAAATTTTTCTAGAAATTAATTCAAATAAAA
AACAATCTGATTTAGAGAAATCTTAA
GenBank Accession No. NM_199494 (GenBank version
dated 11-FEB-2008)
Protein sequence of human fucose kinase
(fucokinase)
(SEQ ID NO: 23)
MEQPKGVDWTVIILTCQYKDSVQVFQRELEVRQKREQIPAGTLLLAVEDP
EKRVGSGGATLNALLVAAEHLSARAGFTVVTSDVLHSAWILILHMGRDFP
FDDCGRAFTCLPVENPEAPVEALVCNLDCLLDIMTYRLGPGSPPGVWVCS
TDMLLSVPANPGISWDSFRGARVIALPGSPAYAQNHGVYLTDPQGLVLDI
YYQGTEAEIQRCVRPDGRVPLVSGVVFFSVETAERLLATHVSPPLDACTY
LGLDSGARPVQLSLFFDILHCMAENVTREDFLVGRPPELGQGDADVAGYL
QSARAQLWRELRDQPLTMAYVSSGSYSYMTSSASEFLLSLTLPGAPGAQI
VHSQVEEQQLLAAGSSVVSCLLEGPVQLGPGSVLQHCHLQGPIHIGAGCL
VTGLDTAHSKALHGRELRDLVLQGHHTRLHGSPGHAFTLVGRLDSWERQG
AGTYLNVPWSEFFKRTGVRAWDLWDPETLPAEYCLPSARLFPVLHPSREL
GPQDLLWMLDHQEDGGEALRAWRASWRLSWEQLQPCLDRAATLASRRDLF
FRQALHKARHVLEARQDLSLRPLIWAAVREGCPGPLLATLDQVAAGAGDP
GVAARALACVADVLGCMAEGRGGLRSGPAANPEWMRPFSYLECGDLAAGV
EALAQERDKWLSRPALLVRAARHYEGAGQILIRQAVMSAQHFVSTEQVEL
PGPGQWVVAECPARVDFSGGWSDTPPLAYELGGAVLGLAVRVDGRRPIGA
RARRIPEPELWLAVGPRQDEMTVKIVCRCLADLRDYCQPHAPGALLKAAF
ICAGIVHVHSELQLSEQLLRTFGGGFELHTWSELPHGSGLGTSSILAGTA
LAALQRAAGRVVGTEALIHAVLHLEQVLTTGGGWQDQVGGLMPGIKVGRS
RAQLPLKVEVEEVTVPEGFVQKLNDHLLLVYTGKTRLARNLLQDVLRSWY
ARLPAVVQNAHSLVRQTEECAEGFRQGSLPLLGQCLTSYWEQKKLMAPGC
EPLTVRRMMDVLAPHVHGQSLAGAGGGGFLYLLTKEPQQKEALEAVLAKT
EGLGNYSIHLVEVDTQGLSLKLLGTEASTCCPFP
GenBank Accession No. NP_659496 (GenBank version
dated 22-OCT-2008)
mRNA sequence of human fucose kinase (fucokinase)
(SEQ ID NO: 24)
ATGGAGCAGCCGAAGGGAGTTGATTGGACAGTCATCATCCTGACCTGCCA
GTACAAGGACAGTGTCCAGGTCTTTCAGAGAGAACTGGAAGTGCGGCAGA
AGCGGGAGCAGATCCCTGCTGGGACGCTGTTACTGGCCGTGGAGGACCCA
GAGAAGCGTGTGGGCAGCGGAGGAGCCACCCTCAACGCCCTGCTGGTGGC
TGCTGAACACCTGAGTGCCCGGGCAGGCTTCACTGTGGTCACATCCGATG
TCCTGCACTCGGCCTGGATCCTCATTCTGCACATGGGTCGAGACTTCCCC
TTTGATGACTGTGGCAGGGCTTTCACCTGCCTCCCCGTGGAGAACCCCGA
GGCCCCCGTGGAAGCCTTGGTCTGCAACCTGGACTGCCTGCTGGACATCA
TGACCTATCGGCTGGGCCCGGGCTCCCCGCCAGGCGTGTGGGTCTGCAGC
ACCGACATGCTGCTGTCTGTTCCTGCAAATCCTGGTATCAGCTGGGACAG
CTTCCGGGGAGCCAGAGTGATCGCCCTCCCAGGGAGCCCGGCCTACGCTC
AGAATCATGGCGTCTACCTAACTGACCCCCAGGGCCTTGTTTTGGACATT
TACTACCAGGGCACTGAGGCAGAGATTCAGCGGTGTGTCAGGCCTGATGG
GCGGGTGCCACTGGTCTCTGGGGTTGTCTTCTTCTCTGTGGAGACTGCCG
AGCGCCTCCTAGCCACCCACGTGAGCCCGCCCCTGGATGCCTGCACCTAC
CTAGGCTTGGACTCCGGAGCCCGGCCTGTCCAGCTGTCTCTGTTTTTTGA
CATTCTCCACTGCATGGCTGAGAACGTGACCAGGGAGGACTTCCTGGTGG
GGAGGCCCCCAGAGTTGGGGCAAGGCGATGCAGATGTAGCGGGTTATCTG
CAGAGCGCCCGGGCCCAGCTGTGGAGGGAGCTTCGCGATCAGCCCCTTAC
CATGGCCTATGTCTCCAGCGGCAGCTACAGCTACATGACCTCCTCAGCCA
GTGAGTTCCTGCTCAGCCTCACACTCCCCGGGGCTCCTGGGGCCCAGATT
GTGCACTCCCAGGTGGAGGAGCAGCAGCTTCTGGCGGCCGGGAGCTCTGT
GGTCAGCTGCCTGCTGGAGGGCCCTGTCCAGCTGGGTCCTGGGAGCGTCC
TGCAGCACTGCCACCTGCAGGGCCCCATTCACATAGGCGCTGGCTGCTTG
GTGACTGGCCTGGATACAGCCCACTCCAAGGCCCTGCATGGCCGGGAGCT
GCGTGACCTTGTCCTGCAGGGACACCACACGCGGCTACACGGCTCCCCGG
GCCACGCCTTCACCCTCGTTGGCCGTCTGGACAGCTGGGAGAGACAGGGG
GCAGGCACATATCTCAACGTGCCCTGGAGTGAATTCTTCAAGAGGACAGG
TGTTCGAGCCTGGGACCTGTGGGACCCTGAGACGCTGCCCGCAGAGTACT
GCCTTCCCAGCGCCCGCCTCTTTCCTGTGCTCCACCCCTCGAGGGAGCTG
GGACCCCAGGACCTGCTGTGGATGCTGGACCACCAGGAGGATGGGGGCGA
GGCCCTGCGAGCCTGGCGGGCCTCCTGGCGCCTGTCCTGGGAGCAGCTGC
AGCCGTGCCTGGATCGGGCTGCCACGCTGGCCTCTCGCCGGGACCTGTTC
TTCCGCCAGGCCCTGCATAAGGCGCGGCACGTGCTGGAGGCCCGGCAGGA
CCTCAGCCTGCGCCCGCTGATCTGGGCTGCTGTCCGCGAGGGCTGCCCCG
GGCCCCTGCTGGCCACGCTGGACCAGGTTGCAGCTGGGGCAGGAGACCCT
GGTGTGGCGGCACGGGCACTGGCCTGTGTGGCGGACGTCCTGGGCTGCAT
GGCAGAGGGCCGTGGGGGCTTGCGGAGCGGGCCAGCTGCCAACCCTGAGT
GGATGCGGCCCTTCTCATACCTGGAGTGTGGAGACCTGGCAGCGGGCGTG
GAGGCGCTTGCCCAGGAGAGGGACAAGTGGCTAAGCAGGCCAGCCTTGCT
GGTGCGAGCGGCCCGCCACTATGAGGGGGCTGGTCAGATCCTGATCCGCC
AGGCTGTGATGTCAGCCCAGCACTTTGTCTCCACAGAGCAGGTGGAACTG
CCGGGACCTGGGCAGTGGGTGGTGGCTGAGTGCCCGGCCCGTGTGGATTT
CTCTGGGGGCTGGAGTGACACGCCACCCCTTGCCTATGAGCTTGGCGGGG
CTGTGCTGGGCCTGGCTGTGCGAGTGGACGGCCGCCGGCCCATCGGAGCC
AGGGCACGCCGCATCCCGGAGCCTGAGCTGTGGCTGGCGGTGGGGCCTCG
GCAGGATGAGATGACTGTGAAGATAGTGTGCCGGTGCCTGGCTGACCTGC
GGGACTACTGCCAGCCTCATGCCCCAGGGGCCCTGCTGAAGGCGGCCTTC
ATCTGTGCAGGGATCGTGCATGTCCACTCGGAACTCCAGCTGAGTGAGCA
GCTGCTCCGCACCTTCGGGGGCGGCTTTGAGCTGCACACCTGGTCTGAGC
TGCCCCACGGCTCTGGCCTGGGCACCAGCAGCATCCTGGCAGGCACTGCC
CTGGCTGCCTTGCAGCGAGCCGCAGGCCGGGTGGTGGGCACGGAAGCCCT
GATCCACGCAGTGCTGCACCTGGAGCAGGTGCTCACCACTGGAGGTGGCT
GGCAGGACCAAGTAGGTGGCCTAATGCCTGGCATCAAGGTGGGGCGCTCC
CGGGCTCAGCTGCCACTGAAGGTGGAGGTAGAAGAGGTCACGGTGCCTGA
GGGCTTTGTCCAGAAGCTCAATGACCACCTGCTCTTGGTGTACACTGGCA
AGACCCGCCTGGCTCGGAACCTGCTGCAGGATGTGCTGAGGAGCTGGTAT
GCCCGACTTCCTGCTGTGGTGCAGAATGCCCACAGCCTGGTACGGCAAAC
TGAGGAGTGTGCTGAAGGCTTCCGCCAAGGAAGCCTGCCTCTGCTGGGCC
AGTGCCTGACCTCGTACTGGGAGCAGAAGAAGCTCATGGCTCCAGGCTGT
GAGCCCCTGACTGTGCGGCGTATGATGGATGTCCTGGCCCCCCACGTGCA
TGGCCAGAGCCTGGCTGGGGCAGGCGGTGGAGGCTTTCTCTATCTGTTGA
CCAAGGAGCCACAGCAAAAGGAGGCCTTGGAGGCGGTGCTGGCCAAGACC
GAGGGCCTTGGGAATTACAGCATCCACCTGGTTGAAGTGGACACTCAGGG
CCTGAGCCTGAAGCTGCTGGGGACCGAGGCCTCAACCTGTTGCCCTTTCC
CATGA
GenBank Accession No. NM_145059 (GenBank version
dated 22-OCT-2008)
Protein sequence of mouse fucose kinase
(fucokinase)
(SEQ ID NO: 25)
MEQSEGVNWTVIILTCQYKDSVQVFQRELEVRQRREQIPAGTMLLAVEDP
QTRVGSGGATLNALLVAAEHLSARAGFTVVTSDVLHSAWILILHMGRDFP
FDDCGRAFTCLPVENPQAPVEALVCNLDCLLDIMTHRLGPGSPPGVWVCS
TDMLLSVPPNPGISWDGFRGARVIAFPGSLAYALNHGVYLTDSQGLVLDI
YYQGTKAEIQRCVGPDGLVPLVSGVVFFSVETAEHLLATHVSPPLDACTY
MGLDSGAQPVQLSLFFDILLCMARNMSRENFLAGRPPELGQGDMDVASYL
KGARAQLWRELRDQPLTMVYVPDGGYSYMTTDATEFLHRLTMPGVAVAQI
VHSQVEEPQLLEATCSVVSCLLEGPVHLGPRSVLQHCHLRGPIRIGAGCF
VSGLDTAHSEALHGLELHDVILQGHHVRLHGSLSRVFTLAGRLDSWERQG
AGMYLNMSWNEFFKKTGIRDWDLWDPDTPPSDRCLLTARLFPVLHPTRAL
GPQDVLWMLHPRKHRGEALRAWRASWRLSWEQLQPCVDRAATLDFRRDLF
FCQALQKARHVLEARQDLCLRPLIRAAVGEGCSGPLLATLDKVAAGAEDP
GVAARALACVADVLGCMAEGRGGLRSGPAANPEWIQPFSYLECGDLMRGV
EALAQEREKWLTRPALLVRAARHYEGAEQILIRQAVMTARHFVSTQPVEL
PAPGQWVVTECPARVDFSGGWSDTPPIAYELGGAVLGLAVRVDGRRPIGA
KARRIPEPELWLAVGPRQDEMTMRIVCRSLDDLRDYCQPHAPGALLKAAF
ICAGIVHLHSELPLLEQLLHSFNGGFELHTWSELPHGSGLGTSSILAGAA
LAALQRAAGRAVGTEALIHAVLHLEQVLTTGGGWQDQVSGLMPGIKVGRS
RAQLPLKVEVEEITVPEGFVQKINDHLLLVYTGKTRLARNLLQDVLRNWY
ARLPVVVQNARRLVRQTEKCAEAFRQGNLPLLGQYLTSYWEQKKLMAPGC
EPLAVQRMMDVLAPYAYGQSLAGAGGGGFLYLLTKEPRQKETLEAVLAKA
EGLGNYSVHLVEVDPQGLSLQLLGHDTRLCGAGPSEVGTT
GenBank Accession No. NP_758487 (GenBank version
dated 05-AUG-2008)
mRNA sequence of mouse fucose kinase (fucokinase)
(SEQ ID NO: 26)
ATGGAGCAGTCAGAGGGAGTCAATTGGACTGTCATTATCCTGACATGCCA
GTACAAGGACAGTGTCCAGGTCTTTCAGAGAGAGCTGGAGGTAAGGCAG
AGACGGGAGCAGATTCCTGCGGGGACGATGTTACTGGCTGTGGAGGATCC
CCAGACTCGAGTCGGCAGCGGAGGAGCCACCCTCAACGCACTGCTGGTGG
CTGCTGAACACTTGAGTGCCCGAGCTGGCTTCACTGTGGTCACGTCCGAT
GTCCTGCACTCTGCCTGGATCCTCATCTTGCACATGGGCCGAGACTTCCC
CTTCGATGACTGTGGCAGGGCCTTCACTTGCCTCCCTGTGGAGAACCCAC
AGGCCCCTGTGGAGGCCTTGGTATGCAACCTGGACTGCCTGTTGGATATC
ATGACCCACCGGCTGGGTCCAGGTTCCCCACCAGGTGTGTGGGTCTGCAG
CACCGACATGCTTCTGTCTGTTCCTCCAAACCCTGGGATCAGTTGGGATG
GCTTCCGGGGAGCCAGAGTGATCGCCTTTCCTGGGAGCCTGGCCTATGCG
TTGAACCACGGTGTCTACCTCACTGACTCACAGGGCTTGGTTTTGGACAT
TTACTACCAGGGCACTAAGGCGGAGATACAACGTTGTGTCGGACCTGATG
GGCTGGTACCATTGGTCTCCGGGGTCGTCTTCTTCTCTGTGGAGACTGCT
GAGCACCTCCTAGCCACCCATGTGAGCCCACCGCTGGATGCCTGCACCTA
TATGGGCTTGGACTCTGGAGCCCAGCCTGTGCAGCTGTCTCTGTTTTTCG
ACATCCTGCTCTGCATGGCTCGGAATATGAGCAGGGAGAACTTCCTGGCT
GGGCGGCCCCCGGAGTTGGGGCAAGGTGACATGGATGTAGCAAGTTACCT
GAAGGGAGCCCGGGCCCAGCTGTGGAGGGAGCTTCGAGATCAGCCCCTCA
CAATGGTGTATGTCCCTGACGGCGGCTACAGCTACATGACGACTGATGCC
ACCGAGTTCCTGCACAGACTCACGATGCCTGGAGTAGCTGTGGCACAGAT
TGTTCACTCCCAGGTGGAGGAGCCACAGCTGCTAGAGGCTACGTGCTCGG
TGGTCAGCTGCCTGCTCGAGGGCCCTGTGCACCTGGGGCCTCGAAGTGTC
CTGCAGCACTGTCACCTGAGGGGCCCCATTCGCATCGGCGCTGGCTGCTT
TGTGAGTGGTCTGGATACAGCCCACTCGGAGGCACTGCATGGCCTGGAGC
TCCATGATGTCATCCTGCAGGGACACCATGTGCGGCTGCATGGCTCCCTG
AGCCGTGTATTTACTCTTGCTGGCCGTCTGGACAGCTGGGAAAGACAGGG
GGCAGGCATGTATCTCAACATGTCCTGGAATGAGTTCTTCAAGAAGACAG
GCATTCGAGACTGGGACCTGTGGGACCCAGATACACCCCCCTCAGATCGA
TGCCTCCTCACTGCCCGCCTTTTCCCTGTGCTCCACCCCACGAGGGCCCT
GGGGCCCCAGGATGTGCTGTGGATGCTGCACCCCCGCAAACACAGAGGTG
AGGCCCTTCGGGCCTGGCGAGCCTCCTGGCGTCTGTCCTGGGAGCAGCTG
CAACCTTGTGTGGACCGGGCTGCCACACTGGACTTCCGCCGAGATCTGTT
CTTCTGCCAGGCCTTGCAGAAGGCAAGGCATGTGTTAGAGGCGCGGCAGG
ACCTCTGCCTACGTCCACTGATCCGGGCCGCTGTCGGGGAAGGTTGCTCT
GGGCCCCTGCTGGCCACACTTGACAAGGTTGCAGCTGGGGCAGAAGATCC
TGGCGTGGCAGCCCGGGCTCTGGCTTGTGTGGCCGATGTGCTGGGCTGCA
TGGCAGAGGGCCGAGGAGGCTTGCGCAGTGGGCCAGCTGCCAACCCTGAG
TGGATTCAGCCTTTCTCATACTTGGAGTGTGGAGACCTGATGAGGGGTGT
GGAGGCGCTTGCCCAGGAGAGAGAGAAGTGGCTGACCAGGCCTGCCTTGC
TGGTTCGAGCTGCCCGCCATTACGAGGGGGCCGAGCAGATCCTGATCCGC
CAGGCTGTGATGACAGCCCGGCACTTCGTCTCCACCCAGCCCGTGGAGCT
GCCCGCACCCGGGCAGTGGGTGGTGACTGAGTGCCCAGCCCGTGTGGATT
TCTCTGGGGGCTGGAGTGACACACCGCCCATTGCCTATGAGCTTGGTGGA
GCAGTGTTGGGCCTGGCTGTGCGGGTGGATGGCCGCCGGCCCATCGGGGC
CAAAGCACGCCGCATCCCGGAGCCTGAGCTCTGGCTGGCAGTGGGACCTC
GGCAGGATGAGATGACCATGAGGATAGTGTGCCGGAGCCTGGATGACCTG
CGGGATTACTGCCAGCCTCATGCCCCAGGGGCCTTGCTGAAGGCAGCCTT
TATCTGTGCTGGCATTGTGCATCTCCACTCAGAGCTCCCTCTGCTTGAAC
AGTTGTTACACTCCTTTAATGGTGGCTTTGAGCTGCACACGTGGTCAGAG
CTGCCGCACGGCTCTGGTCTTGGCACCAGCAGCATCCTGGCAGGGGCTGC
CCTGGCTGCCTTACAGCGGGCTGCAGGCCGGGCAGTGGGCACGGAGGCTC
TCATCCACGCAGTGCTGCACCTGGAGCAGGTGCTCACCACAGGAGGTGGC
TGGCAGGACCAAGTCAGTGGCCTAATGCCTGGCATCAAAGTGGGGCGCTC
CCGGGCCCAGCTGCCCCTCAAGGTGGAGGTGGAGGAAATCACTGTGCCTG
AGGGCTTTGTCCAGAAGATCAATGACCATCTGCTCCTGGTTTATACCGGC
AAGACCCGATTGGCCCGGAATCTGCTGCAGGACGTGCTGAGGAACTGGTA
CGCTCGGTTGCCCGTTGTGGTACAGAATGCCCGCAGACTGGTGCGACAGA
CCGAGAAGTGCGCTGAAGCTTTCCGCCAAGGAAACCTGCCTCTGCTGGGA
CAGTACCTGACCTCATACTGGGAGCAGAAGAAGCTTATGGCCCCAGGCTG
CGAGCCGCTGGCCGTGCAGCGAATGATGGATGTCCTGGCCCCGTATGCGT
ATGGCCAAAGCCTGGCAGGGGCAGGTGGTGGGGGCTTTCTCTATCTATTG
ACCAAGGAACCCCGGCAGAAAGAGACTCTGGAAGCTGTCCTGGCCAAGGC
TGAGGGCCTTGGCAACTACAGTGTCCACCTGGTGGAAGTGGATCCTCAGG
GCCTGAGCCTGCAGCTGCTGGGACACGACACCCGTCTTTGTGGGGCCGGG
CCCTCTGAAGTGGGCACCACCTAG
GenBank Accession No. NM_172283 (GenBank version
dated 05-AUG-2008)
Protein sequence of rat fucose kinase (fucokinase)
(SEQ ID NO: 27)
MDQPKGVNWTVIILTCQYKDSVQVFQRELEVRQKREQIPAGTMLLAVEDP
QTRVGSGGATLNALLVAAEHLSARAGFTVVTSDVLHSAWILILHMGRDFP
FDDCGRAFTCLPVENPQAPVEALVCNLDCLLDIMTHRLGPGSPPGVWVCS
TDMLLSVPPNPGISWDGFRGTRVIAFPGSLAYALNHGVYLTDSQGVVLDI
YYQGTKAEIQRCVRPDGLVPLVSGVVFFSVETAEHLLATHVSPPLDACTY
MGLDSGAQPVQLSLFFDILLCMARNMSRENFVAGRPPEMGQGDPDVARYL
KGARAQLWRELRDQPLTMVYVPDGGYSYMTTDATEFLHRLTMPGVAVAQI
VHSQVEEPQLLEATCSVVSCLLEGPVHLGPRSVLQHCHLRGPIHIGAGCF
VSGLDTAHSEALHGLELHDLILQGHHIRLHGSQSRVFTLAGRLDSWERQG
AGMYLNMSWNEFFKKTGIRDWDLWDPDTPLSDRCLLSARLFPVLHPTRAL
GPQDVLWMLHPHKDRGEALRAWRASWRLSWEQLQPRLDRAATLDFRRDLF
FRQALQKARHVLEARQDLCLHPLIRAAVGEGCSGPLLATLDKVAAGAEDP
GVAARALACVADVLGCMAEGQGGLRSGPAANPEWIQPFSYLERGDLMRGV
EALAQEREKWLTRPALLVRAARHYEGAEQILIRQAVMTARHFVSTQPVEL
PAPGQWVVTECPARVDFSGGWSDTPPIAYELGGAVLGLAVRVDGRRPIGA
KARRILEPELWLAVGPRQDEMTVKIVCRSLDDLQDYCQPHAPGALLKAAF
ICADIVHVNSEVPLHEQLLRSFNGGFELHTWSELPHGSGLGTSSILAGAA
LAALQRAAGRTVGTEALIHAVLHLEQVLTTGGGWQDQVSGLMPGIKVGRS
RAQLPLKVEVEEITVPENFVQRKLMAPGCEPLAVHRMMDVLAPYAFGQSL
AGAGGGGFLYLLTKEPRQKEVLEAVLAKVEGLGNYSVHLVQVDTQGLSLQ
LLGHDAHLCGAGPSEVGNT
GenBank Accession No. NP_001100899 (GenBank
version dated 05-AUG-2008)
mRNA sequence of rat fucose kinase (fucokinase)
(SEQ ID NO: 28)
ATGGACCAGCCAAAGGGGGTCAATTGGACGGTCATTATCCTGACATGCCA
GTACAAGGACAGTGTCCAGGTCTTTCAGAGAGAGCTGGAGGTAAGGCAG
AAGCGGGAGCAGATCCCTGCCGGGACGATGTTACTGGCTGTGGAGGACCC
CCAGACCCGAGTAGGCAGTGGAGGAGCTACTCTCAATGCACTGCTGGTGG
CTGCTGAGCACCTGAGTGCCCGAGCTGGCTTCACCGTGGTCACGTCAGAT
GTCCTGCACTCGGCTTGGATTCTCATCTTGCACATGGGCCGAGACTTCCC
CTTTGATGACTGTGGCAGGGCCTTCACTTGCCTCCCTGTGGAGAATCCAC
AGGCCCCTGTGGAGGCCTTGGTATGCAACCTGGACTGCCTGTTGGATATC
ATGACCCACCGGCTGGGTCCAGGATCCCCACCAGGTGTGTGGGTCTGCAG
CACCGACATGCTTCTGTCTGTTCCTCCAAACCCTGGGATCAGTTGGGATG
GCTTCCGGGGAACCAGAGTGATCGCCTTTCCTGGGAGCCTGGCCTACGCT
CTAAACCACGGGGTCTACCTCACTGACTCGCAGGGCGTGGTTTTGGACAT
TTACTACCAGGGCACTAAGGCAGAGATACAACGGTGTGTCAGGCCTGATG
GACTGGTACCACTGGTCTCTGGGGTTGTCTTCTTCTCTGTGGAGACTGCT
GAGCACCTCCTAGCCACCCACGTGAGCCCACCGCTGGACGCCTGCACCTA
TATGGGCTTGGACTCTGGAGCCCAGCCTGTGCAGCTGTCTCTGTTTTTCG
ACATCCTGCTCTGCATGGCTCGGAATATGAGCAGGGAGAACTTCGTGGCT
GGGCGGCCCCCGGAGATGGGGCAAGGTGACCCGGATGTAGCACGTTACCT
GAAGGGAGCCCGGGCCCAGCTGTGGAGGGAGCTTCGAGATCAGCCCCTCA
CTATGGTGTATGTCCCTGATGGCGGTTACAGTTACATGACAACTGATGCC
ACGGAGTTCCTGCACAGACTCACGATGCCTGGAGTAGCTGTGGCCCAGAT
TGTTCACTCTCAGGTGGAGGAGCCACAGCTGCTAGAGGCTACGTGCTCCG
TGGTCAGCTGCCTGCTGGAGGGTCCCGTGCACCTGGGGCCTCGAAGTGTC
CTGCAGCACTGTCACCTGAGGGGCCCCATTCATATTGGCGCTGGCTGCTT
TGTGAGTGGCCTGGATACCGCCCACTCCGAGGCACTGCATGGCCTGGAGC
TTCATGACCTCATCCTTCAGGGACACCACATACGGCTGCATGGCTCCCAG
AGTCGTGTATTCACTCTTGCTGGCCGTCTGGACAGCTGGGAAAGACAGGG
GGCAGGCATGTATCTCAACATGTCCTGGAATGAGTTCTTCAAGAAGACAG
GCATTCGAGACTGGGACCTGTGGGACCCAGATACACCCCTCTCAGATCGA
TGCCTTCTCAGTGCCCGCCTTTTCCCTGTGCTCCACCCCACGAGGGCTCT
GGGGCCCCAGGATGTGCTGTGGATGCTGCATCCTCATAAGGACAGAGGCG
AGGCCCTGCGTGCCTGGAGAGCCTCCTGGCGTCTGTCCTGGGAGCAGCTG
CAACCTCGCCTGGACCGGGCTGCCACACTGGACTTCCGTCGGGATCTGTT
CTTCCGCCAGGCCTTGCAGAAGGCGAGGCATGTGTTAGAGGCCCGGCAGG
ACCTCTGCCTACATCCACTGATCCGGGCTGCTGTCGGTGAAGGTTGCTCT
GGGCCCCTGCTGGCCACACTTGACAAGGTTGCAGCAGGGGCAGAAGATCC
TGGTGTGGCAGCCCGGGCTCTGGCTTGTGTGGCAGATGTACTCGGCTGCA
TGGCAGAGGGCCAAGGAGGCTTGCGCAGTGGGCCAGCTGCCAACCCTGAG
TGGATTCAGCCTTTCTCATACTTGGAACGTGGAGACCTCATGAGGGGTGT
GGAGGCACTTGCCCAGGAAAGAGAGAAGTGGCTGACCAGGCCTGCCTTGT
TGGTTCGAGCTGCCCGCCATTATGAGGGGGCTGAGCAGATCCTGATCCGA
CAGGCTGTGATGACAGCCCGGCACTTCGTCTCCACCCAGCCAGTGGAATT
GCCAGCACCTGGGCAGTGGGTGGTGACTGAGTGCCCAGCCCGTGTGGATT
TCTCTGGGGGCTGGAGTGACACACCACCCATTGCCTATGAGCTTGGTGGA
GCAGTATTGGGCCTGGCTGTTCGGGTGGATGGCCGCCGGCCCATCGGGGC
CAAGGCACGCCGCATCCTAGAGCCTGAGCTCTGGCTGGCAGTGGGACCTC
GACAGGATGAGATGACCGTGAAGATAGTGTGCCGGAGCCTTGATGACCTG
CAGGATTACTGCCAGCCTCATGCCCCAGGTGCCTTGCTGAAGGCAGCCTT
TATCTGTGCGGATATTGTGCATGTCAACTCAGAGGTCCCTCTGCATGAAC
AGTTGCTACGCTCGTTTAATGGTGGCTTTGAGCTGCACACATGGTCAGAG
CTGCCACACGGCTCTGGTCTTGGCACTAGCAGCATCTTGGCAGGGGCTGC
CCTGGCTGCTTTGCAGCGGGCTGCAGGCCGGACAGTGGGCACAGAGGCTC
TCATCCATGCAGTGTTGCACCTGGAGCAGGTGCTCACCACAGGAGGTGGC
TGGCAGGACCAAGTGAGTGGCCTAATGCCTGGCATCAAGGTGGGGCGCTC
TCGGGCACAGCTGCCCCTAAAGGTGGAGGTGGAGGAAATCACTGTGCCTG
AGAACTTTGTCCAGAGGAAGCTTATGGCCCCAGGCTGTGAGCCGCTGGCT
GTGCATCGGATGATGGATGTCCTGGCCCCTTATGCCTTCGGCCAAAGTCT
GGCAGGGGCAGGCGGTGGGGGCTTTCTCTATCTGTTGACCAAGGAACCCC
GGCAGAAAGAGGTCCTAGAAGCTGTGCTGGCCAAGGTGGAGGGCCTCGGC
AACTACAGCGTCCACCTGGTGCAAGTGGACACTCAGGGCCTGAGCCTGCA
GCTGCTAGGACATGACGCCCATCTTTGCGGGGCTGGGCCCTCTGAAGTGG
GCAACACCTAG
GenBank Accession No. NP_001100899 (GenBank
version dated 05-AUG-2008)
Fucosyltransferases
[0533] Fucosylated glycans are synthesized by fucosyltransferases, using GDP-fucose as the activated sugar-nucleotide donor. Thirteen fucosyltransferase genes have thus far been identified in the human genome, and include FUT8, FUT4, FUT7, FUT3 and FUT9. FUT8 is an α(1,6)-fucosyltransferase that directs addition of fucose to asparagine-linked GlcNAc moieties, resulting in core fucosylation.
[0000]
Protein sequence of human fucosyltransferase 8 (α(1,6)-fucosyltransferase)
(SEQ ID NO: 29)
MAITVSLVNNKRKIVVLAQPTTVKRKRITPYKSIMTDLYYLSQTDGAGDWRE
KEAKDLTELVQRRITYLQNPKDCSKAKKLVCNINKGCGYGCQLHHVVYCFM
IAYGTQRTLILESQNWRYATGGWETVFRPVSETCTDRSGISTGHWSGEVKDK
NVQVVELPIVDSLHPRPPYLPLAVPEDLADRLVRVHGDPAVWWVSQFVKYLI
RPQPWLEKEIEEATKKLGFKHPVIGVHVRRTDKVGTEAAFHPIEEYMVHVEE
HFQLLARRMQVDKKRVYLATDDPSLLKEAKTKYPNYEFISDNSISWSAGLHN
RYTENSLRGVILDIHFLSQADFLVCTFSSQVCRVAYEIMQTLHPDASANFHSL
DDIYYFGGQNAHNQIAIYAHQPRTADEIPMEPGDIIGVAGNHWDGYSKGVNR
KLGRTGLYPSYKVREKIETVKYPTYPEAEK
GenBank Accession No. NP_004480 (GenBank version dated 22 OCT. 2008)
mRNA sequence of human fucosyltransferase 8 (α1,6)-fucosyltransferase)
(SEQ ID NO: 30)
ggccgacccgagcagccggttccctcctctccaggccccctccccatcccacccccgccgcctggccccagccgaccc
gtcccttcgtctccccgcggaatggggccggcactgctcagggtcgcgcgccctggacccagctcgctctcggtctcgcg
ctgtcagcgactgcccggctcgcgccgcctcgcgctctgcctcagtcagtggcgccgaaggctccgttaagcggcggcg
gcggttcctgtttccgtttcttcctctccgttcggtcgggagtagcatcctccactcagccacccttcccactcccccatcgtgg
ggcagctgcggctgagggctgtggctttggcagctgcgacggggagcggcggagaccgcctctgctcccgcctggggt
tgctgcttttgctcagaggacatccatgaccctaatggtctttttgttcaagataaagtgattttttgcctttgttgattaactggac
aaattcaggataccagaaggccctattgatcaggggccagctataggaagagtacgcgttttagaagagcagcttgttaag
gccaaagaacagattgaaaattacaagaaacagaccagaaatggtctggggaaggatcatgaaatcctgaggaggagga
ttgaaaatggagctaaagagctctggtttttcctacagagtgaattgaagaaattaaagaacttagaaggaaatgaactccaa
agacatgcagatgaatttcttttggatttaggacatcatgaaaggattctgatggcaattactgtctcattagtgaacaataaaa
gaaaaattgttgtattagcacaacctactactgtgaagaggaaaagaattaccccatacaagtctataatgacggatctatact
acctcagtcagacagatggagcaggtgattggcgggaaaaagaggccaaagatctgacagaactggttcagcggagaat
aacatatcttcagaatcccaaggactgcagcaaagccaaaaagctggtgtgtaatatcaacaaaggctgtggctatggctgt
cagctccatcatgtggtctactgcttcatgattgcatatggcacccagcgaacactcatcttggaatctcagaattggcgctat
gctactggtggatgggagactgtatttaggcctgtaagtgagacatgcacagacagatctggcatctccactggacactggt
caggtgaagtgaaggacaaaaatgttcaagtggtcgagcttcccattgtagacagtcttcatccccgtcctccatatttaccct
tggctgtaccagaagacctcgcagatcgacttgtacgagtgcatggtgaccctgcagtgtggtgggtgtctcagtttgtcaa
atacttgatccgcccacagccttggctagaaaaagaaatagaagaagccaccaagaagcttggcttcaaacatccagttatt
ggagtccatgtcagacgcacagacaaagtgggaacagaagctgccttccatcccattgaagagtacatggtgcatgttgaa
gaacattttcagcttcttgcacgcagaatgcaagtggacaaaaaaagagtgtatttggccacagatgacccttctttattaaag
gaggcaaaaacaaagtaccccaattatgaatttattagtgataactctatttcctggtcagctggactgcacaatcgatacaca
gaaaattcacttcgtggagtgatcctggatatacattttctctctcaggcagacttcctagtgtgtactttttcatcccaggtctgt
cgagttgcttatgaaattatgcaaacactacatcctgatgcctctgcaaacttccattctttagatgacatctactattttggggg
ccagaatgcccacaatcaaattgccatttatgctcaccaaccccgaactgcagatgaaattcccatggaacctggagatatc
attggtgtggctggaaatcattgggatggctattctaaaggtgtcaacaggaaattgggaaggacgggcctatatccctccta
caaagttcgagagaagatagaaacggtcaagtaccccacatatcctgaggctgagaaataaagctcagatggaagagata
aacgaccaaactcagttcgaccaaactcagttcaaaccatttcagccaaactgtagatgaagagggctctgatctaacaaaa
taaggttatatgagtagatactctcagcaccaagagcagctgggaactgacataggcttcaattggtggaattcctctttaaca
agggctgcaatgccctcatacccatgcacagtacaataatgtactcacatataacatgcaaacaggttgttttctactttgccc
ctttcagtatgtccccataagacaaacactgccatattgtgtaatttaagtgacacagacattttgtgtgagacttaaaacatggt
gcctatatctgagagacctgtgtgaactattgagaagatcggaacagctccttactctgaggaagttgattcttatttgatggtg
gtattgtgaccactgaattcactccagtcaacagattcagaatgagaatggacgtttggtttttttttgtttttgtttttgttttttccttt
ataaggttgtctgtttttttttttttaaataattgcatcagttcattgacctcatcattaataagtgaagaatacatcagaaaataaaat
attcactctccattagaaaattttgtaaaacaatgccatgaacaaattctttagtactcaatgtttctggacattctctttgataaca
aaaaataaattttaaaaaggaattttgtaaagtttctagaattttatatcattggatgatatgttgatcagccttatgtggaagaact
gtgataaaaagaggagctttttagtttttcagcttaaaaaaa
GenBank Accession No. NP_004480 (GenBank version dated 22 OCT. 2008)
Protein sequence of rat fucosyltransferase 8 (α1,6)-fucosyltransferase)
(SEQ ID NO: 31)
MRAWTGSWRWIMLILFAWGTLLFYIGGHLVRDNDHPDHSSRELSKILAKLER
LKQQNEDLRRMAESLR1PEGPIDQGTATGRVRVLEEQLVKAKEQIENYKKQA
RNGLGKDHELLRRRIENGAKELWFFLQSELKKLKHLEGNELQRHADEILLDL
GHHERSIMTDLYYLSQTDGAGDWREKEAKDLTELVQRRITYLQNPKDCSKA
RKLVCNINKGCGYGCQLHHVVYCFMIAYGTQRTLILESQNWRYATGGWETV
FRPVSETCTDRSGLSTGHWSGEVNDKNIQVVELPIVDSLHPRPPYLPLAVPEDL
ADRLVRVHGDPAVWWVSQFVKYLIRPQPWLEKEIEEATKKLGFKHPVIGVH
VRRTDKVGTEAAFHPIEEYMVHVEEHFQLLARRMQVDKKRVYLATDDPALL
KEAKTKYSNYEFISDNSISWSAGLHNRYTENSLRGVILDIHFLSQADFLVCTFS
SQVCRVAYEIMQTLHPDASANFHSLDDIYYFGGQNAHNQIAVYPHKPRTDEEI
PMEPGDIIGVAGNHWDGYSKGVNRKLGKTGLYPSYKVREKIETVKYPTYPEA
EK
GenBank Accession No. NP_001002289 (GenBank version dated 5 OCT. 2008)
mRNA sequence of rat fucosyltransferase 8 (α1,6)-fucosyltransferase)
(SEQ ID NO: 32)
atgcgggcatggactggttcctggcgttggattatgctcattctttttgcctgggggaccttgttgttttatataggtggtcatttg
gttcgagataatgaccaccctgatcactctagcagagaactctccaagattcttgcaaagcttgaacgcttaaaacaacaaaa
tgaagacttgaggcgaatggctgagtctctacgaataccagaaggccccattgaccaggggacggctacgggaagagtc
cgtgttttagaagaacagcttgttaaggccaaagaacagattgaaaattacaagaaacaagccagaaatggtctggggaag
gatcatgaactcttaaggaggaggattgaaaatggagctaaagagctctggttttttctacaaagtgaactgaagaaattaaa
gcatctagaaggaaatgaactccaaagacatgcagatgaaattcttttggatttaggacaccatgaaaggtctatcatgacgg
atctatactacctcagtcaaacagatggagcaggggattggcgtgaaaaagaggccaaagatctgacagagctggtccag
cggagaataacttatctccagaatcccaaggactgcagcaaagccaggaagctggtgtgtaacatcaataagggctgtgg
ctatggttgccaactccatcacgtggtctactgtttcatgattgcttatggcacccagcgaacactcatcttggaatctcagaatt
ggcgctatgctactggtggatgggagactgtgtttagacctgtaagtgagacatgcacagacagatctggcctctccactgg
acactggtcaggtgaagtgaatgacaaaaatattcaagtggtggagctccccattgtagacagcctccatcctcggcctcctt
acttaccactggctgttccagaagaccttgcagatcgactcgtaagagtccatggtgatcctgcagtgtggtgggtgtccca
gttcgtcaaatatttgattcgtccacaaccttggctagaaaaggaaatagaagaagccaccaagaagcttggcttcaaacatc
cagtcattggagtccatgtcagacgcacagacaaagtgggaacagaggcagccttccatcccatcgaagagtacatggta
catgttgaagaacattttcagcttctcgcacgcagaatgcaagtggataaaaaaagagtatatctggctaccgatgaccctgc
tttgttaaaggaggcaaagacaaagtactccaattatgaatttattagtgataactctatttcttggtcagctggattacacaatc
ggtacacagaaaattcacttcggggcgtgatcctggatatacactttctctctcaggctgacttcctagtgtgtactttttcatcc
caggtctgtcgggttgcttatgaaatcatgcaaaccctgcatcctgatgcctctgcaaacttccactctttagatgacatctact
attttggaggccaaaatgcccacaaccagattgccgtttatcctcacaaacctcgaactgatgaggaaattccaatggaacct
ggagatatcattggtgtggctggaaaccattgggatggttattctaaaggtgtcaacagaaaacttggaaaaacaggcttata
tccctcctacaaagtccgagagaagatagaaacagtcaagtatcccacatatcctgaagctgaaaaatag
GenBank Accession No. NM_001002289 (GenBank version dated 5 OCT. 2008)
Protein sequence of mouse fucosyltransferase 8 (α1,6)-fucosyltransferase)
(SEQ ID NO: 33)
MRAWTGSWRWIMLILFAWGTLLFYIGGHLVRDNDHPDHSSRELSKILAKLER
LKQQNEDLRRMAESLR1PEGPIDQGTATGRVRVLEEQLVKAKEQIENYKKQA
RNGLGKDHEILRRRIENGAKELWFFLQSELKKLKHLEGNELQRHADEILLDLG
HHERSIMTDLYYLSQTDGAGDWREKEAKDLTELVQRRITYLQNPKDCSKAR
KLVCNINKGCGYGCQLHHVVYCFMIAYGTQRTLILESQNWRYATGGWETVF
RPVSETCTDRSGLSTGHWSGEVNDKNIQVVELPIVDSLHPRPPYLPLAVPEDL
ADRLLRVHGDPAVWWVSQFVKYLIRPQPWLEKEIEEATKKLGFKHPVIGVHV
RRTDKVGTEAAFHPIEEYMVHVEEHFQLLARRMQVDKKRVYLATDDPTLLK
EAKTKYSNYEFISDNSISWSAGLHNRYTENSLRGVILDIHFLSQADFLVCTFSS
QVCRVAYEIMQTLHPDASANFHSLDDIYYFGGQNAHNQIAVYPHKPRTEEEIP
MEPGDIIGVAGNHWDGYSKGINRKLGKTGLYPSYKVREKIETVKYPTYPEAE
K
GenBank Accession No. NP_058589 (GenBank version dated 04 JAN. 2009)
mRNA sequence of mouse fucosyltransferase 8 (A1,6)-fucosyltransferase)
(SEQ ID NO: 34)
atgcgggcatggactggttcctggcgttggattatgctcattctttttgcctgggggaccttgttattttatataggtggtcatttg
gttcgagataatgaccaccctgatcactccagcagagaactctccaagattcttgcaaagcttgaacgcttaaaacagcaaa
atgaagacttgaggcgaatggctgagtctctccgaataccagaaggccccattgaccaggggacagctacaggaagagt
ccgtgttttagaagaacagcttgttaaggccaaagaacagattgaaaattacaagaaacaagctagaaatggtctggggaa
ggatcatgaaatcttaagaaggaggattgaaaatggagctaaagagctctggttttttctacaaagcgaactgaagaaattaa
agcatttagaaggaaatgaactccaaagacatgcagatgaaattcttttggatttaggacaccatgaaaggtctatcatgaca
gatctatactacctcagtcaaacagatggagcaggggattggcgtgaaaaagaggccaaagatctgacagagctggtcca
gcggagaataacatatctccagaatcctaaggactgcagcaaagccaggaagctggtgtgtaacatcaataaaggctgtg
gctatggttgtcaactccatcacgtggtctactgtttcatgattgcttatggcacccagcgaacactcatcttggaatctcagaa
ttggcgctatgctactggtggatgggagactgtgtttagacctgtaagtgagacatgtacagacagatctggcctctccactg
gacactggtcaggtgaagtaaatgacaaaaacattcaagtggtcgagctccccattgtagacagcctccatcctcggcctcc
ttacttaccactggctgttccagaagaccttgcagaccgactcctaagagtccatggtgaccctgcagtgtggtgggtgtccc
agtttgtcaaatacttgattcgtccacaaccttggctggaaaaggaaatagaagaagccaccaagaagcttggcttcaaaca
tccagttattggagtccatgtcagacgcacagacaaagtgggaacagaagcagccttccaccccatcgaggagtacatgg
tacacgttgaagaacattttcagcttctcgcacgcagaatgcaagtggataaaaaaagagtatatctggctactgatgatccta
ctttgttaaaggaggcaaagacaaagtactccaattatgaatttattagtgataactctatttcttggtcagctggactacacaat
cggtacacagaaaattcacttcggggtgtgatcctggatatacactttctctcacaggctgactttctagtgtgtactttttcatcc
caggtctgtcgggttgcttatgaaatcatgcaaaccctgcatcctgatgcctctgcgaacttccattctttggatgacatctact
attttggaggccaaaatgcccacaatcagattgctgtttatcctcacaaacctcgaactgaagaggaaattccaatggaacct
ggagatatcattggtgtggctggaaaccattgggatggttattctaaaggtatcaacagaaaacttggaaaaacaggcttata
tccctcctacaaagtccgagagaagatagaaacagtcaagtatcccacatatcctgaagctgaaaaatag
GenBank Accession No. NM_016893 (GenBank version dated 04 JAN. 2009)
GDP-Fucose Transporters
[0534] Fucosylated glycans are synthesized by fucosyltransferases in the Golgi apparatus, while GDP-fucose is synthesized in the cytosol. Thus, GDP-fucose must be translocated to the Golgi by a GDP-fucose transporter, such as GDP-fucose transporter 1 (FUCT1).
[0000]
Protein sequence of human GDP-fucose transporter 1
(FUCT1)
(SEQ ID NO: 35)
MNRAPLKRSRILHMALTGASDPSAEAEANGEKPFLLRALQIALVVSLYW
VTSISMVFLNKYLLDSPSLRLDTPIFVTFYQCLVTTLLCKGLSALAACC
PGAVDFPSLRLDLRVARSVLPLSVVFIGMITFNNLCLKYVGVAFYNVGR
SLTTVFNVLLSYLLLKQTTSFYALLTCGIIIGGFWLGVDQEGAEGTLSW
LGTVFGVLASLCVSLNAIYTTKVLPAVDGSIWRLTFYNNVNACILFLPL
LLLLGELQALRDFAQLGSAHFWGMMTLGGLFGFAIGYVTGLQIKFTSPL
THNVSGTAKACAQTVLAVLYYEETKSFLWWTSNMMVLGGSSAYTWVRGW
EMKKTPEEPSPKDSEKSAMGV
GenBank Accession No. NP_060859 (GenBank version
dated 27 FEB. 2009)
mRNA sequence of human GDP-fucose transporter 1
(FUCT1)
(SEQ ID NO: 36)
ATGAATAGGGCCCCTCTGAAGCGGTCCAGGATCCTGCACATGGCGCTGA
CCGGGGCCTCAGACCCCTCTGCAGAGGCAGAGGCCAACGGGGAGAAGCC
CTTTCTGCTGCGGGCATTGCAGATCGCGCTGGTGGTCTCCCTCTACTGG
GTCACCTCCATCTCCATGGTGTTCCTTAATAAGTACCTGCTGGACAGCC
CCTCCCTGCGGCTGGACACCCCCATCTTCGTCACCTTCTACCAGTGCCT
GGTGACCACGCTGCTGTGCAAAGGCCTCAGCGCTCTGGCCGCCTGCTGC
CCTGGTGCCGTGGACTTCCCCAGCTTGCGCCTGGACCTCAGGGTGGCCC
GCAGCGTCCTGCCCCTGTCGGTGGTCTTCATCGGCATGATCACCTTCAA
TAACCTCTGCCTCAAGTACGTCGGTGTGGCCTTCTACAATGTGGGCCGC
TCACTCACCACCGTCTTCAACGTGCTGCTCTCCTACCTGCTGCTCAAGC
AGACCACCTCCTTCTATGCCCTGCTCACCTGCGGTATCATCATCGGGGG
CTTCTGGCTTGGTGTGGACCAGGAGGGGGCAGAAGGCACCCTGTCGTGG
CTGGGCACCGTCTTCGGCGTGCTGGCTAGCCTCTGTGTCTCGCTCAACG
CCATCTACACCACGAAGGTGCTCCCGGCGGTGGACGGCAGCATCTGGCG
CCTGACTTTCTACAACAACGTCAACGCCTGCATCCTCTTCCTGCCCCTG
CTCCTGCTGCTCGGGGAGCTTCAGGCCCTGCGTGACTTTGCCCAGCTGG
GCAGTGCCCACTTCTGGGGGATGATGACGCTGGGCGGCCTGTTTGGCTT
TGCCATCGGCTACGTGACAGGACTGCAGATCAAGTTCACCAGTCCGCTG
ACCCACAATGTGTCGGGCACGGCCAAGGCCTGTGCCCAGACAGTGCTGG
CCGTGCTCTACTACGAGGAGACCAAGAGCTTCCTCTGGTGGACGAGCAA
CATGATGGTGCTGGGCGGCTCCTCCGCCTACACCTGGGTCAGGGGCTGG
GAGATGAAGAAGACTCCGGAGGAGCCCAGCCCCAAAGACAGCGAGAAGA
GCGCCATGGGGGTGTGA
GenBank Accession No. NM_018389 (GenBank version
dated 27 FEB. 2009)
Protein sequence of mouse GDP-fucose transporter 1
(FUCT1)
(SEQ ID NO: 37)
MNRAPLKRSRILRMALTGVSAVSEESESGNKPFLLRALQIALVVSSLYW
VTSISMVFLNKYLLDSPSLQLDTPIFVTFYQCLVTSLLCKGLSTLATCC
PGMVDFPTLNLDLKVARSVLPLSVVFIGMITFNNLCLKYVGVPFYNVGR
SLTTVFNVLLSYLLLKQTTSFYALLTCGVIIGGFWLGIDQEGAEGTLSL
TGTIFGVLASLCVSLNAIYTKKVLPAVDHSIWRLTFYNNVNACVLFLPL
MIVLGELRALLAFTHLSSAHFWLMMTLGGLFGFAIGYVTGLQIKFTSPL
THNVSGTAKACAQTVLAVLYYEEIKSFLWWTSNLMVLGGSSAYTWVRGW
EMQKTQEDPSSKDGEKSAIRV
GenBank Accession No. NP_997597 (GenBank version
dated 21-SEP-2008)
mRNA sequence of mouse GDP-fucose transporter 1
(FUCT1)
(SEQ ID NO: 38)
ATGAACAGGGCGCCTCTGAAGCGGTCCAGGATCCTGCGCATGGCGCTGA
CTGGAGTCTCTGCTGTCTCCGAGGAGTCAGAGAGCGGGAACAAGCCATT
TCTGCTCCGGGCTCTGCAGATCGCGCTGGTGGTCTCTCTCTACTGGGTC
ACCTCCATTTCCATGGTATTCCTCAACAAGTACCTGCTGGACAGCCCCT
CCCTGCAGCTGGATACCCCCATTTTTGTCACCTTCTACCAATGCCTGGT
GACCTCACTGCTGTGCAAGGGCCTCAGCACTCTGGCCACCTGCTGCCCC
GGCATGGTAGACTTCCCCACCCTAAACCTGGACCTCAAGGTGGCCCGAA
GTGTGCTGCCGCTGTCAGTGGTCTTTATCGGCATGATAACCTTCAATAA
CCTCTGCCTCAAGTACGTAGGGGTGCCCTTCTACAACGTGGGACGCTCG
CTCACCACCGTGTTCAACGTTCTTCTCTCCTACCTGCTGCTCAAACAGA
CCACTTCCTTCTATGCCCTGCTCACCTGCGGCGTCATCATTGGTGGTTT
CTGGCTGGGTATAGACCAAGAAGGAGCTGAGGGAACCTTGTCCCTGACG
GGCACCATCTTCGGGGTGCTGGCCAGCCTCTGCGTCTCCCTCAATGCCA
TCTATACCAAGAAGGTGCTCCCTGCAGTAGACCACAGTATCTGGCGCCT
AACCTTCTATAACAATGTCAATGCCTGCGTGCTCTTCTTGCCCCTGATG
ATAGTGCTGGGCGAGCTCCGTGCCCTCCTGGCCTTCACTCATCTGAGCA
GTGCCCACTTCTGGCTCATGATGACGCTGGGTGGCCTGTTTGGCTTTGC
CATCGGCTATGTGACAGGACTGCAGATCAAATTCACCAGTCCCCTGACC
CATAACGTGTCAGGCACGGCCAAGGCCTGTGCACAGACAGTGCTGGCCG
TGCTCTACTACGAAGAGATTAAGAGCTTCCTGTGGTGGACAAGCAACCT
GATGGTGCTGGGTGGCTCCTCCGCCTACACCTGGGTCAGGGGCTGGGAG
ATGCAGAAGACCCAGGAGGACCCCAGCTCCAAAGATGGTGAGAAGAGTG
CTATCAGGGTGTGA
GenBank Accession No. NM_211358 (GenBank version
dated 21 SEP. 2008)
Protein sequence of rat GDP-fucose transporter 1
(FUCT1)
(SEQ ID NO: 39)
MNRVPLKRSRILRMALTGASAVSEEADSENKPFLLRALQIALVVSLYWV
TSISMVFLNKYLLDSPSLQLDTPIFVTFYQCLVTSLLCKGLSTLATCCP
GMVDFPTLNLDLKVARSVLPLSVVFIGMITFNNLCLKYVGVAFYNVGRS
LTTVFNVLLSYLLLKQTTSFYALLTCAIIIGGFWLGIDQEGAEGTLSLT
GTIFGVLASLCVSLNAIYTKKVLPAVDHSIWRLTFYNNVNACVLFLPLM
VVLGELHALLAFAHLNSAHFWVMMTLGGLFGFAIGYVTGLQIKFTSPLT
HNVSGTAKACAQTVLAVLYYEEIKSFLWWTSNLMVLGGSSAYTWVRGWE
MQKTQEDPSSKEGEKSAIGV
GenBank Accession No. NP_001101218 (GenBank
version dated 18 FEB. 2009)
mRNA sequence of rat GDP-fucose transporter 1
(FUCT1)
(SEQ ID NO: 40)
ATGAACAGGGTCCCTCTGAAGCGGTCCAGGATCCTGCGCATGGCGCTGA
CTGGAGCCTCTGCTGTCTCTGAGGAGGCAGACAGCGAGAACAAGCCATT
TCTGCTACGGGCTCTGCAGATCGCGCTGGTGGTTTCTCTCTACTGGGTC
ACCTCCATCTCCATGGTATTCCTCAACAAGTACCTGCTGGACAGCCCCT
CCCTGCAGCTGGATACCCCCATCTTCGTCACCTTCTACCAATGCCTGGT
GACCTCACTGCTGTGCAAGGGCCTCAGCACTCTGGCCACCTGCTGCCCT
GGCATGGTAGACTTCCCCACCCTAAACCTGGACCTCAAGGTGGCCCGAA
GTGTGCTGCCGCTGTCCGTGGTCTTTATCGGCATGATAACCTTCAATAA
CCTCTGCCTCAAGTACGTGGGGGTGGCCTTCTACAACGTGGGACGCTCG
CTCACTACCGTGTTCAATGTGCTTCTCTCCTACCTGCTGCTTAAACAGA
CCACTTCCTTTTATGCCCTGCTCACCTGTGCCATCATCATTGGTGGTTT
CTGGCTGGGAATAGATCAAGAGGGAGCTGAGGGCACCCTGTCCCTGACG
GGCACCATCTTCGGGGTGCTGGCCAGCCTCTGTGTCTCACTCAATGCCA
TCTACACCAAGAAGGTGCTCCCTGCCGTAGACCACAGTATCTGGCGCCT
AACCTTCTATAACAACGTCAACGCCTGTGTGCTCTTCTTGCCCCTGATG
GTAGTGCTGGGCGAGCTCCATGCTCTCCTGGCCTTCGCTCATCTGAACA
GCGCCCACTTCTGGGTCATGATGACGCTGGGTGGACTCTTCGGCTTTGC
CATTGGCTATGTGACAGGACTGCAGATCAAATTCACCAGTCCCCTGACC
CATAATGTGTCGGGCACAGCCAAGGCCTGTGCACAGACAGTGCTGGCTG
TGCTCTACTATGAAGAGATTAAGAGCTTCCTGTGGTGGACAAGCAACTT
GATGGTGCTGGGTGGCTCCTCTGCCTACACCTGGGTCAGGGGCTGGGAG
ATGCAGAAGACCCAGGAGGACCCCAGCTCCAAAGAGGGTGAGAAGAGTG
CTATCGGGGTGTGA
GenBank Accession No. NM_001107748 (GenBank
version dated 18 FEB. 2009)
Protein sequence of Chinese hamster GDP-fucose
transporter 1 (FUCT1)
(SEQ ID NO: 41)
MNRAPLKRSRILRMALTGGSTASEEADEDSRNKPFLLRALQIALVVSLY
WVTSISMVFLNKYLLDSPSLQLDTPIFVTFYQCLVTSLLCKGLSTLATC
CPGTVDFPTLNLDLKVARSVLPLSVVFIGMISFNNLCLKYVGVAFYNVG
RSLTTVFNVLLSYLLLKQTTSFYALLTCGIIIGGFWLGIDQEGAEGTLS
LIGTIFGVLASLCVSLNAIYTKKVLPAVDNSIWRLTFYNNVNACVLFLP
LMVLLGELRALLDFAHLYSAHFWLMMTLGGLFGFAIGYVTGLQIKFTSP
LTHNVSGTAKACAQTVLAVLYYEETKSFLWWTSNLMVLGGSSAYTWVRG
WEMQKTQEDPSSKEGEKSAIRV
GenBank Accession No. BAE16173 (GenBank version
dated 12 SEP. 2008)
mRNA sequence of Chinese hamster GDP-fucose
transporter 1 (FUCT1)
(SEQ ID NO: 42)
ATGAACAGGGCGCCTCTGAAGCGGTCCAGGATCCTGCGCATGGCGCTGA
CTGGAGGCTCCACTGCCTCTGAGGAGGCAGATGAGGACAGCAGGAACAA
GCCGTTTCTGCTGCGGGCGCTGCAGATCGCGCTGGTCGTCTCTCTCTAC
TGGGTCACCTCCATCTCCATGGTATTCCTCAACAAGTACCTGCTGGACA
GCCCCTCCCTGCAGCTGGATACCCCTATCTTCGTCACTTTCTACCAATG
CCTGGTGACCTCTCTGCTGTGCAAGGGCCTCAGCACTCTGGCCACCTGC
TGCCCTGGCACCGTTGACTTCCCCACCCTGAACCTGGACCTTAAGGTGG
CCCGCAGCGTGCTGCCACTGTCGGTAGTCTTCATTGGCATGATAAGTTT
CAATAACCTCTGCCTCAAGTACGTAGGGGTGGCCTTCTACAACGTGGGG
CGCTCGCTCACCACCGTGTTCAATGTGCTTCTGTCCTACCTGCTGCTCA
AACAGACCACTTCCTTCTATGCCCTGCTCACATGTGGCATCATCATTGG
TGGTTTCTGGCTGGGTATAGACCAAGAGGGAGCTGAGGGCACCCTGTCC
CTCATAGGCACCATCTTCGGGGTGCTGGCCAGCCTCTGCGTCTCCCTCA
ATGCCATCTATACCAAGAAGGTGCTCCCAGCAGTGGACAACAGCATCTG
GCGCCTAACCTTCTATAACAATGTCAATGCCTGTGTGCTCTTCTTGCCC
CTGATGGTTCTGCTGGGTGAGCTCCGTGCCCTCCTTGACTTTGCTCATC
TGTACAGTGCCCACTTCTGGCTCATGATGACGCTGGGTGGCCTCTTCGG
CTTTGCCATTGGCTATGTGACAGGACTGCAGATCAAATTCACCAGTCCC
CTGACCCACAATGTATCAGGCACAGCCAAGGCCTGTGCGCAGACAGTGC
TGGCCGTGCTCTACTATGAAGAGACTAAGAGCTTCCTGTGGTGGACAAG
CAACCTGATGGTGCTGGGTGGCTCCTCAGCCTATACCTGGGTCAGGGGC
TGGGAGATGCAGAAGACCCAAGAGGACCCCAGCTCCAAAGAGGGTGAGA
AGAGTGCTATCAGGGTGTGA
GenBank Accession No. AB222037 (GenBank version
dated 12 SEP. 2008)
[0535] Proteins or nucleic acids used in the methods and cells described herein (e.g., GMD, FX, GFPP, fucose kinase, GDP-fucose synthetase, a fucosyltransferase or a GDP-fucose transporter) include mammalian (e.g., human, mouse, rat or hamster) proteins. A protein, nucleic acid or cell can be a primate (e.g., human) protein, nucleic acid or cell. In other embodiments the protein, nucleic acid or cell is a rodent (e.g., a mouse, rat or hamster) protein, nucleic acid or cell.
[0536] A protein sequence, e.g., a protein encoding sequence, can be used to decrease the protein expression in a cell. For example, a decrease in protein expression can be achieved by inactivating the endogenous gene, e.g., in the control or structural regions. A cloned sequence can be used to make a construct that will insert a deletion or other event into an endogenous gene to decrease levels of the protein it expresses.
[0537] The expression of endogenous protein can be decreased by the use of a genetic construct from the same species as the endogenous protein, or from a different species. For example, the expression of an endogenous protein in a mouse cell can be modulated with a construct made from mouse protein or with one made from a protein sequence from another species, e.g., a different rodent species. The protein of a rodent, e.g., a hamster, such as a Chinese hamster, can be manipulated with an allogeneic sequence (from the same species) or a xenogeneic sequence (from a different species). For example, a CHO cell can be manipulated with a Chinese hamster, mouse or rat sequence.
[0538] A nucleic acid sequence from one of the proteins disclosed herein can be used to isolate a gene from a different species. For example, a mouse or rat sequence described herein can be used to make primers to isolate a sequence from another rodent, e.g., a hamster, e.g., a Chinese hamster. That sequence can them be used to modify protein expression in a cell, e.g., in a Chinese hamster cell, such as a CHO cell.
Manipulations
[0539] As described above, a manipulation, as used herein, refers to a property of a cell. Examples of manipulations include the presence in or on the cell of an exogenous inhibitor of an enzyme involved in the biosynthesis of GDP-fucose, or a nucleic acid antagonist (e.g., an siRNA)
[0540] A manipulated cell can be, e.g., a vertebrate, mammalian or rodent cell. Primers or other nucleic acids used, e.g., to form or make manipulations, can be, e.g., vertebrate, mammalian or rodent sequences. For example, a rodent primer or other nucleic acid, e.g., a nucleic acid encoding an active or inactivate rodent GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, a fucosyltransferase or GDP-fucose transporter protein, can be used to manipulate a rodent cell. Similarly, a mammalian cell having a manipulation can be made with mammalian nucleic acids, e.g., mammalian primers or a nucleic acid encoding a mammalian GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, a fucosyltransferase or GDP-fucose transporter protein. A sequence from a first species can be used to manipulate a cell of a second species. E.g., a primer or nucleic acid from a first species, e.g., a first rodent species, e.g., a mouse or rat, can be used to manipulate a cell from a second species, e.g., a second rodent species, e.g., a hamster cell, e.g., a CHO cell.
Nucleic Acid Antagonists
[0541] In some embodiments, nucleic acid antagonists are used to decrease expression of a target protein, e.g., a protein involved in regulating GDP-fucose levels, e.g., a protein involved in GDP-fucose biosynthesis, a fucosyltransferase or a GDP-fucose transporter. In one embodiment, the nucleic acid antagonist is an siRNA that targets mRNA encoding the target protein. Other types of antagonistic nucleic acids can also be used, e.g., a nucleic acid aptamer, a dsRNA, a ribozyme, a triple-helix former, or an antisense nucleic acid.
[0542] siRNAs can be used to inhibit expression of a protein involved in GDP-fucose biosynthesis, a fucosyltransferase or a GDP-fucose transporter. siRNAs are small double stranded RNAs (dsRNAs) that optionally include overhangs. For example, the duplex region of an siRNA is about 18 to 25 nucleotides in length, e.g., about 19, 20, 21, 22, 23, or 24 nucleotides in length. Typically the siRNA sequences are exactly complementary to the target mRNA. dsRNAs and siRNAs in particular can be used to silence gene expression in mammalian cells (e.g., human cells). See, e.g., Clemens, J. C. et al. (2000) Proc. Natl. Sci. USA 97, 6499-6503; Billy, E. et al. (2001) Proc. Natl. Sci. USA 98, 14428-14433; Elbashir et al. (2001) Nature 411(6836):494-8; Yang, D. et al. (2002) Proc. Natl. Acad. Sci. USA 99, 9942-9947, US 2003-0166282, 2003-0143204, 2004-0038278, and 2003-0224432.
[0543] Anti-sense agents can also be used to inhibit expression of a protein involved in GDP-fucose biosynthesis or a fucosyltransferase and include, for example, from about 8 to about 80 nucleobases (i.e. from about 8 to about 80 nucleotides), e.g., about 8 to about 50 nucleobases, or about 12 to about 30 nucleobases. Anti-sense compounds include ribozymes, external guide sequence (EGS) oligonucleotides (oligozymes), and other short catalytic RNAs or catalytic oligonucleotides that hybridize to the target nucleic acid and modulate its expression. Anti-sense compounds can include a stretch of at least eight consecutive nucleobases that are complementary to a sequence in the target gene. An oligonucleotide need not be 100% complementary to its target nucleic acid sequence to be specifically hybridizable. An oligonucleotide is specifically hybridizable when binding of the oligonucleotide to the target interferes with the normal function of the target molecule to cause a loss of utility, and there is a sufficient degree of complementarity to avoid non-specific binding of the oligonucleotide to non-target sequences under conditions in which specific binding is desired.
[0544] Hybridization of antisense oligonucleotides with mRNA can interfere with one or more of the normal functions of mRNA. The functions of mRNA to be interfered with include all vital functions such as, for example, translocation of the RNA to the site of protein translation, translation of protein from the RNA, splicing of the RNA to yield one or more mRNA species, and catalytic activity that may be engaged in by the RNA. Binding of specific protein(s) to the RNA may also be interfered with by antisense oligonucleotide hybridization to the RNA.
[0545] Exemplary antisense compounds include DNA or RNA sequences that specifically hybridize to the target nucleic acid. The complementary region can extend for between about 8 to about 80 nucleobases. The compounds can include one or more modified nucleobases. Modified nucleobases may include, e.g., 5-substituted pyrimidines such as 5-iodouracil, 5-iodocytosine, and C5-propynyl pyrimidines such as C5-propynylcytosine and C5-propynyluracil. Other suitable modified nucleobases include N4-(C1-C12)alkylaminocytosines and N4,N4-(C1-C12)dialkylaminocytosines. Modified nucleobases may also include 7-substituted-8-aza-7-deazapurines and 7-substituted-7-deazapurines such as, for example, 7-iodo-7-deazapurines, 7-cyano-7-deazapurines, 7-aminocarbonyl-7-deazapurines. Examples of these include 6-amino-7-iodo-7-deazapurines, 6-amino-7-cyano-7-deazapurines, 6-amino-7-aminocarbonyl-7-deazapurines, 2-amino-6-hydroxy-7-iodo-7-deazapurines, 2-amino-6-hydroxy-7-cyano-7-deazapurines, and 2-amino-6-hydroxy-7-aminocarbonyl-7-deazapurines. Furthermore, N6-(C1-C12)alkylaminopurines and N6,N6-(C1-C12)dialkylaminopurines, including N6-methylaminoadenine and N6,N6-dimethylaminoadenine, are also suitable modified nucleobases. Similarly, other 6-substituted purines including, for example, 6-thioguanine may constitute appropriate modified nucleobases. Other suitable nucleobases include 2-thiouracil, 8-bromoadenine, 8-bromoguanine, 2-fluoroadenine, and 2-fluoroguanine. Derivatives of any of the aforementioned modified nucleobases are also appropriate. Substituents of any of the preceding compounds may include C 1 -C 30 alkyl, C 2 -C 30 alkenyl, C 2 -C 30 alkynyl, aryl, aralkyl, heteroaryl, halo, amino, amido, nitro, thio, sulfonyl, carboxyl, alkoxy, alkylcarbonyl, alkoxycarbonyl, and the like.
[0546] Descriptions of other types of nucleic acid agents are also available. See, e.g., U.S. Pat. No. 4,987,071; U.S. Pat. No. 5,116,742; U.S. Pat. No. 5,093,246; Woolf et al. (1992) Proc Natl Acad Sci USA ; Antisense RNA and DNA, D. A. Melton, Ed., Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y. (1988); 89:7305-9; Haselhoff and Gerlach (1988) Nature 334:585-59; Helene, C. (1991) Anticancer Drug Des. 6:569-84; Helene (1992) Ann. N.Y. Acad. Sci. 660:27-36; and Maher, L. J. (1992) Bioassays 14:807-15.
Genetically Engineered Cells
[0547] In some embodiments, a cell can be selected that has been genetically engineered for permanent or regulated inactivation (complete or partial) of a gene encoding a gene involved in GDP-fucose biosynthesis or a fucosyltransferase, or a protein involved in regulating GDP-fucose levels. For example, genes described herein can be inactivated. Permanent or regulated inactivation of gene expression can be achieved by targeting to a gene locus with a transfected plasmid DNA construct or a synthetic oligonucleotide. The plasmid construct or oligonucleotide can be designed to several forms. These include the following: 1) insertion of selectable marker genes or other sequences within an exon of the gene being inactivated; 2) insertion of exogenous sequences in regulatory regions of non-coding sequence; 3) deletion or replacement of regulatory and/or coding sequences; and, 4) alteration of a protein coding sequence by site specific mutagenesis.
[0548] In the case of insertion of a selectable marker gene into a coding sequence, it is possible to create an in-frame fusion of an endogenous exon of the gene with the exon engineered to contain, for example, a selectable marker gene. In this way following successful targeting, the endogenous gene expresses a fusion mRNA (nucleic acid sequence plus selectable marker sequence). Moreover, the fusion mRNA would be unable to produce a functional translation product.
[0549] In the case of insertion of DNA sequences into regulatory regions, the transcription of a gene can be reduced or silenced by disrupting the endogenous promoter region or any other regions in the 5′ untranslated region (5′ UTR) that is needed for transcription. Such regions include, for example, translational control regions and splice donors of introns. Secondly, a new regulatory sequence can be inserted upstream of the gene that would alter expression, e.g., eliminate expression, reduce expression, or render the gene subject to the control of extracellular factors. It would thus be possible to down-regulate or extinguish gene expression as desired for glycoprotein production. Moreover, a sequence that includes a selectable marker and a promoter can be used to disrupt expression of the endogenous sequence. Finally, all or part of the endogenous gene could be deleted by appropriate design of targeting substrates.
[0550] Cells Genetically Engineered to Express a Component Involved in Regulating GDP-fucose levels
[0551] Cells can be genetically engineered to express a component involved in regulation of GDP-fucose levels, e.g., a cell can be genetically engineered to overexpress a GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, a GDP-fucose transporter, and/or a fucosyltransferase. When cells are to be genetically modified for the purposes of expressing or overexpressing a component, the cells may be modified by conventional genetic engineering methods or by gene activation.
[0552] According to conventional methods, a DNA molecule that contains cDNA or genomic DNA sequence encoding desired protein may be contained within an expression construct and transfected into primary, secondary, or immortalized cells by standard methods including, but not limited to, liposome-, polybrene-, or DEAE dextran-mediated transfection, electroporation, calcium phosphate precipitation, microinjection, or velocity driven microprojectiles (see, e.g., U.S. Pat. No. 6,048,729).
[0553] Alternatively, one can use a system that delivers the genetic information by viral vector. Viruses known to be useful for gene transfer include adenoviruses, adeno associated virus, herpes virus, mumps virus, pollovirus, retroviruses, Sindbis virus, and vaccinia virus such as canary pox virus.
[0554] Alternatively, the cells may be modified using a gene activation approach, for example, as described in U.S. Pat. No. 5,641,670; U.S. Pat. No. 5,733,761; U.S. Pat. No. 5,968,502; U.S. Pat. No. 6,200,778; U.S. Pat. No. 6,214,622; U.S. Pat. No. 6,063,630; U.S. Pat. No. 6,187,305; U.S. Pat. No. 6,270,989; and U.S. Pat. No. 6,242,218.
[0555] Accordingly, the term “genetically engineered,” as used herein in reference to cells, is meant to encompass cells that express a particular gene product following introduction of a DNA molecule encoding the gene product and/or including regulatory elements that control expression of a coding sequence for the gene product. The DNA molecule may be introduced by gene targeting or homologous recombination, i.e., introduction of the DNA molecule at a particular genomic site.
[0556] Methods of transfecting cells, and reagents such as promoters, markers, signal sequences that can be used for recombinant expression are known.
[0557] A component involved in regulating levels of GDP-fucose, e.g., GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, a fucosyltransferase or a GDP-fucose transporter, can be placed under a selected form of control, e.g., inducible control. For example, a sequence encoding GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, a fucosyltransferase or a GDP-fucose transporter, can be placed under the control of a promoter or other control element that is responsive to an inducer (or inhibitor) of expression. Such systems allow the cell to be maintained under a variety of conditions, e.g., a condition wherein the gene, e.g., a gene encoding GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, a fucosyltransferase or a GDP-fucose transporter, is expressed or not expressed. This allows culture of the cell under a first condition, which provides glycoproteins having a first glycosylation state (e.g., fucosylated), or under a second condition, which provides glycoproteins having a second glycosylation state (e.g., lacking fucosylation).
[0558] Cells can also be engineered to express a hybrid nucleic acid; that is, a nucleic acid comprising at least two segments which have been isolated from at least two different sources. As one example of manipulation of a cell with a hybrid nucleic acid, a mammalian cell having a manipulation may express a hybrid nucleic acid comprising a regulatory sequence, such as a promoter and/or terminator sequence, of mammalian cell origin, which is functionally linked to a coding sequence, which may be of origin from a different species, e.g., from a different mammal or non-mammalian. In this manner, for example, a cell may be manipulated so that it can be induced to express the coding sequence in response to a stimulus that does not naturally induce expression of the linked coding sequence. An example of such a system is the TET On/Off regulatory system. In the Tet-Off system, gene expression is turned on when tetracycline (Tc) or doxycycline (Dox; a Tc derivative) is removed from the culture medium. In contrast, expression is turned on in the Tet-On system by the addition of Dox. The Tet-On system is responsive only to Dox, not to Tc. Both systems permit gene expression to be tightly regulated in response to varying concentrations of Tc or Dox.
[0559] Generally, one of ordinary skill can select promoters for a desired level of gene expression and place a selected gene under the control of such a promoter. The term promoter as used herein refers to a polynucleotide sequence which allows and controls the transcription of the genes or sequences functionally connected therewith. The sequences of promoters are deposited in databases such as GeneBank, and may be obtained as separate elements or elements cloned within polynucleotide sequences from commercial or individual sources. Exemplary types of promoters that can be used to express a desired gene of interest in eukaryotic cells (e.g., animal cells) include, but not limited to, constitutive and inducible promoters.
[0560] The activity of promoters may vary from one another in their strength, for example, across different cell types. Promoters that are particularly suitable for high expression in eukaryotic cells (e.g., animal cells) include, but not limited to, cytomegalovirus (CMV) immediate-early promoter, simian virus 40 (SV40) immediate-early promoter, human elongation factor 1α (EF-1α) promoter, chicken β-Actin promoter coupled with CMV early enhancer (CAG promoter), adenovirus major late promoter, and Rous sarcoma virus (RSV) promoter. Promoters that are suitable for intermediate or weak expression in eukaryotic cells (e.g., animal cells) include, but not limited to, human Ubiquitin C (UbC) promoter, murine phosphoglycerate kinase-1 (PGK) promoter, and herpes simplex virus (HSV) thymidine kinase (TK) promoter. Comparisons of the strength of various constitutive and inducible promoters in ectopic gene expression are described in, e.g., Qin, J. Y. et al., PLoS ONE 2010, 5(5):e10611; Cheng, X. et al., Int. J. Radiat. Biol. 1995, 67(3):261-267; Foecking, M. K. et al., Gene 1986, 45(1):101-105; Davis, M. G. et al., Biotechnol. Biochem. 1988, 10(1):6-12; Liu, Z. et al., Anal. Biochem. 1997, 246(1):150-152; Wenger, R. H. et al., Anal. Biochem. 1994, 221(2):416-418; Kronman, C. et al, Gene 1992, 121(2):295-304; Thompson, T. A. et al., In Vitro Cell Dev. Biol. 1993, 29A (2):165-170; Thompson, E. M. et al., Gene 1990, 96(2):257-262). One of ordinary skill can evaluate a particular combination of promoter, gene, and cell line to obtain the desired level of expression.
[0561] As mentioned above, with inducible promoters the activity of the promoter may be regulated (e.g., reduced or increased) in response to a signal (e.g., chemical signal (e.g., tetracycline, steroids, metal) or physical signal (e.g., temperature)). One example of an inducible promoter is the tetracycline (tet) promoter. As mentioned above, the tet promoter contains tetracycline a operator sequence (tetO) which can be induced by a tetracycline-regulated transactivator protein (tTA). Exemplary tetracycline-regulated promoters are described in e.g., U.S. Pat. Nos. 5,851,796, 5,464,758, 5,650,298, 5,589,362, 5,654,168, 5,789,156, 5,814,618, 5,888,981, 6,004,941, 6,136,954 and 6,271,348. Exemplary steroid-regulated promoters are described in e.g., U.S. Pat. Nos. 5,512,483 and 6,379,945. Exemplary metal-regulated promoters are described in e.g., U.S. Pat. Nos. 4,579,821 and 4,601,978. Examples of other inducible promoters include the jun, fos and heat shock promoter (see also Sambrook, J. et al., Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y., 1989; Gossen, M. et al., Curr. Opinions Biotech. 1994, 5, 516-520).
[0562] The promoters described herein can be functionally combined with one or more regulatory sequences to regulate (e.g., increase, decrease, optimize, repress, induce) the transcription activity in an expression cassette. For example, the promoter can be functionally linked to one or more enhancer sequences (e.g., a CMV or SV40 enhancer) to increase transcriptional activity, or one or more binding sites for transcription factors (e.g., Sp1, AP1) to up- or down-regulate transcriptional activity. In an embodiment, the regulatory sequence can be positioned in front of or behind the promoter.
Transcription Factors
[0563] The expression of a gene which conditions the level of GDP-fucose can also be down regulated by reducing, e.g., eliminating, the expression of a transcription factor which positively controls expression of the gene. E.g., Arnt, ATF6, SREBP-1c, Lmo2, HNF-1A, GCNF-2, CUTL1, STAT3, POU2F1a or EsF-1 can be targeted to down regulate GDP-fucose synthetase. HFH-1, Gfi-1, c-Myb, POU2F2C, AREB6, AORalpha2, POU3F1, LUN-1, or PPAR-gamma2 can be targeted to down regulate fucose kinase. Evi-1, STAT1beta, GATA-3, POU2F1A, POU3F2 (N-Oct-5b), AREB6, N-Myc, CUTL1, HSFlshort, or C/EBPbeta can be targeted to down regulate GNDS.
Chemical Inhibitors of GMD, FX, Fucokinase, GFPP or GDP-Fucose Synthetase
[0564] Enzyme inhibitors are molecules that bind to enzymes and decrease their activities. The binding of an inhibitor may stop a substrate from entering the enzyme active site and/or hinder the enzyme from catalyzing its reaction. Inhibitor binding may be either reversible or irreversible. Irreversible inhibitors usually react with the enzyme and change it chemically. These inhibitors modify key amino acid residues needed for enzyme activity. In contrast, reversible inhibitors bind non-covalently and different types of inhibition are produced depending on whether these inhibitors bind the enzyme, the enzyme-substrate complex, or both.
[0565] In some embodiments, the addition of particular chemical reagents or inhibitors may be used to lower the levels of the GDP-fucose. These reagents or inhibitors may inhibit GMD, FX, fucokinase, GFPP, GDP-fucose synthetase, or enzymes involved in the biosynthesis of GDP-mannose. Examples of these inhibitors include, but are not limited to, guanosine-5′-O-(2-thiodiphosphate)-fucose, guanosine-5′-O-(2-thiodiphosphate)-mannose, pyridoxal-5′-phosphate, GDP-4-dehydro-6-L-deoxygalactose, GDP-L-fucose, guanosine diphosphate (GDP), guanosine monophosphate (GMP), GDP-D-glucose, p-chloromercuriphenylsulfonate EDTA and fucose.
Glycoproteins
[0566] Glycoproteins that can be made by methods described herein include those in Table 1 below.
[0000]
TABLE 1
Protein Product
Reference Listed Drug
interferon gamma-1b
Actimmune ®
alteplase; tissue plasminogen activator
Activase ®/Cathflo ®
Recombinant antihemophilic factor
Advate
human albumin
Albutein ®
Laronidase
Aldurazyme ®
interferon alfa-N3, human leukocyte derived
Alferon N ®
human antihemophilic factor
Alphanate ®
virus-filtered human coagulation factor IX
AlphaNine ® SD
Alefacept; recombinant, dimeric fusion protein LFA3-Ig
Amevive ®
Bivalirudin
Angiomax ®
darbepoetin alfa
Aranesp ™
Bevacizumab
Avastin ™
interferon beta-1a; recombinant
Avonex ®
coagulation factor IX
BeneFix ™
Interferon beta-1b
Betaseron ®
Tositumomab
BEXXAR ®
antihemophilic factor
Bioclate ™
human growth hormone
BioTropin ™
botulinum toxin type A
BOTOX ®
Alemtuzumab
Campath ®
acritumomab; technetium-99 labeled
CEA-Scan ®
alglucerase; modified form of beta-glucocerebrosidase
Ceredase ®
imiglucerase; recombinant form of beta-glucocerebrosidase
Cerezyme ®
crotalidae polyvalent immune Fab, ovine
CroFab ™
digoxin immune fab [ovine]
DigiFab ™
Rasburicase
Elitek ®
Etanercept
ENBREL ®
epoietin alfa
Epogen ®
Cetuximab
Erbitux ™
algasidase beta
Fabrazyme ®
Urofollitropin
Fertinex ™
follitropin beta
Follistim ™
Teriparatide
FORTEO ®
human somatropin
GenoTropin ®
Glucagon
GlucaGen ®
follitropin alfa
Gonal-F ®
antihemophilic factor
Helixate ®
Antihemophilic Factor; Factor XIII
HEMOFIL
adefovir dipivoxil
Hepsera ™
Trastuzumab
Herceptin ®
Insulin
Humalog ®
antihemophilic factor/von Willebrand factor complex-human
Humate-P ®
Somatotropin
Humatrope ®
Adalimumab
HUMIRA ™
human insulin
Humulin ®
recombinant human hyaluronidase
Hylenex ™
interferon alfacon-1
Infergen ®
eptifibatide
Integrilin ™
alpha-interferon
Intron A ®
Palifermin
Kepivance
Anakinra
Kineret ™
antihemophilic factor
Kogenate ®FS
insulin glargine
Lantus ®
granulocyte macrophage colony-stimulating factor
Leukine ®/Leukine ® Liquid
lutropin alfa for injection
Luveris
OspA lipoprotein
LYMErix ™
Ranibizumab
LUCENTIS ®
gemtuzumab ozogamicin
Mylotarg ™
Galsulfase
Naglazyme ™
Nesiritide
Natrecor ®
Pegfilgrastim
Neulasta ™
Oprelvekin
Neumega ®
Filgrastim
Neupogen ®
Fanolesomab
NeutroSpec ™ (formerly LeuTech ®)
somatropin [rDNA]
Norditropin ®/Norditropin Nordiflex ®
Mitoxantrone
Novantrone ®
insulin; zinc suspension;
Novolin L ®
insulin; isophane suspension
Novolin N ®
insulin, regular;
Novolin R ®
Insulin
Novolin ®
coagulation factor VIIa
NovoSeven ®
Somatropin
Nutropin ®
immunoglobulin intravenous
Octagam ®
PEG-L-asparaginase
Oncaspar ®
abatacept, fully human soluable fusion protein
Orencia ™
muromomab-CD3
Orthoclone OKT3 ®
high-molecular weight hyaluronan
Orthovisc ®
human chorionic gonadotropin
Ovidrel ®
live attenuated Bacillus Calmette-Guerin
Pacis ®
peginterferon alfa-2a
Pegasys ®
pegylated version of interferon alfa-2b
PEG-Intron ™
Abarelix (injectable suspension); gonadotropin-releasing
Plenaxis ™
hormone antagonist
epoietin alfa
Procrit ®
Aldesleukin
Proleukin, IL-2 ®
Somatrem
Protropin ®
dornase alfa
Pulmozyme ®
Efalizumab; selective, reversible T-cell blocker
RAPTIVA ™
combination of ribavirin and alpha interferon
Rebetron ™
Interferon beta 1a
Rebif ®
antihemophilic factor
Recombinate ® rAHF/
antihemophilic factor
ReFacto ®
Lepirudin
Refludan ®
Infliximab
REMICADE ®
Abciximab
ReoPro ™
Reteplase
Retavase ™
Rituxima
Rituxan ™
interferon alfa-2 a
Roferon-A ®
Somatropin
Saizen ®
synthetic porcine secretin
SecreFlo ™
Basiliximab
Simulect ®
Eculizumab
SOLIRIS (R)
Pegvisomant
SOMAVERT ®
Palivizumab; recombinantly produced, humanized mAb
Synagis ™
thyrotropin alfa
Thyrogen ®
Tenecteplase
TNKase ™
Natalizumab
TYSABRI ®
human immune globulin intravenous 5% and 10% solutions
Venoglobulin-S ®
interferon alfa-n1, lymphoblastoid
Wellferon ®
drotrecogin alfa
Xigris ™
Omalizumab; recombinant DNA-derived humanized
Xolair ®
monoclonal antibody targeting immunoglobulin-E
Daclizumab
Zenapax ®
ibritumomab tiuxetan
Zevalin ™
Somatotropin
Zorbtive ™ (Serostim ®)
Analytical Methods
[0567] In general, a glycan preparation can be subjected to analysis to determine whether the glycan includes a particular type of structure (e.g., a glycan structure described herein). In some embodiments, the analysis comprises comparing the structure and/or function of glycans in one glycoprotein preparation to structure and/or function of glycans in at least one other glycoprotein preparation. In some embodiments, the analysis comprises comparing the structure and/or function of glycans in one or more of the samples to structure and/or function of glycans in a reference sample.
[0568] Structure and composition of glycans can be analyzed by any available method. In some embodiments, glycan structure and composition are analyzed by chromatographic methods, mass spectrometry (MS) methods, chromatographic methods followed by MS, electrophoretic methods, electrophoretic methods followed by MS, nuclear magnetic resonance (NMR) methods, and combinations thereof.
[0569] In some embodiments, glycan structure and composition can be analyzed by chromatographic methods, including but not limited to, liquid chromatography (LC), high performance liquid chromatography (HPLC), ultra performance liquid chromatography (HPLC), thin layer chromatography (TLC), amide column chromatography, and combinations thereof.
[0570] In some embodiments, glycan structure and composition can be analyzed by mass spectrometry (MS) and related methods, including but not limited to, tandem MS, LC-MS, LC-MS/MS, matrix assisted laser desorption ionisation mass spectrometry (MALDI-MS), Fourier transform mass spectrometry (FTMS), ion mobility separation with mass spectrometry (IMS-MS), electron transfer dissociation (ETD-MS), and combinations thereof.
[0571] In some embodiments, glycan structure and composition can be analyzed by electrophoretic methods, including but not limited to, capillary electrophoresis (CE), CE-MS, gel electrophoresis, agarose gel electrophoresis, acrylamide gel electrophoresis, SDS-polyacrylamide gel electrophoresis (SDS-PAGE) followed by Western blotting using antibodies that recognize specific glycan structures, and combinations thereof.
[0572] In some embodiments, glycan structure and composition can be analyzed by nuclear magnetic resonance (NMR) and related methods, including but not limited to, one-dimensional NMR (1D-NMR), two-dimensional NMR (2D-NMR), correlation spectroscopy magnetic-angle spinning NMR (COSY-NMR), total correlated spectroscopy NMR (TOCSY-NMR), heteronuclear single-quantum coherence NMR (HSQC-NMR), heteronuclear multiple quantum coherence (HMQC-NMR), rotational nuclear overhauser effect spectroscopy NMR (ROESY-NMR), nuclear overhauser effect spectroscopy (NOESY-NMR), and combinations thereof.
[0573] In some embodiments, techniques described herein may be combined with one or more other technologies for the detection, analysis, and or isolation of glycans or glycoproteins. For example, in certain embodiments, glycans are analyzed in accordance with the present disclosure using one or more available methods (to give but a few examples, see Anumula, Anal. Biochem. 350(1):1, 2006; Klein et al., Anal. Biochem., 179:162, 1989; and/or Townsend, R.R. Carbohydrate Analysis” High Performance Liquid Chromatography and Capillary Electrophoresis, Ed. Z. El Rassi, pp 181-209, 1995, each of which is incorporated herein by reference in its entirety). For example, in some embodiments, glycans are characterized using one or more of chromatographic methods, electrophoretic methods, nuclear magnetic resonance methods, and combinations thereof. Exemplary such methods include, for example, NMR, mass spectrometry, liquid chromatography, 2-dimensional chromatography, SDS-PAGE, antibody staining, lectin staining, monosaccharide quantitation, capillary electrophoresis, fluorophore-assisted carbohydrate electrophoresis (FACE), micellar electrokinetic chromatography (MEKC), exoglycosidase or endoglycosidase treatments, and combinations thereof. Those of ordinary skill in the art will be aware of other techniques that can be used to characterize glycans together with the methods described herein.
[0574] In some embodiments, methods described herein allow for detection of a glycan structure (such as a glycan structure described herein) that is present at low levels within a population of glycans. For example, the present methods allow for detection of glycan species that are present at levels less than 10%, less than 5%, less than 4%, less than 3%, less than 2%, less than 1.5%, less than 1%, less than 0.75%, less than 0.5%, less than 0.25%, less than 0.1%, less than 0.075%, less than 0.05%, less than 0.025%, or less than 0.01% within a population of glycans.
[0575] In some embodiments, methods described herein allow for detection of particular structures (e.g., a glycan structure described herein) that are present at low levels within a population of glycans. For example, the present methods allow for detection of particular structures that are present at levels less than 10%, less than 5%, less than 4%, less than 3%, less than 2%, less than 1.5%, less than 1%, less than 0.75%, less than 0.5%, less than 0.25%, less than 0.1%, less than 0.075%, less than 0.05%, less than 0.025%, or less than 0.01% within a population of glycans.
[0576] In some embodiments, methods described herein allow for detection of relative levels of individual glycan species within a population of glycans. For example, the area under each peak of a liquid chromatograph can be measured and expressed as a percentage of the total. Such an analysis provides a relative percent amount of each glycan species within a population of glycans. In another example, relative levels of individual glycan species are determined from areas of peaks in a 1D-NMR experiment, or from volumes of cross peaks from a 1 H- 15 N HSQC spectrum (e.g., with correction based on responses from standards), or by relative quantitation by comparing the same peak across samples.
[0577] In some embodiments, a biological activity of a glycoprotein preparation (e.g., a glycoprotein preparation) is assessed. Biological activity of glycoprotein preparations can be analyzed by any available method. In some embodiments, a binding activity of a glycoprotein is assessed (e.g., binding to a receptor). In some embodiments, a therapeutic activity of a glycoprotein is assessed (e.g., an activity of a glycoprotein in decreasing severity or symptom of a disease or condition, or in delaying appearance of a symptom of a disease or condition). In some embodiments, a pharmacologic activity of a glycoprotein is assessed (e.g., bioavailability, pharmacokinetics, pharmacodynamics). For methods of analyzing bioavailability, pharmacokinetics, and pharmacodynamics of glycoprotein therapeutics, see, e.g., Weiner et al., J. Pharm. Biomed. Anal. 15(5):571-9, 1997; Srinivas et al., J. Pharm. Sci. 85(1):1-4, 1996; and Srinivas et al., Pharm. Res. 14(7):911-6, 1997.
[0578] As would be understood to one of skill in the art, the particular biological activity or therapeutic activity that can be tested will vary depending on the particular glycoprotein or glycan structure.
[0579] The potential adverse activity or toxicity (e.g., propensity to cause hypertension, allergic reactions, thrombotic events, seizures, or other adverse events) of glycoprotein preparations can be analyzed by any available method. In some embodiments, immunogenicity of a glycoprotein preparation is assessed, e.g., by determining whether the preparation elicits an antibody response in a subject.
Cells & Cell Lines
[0580] Methods described herein use cells to produce products having reduced fucosylation. Examples of cells useful in these and other methods described herein follow.
[0581] The cell useful in the methods described herein can be eukaryotic or prokaryotic, as long as the cell provides or has added to it the enzymes to activate and attach saccharides present in the cell or saccharides present in the cell culture medium or fed to the cells. Examples of eukaryotic cells include yeast, insect, fungi, plant and animal cells, especially mammalian cells. Suitable mammalian cells include any normal mortal or normal or abnormal immortal animal or human cell, including: monkey kidney CV1 line transformed by SV40 (COS-7, ATCC CRL 1651); human embryonic kidney line (293) (Graham et al., J. Gen. Virol. 36:59 (1977)); baby hamster kidney cells (BHK, ATCC CCL 10); Chinese Hamster Ovary (CHO), e.g., DG44, DUKX-V11, GS-CHO (ATCC CCL 61, CRL 9096, CRL 1793 and CRL 9618); mouse sertoli cells (TM4, Mather, Biol. Reprod. 23:243 251 (1980)); monkey kidney cells (CV1 ATCC CCL 70); African green monkey kidney cells (VERO-76, ATCC CRL 1587); human cervical carcinoma cells (HeLa, ATCC CCL 2); buffalo rat liver cells (BRL 3A, ATCC CRL 1442); human lung cells (W138, ATCC CCL 75); human liver cells (Hep G2, HB 8065); mouse melanoma cells (NSO); mouse mammary tumor (MMT 060562, ATCC CCL51), TR1 cells (Mather, et al., Annals N.Y. Acad. Sci. 383:44 46 (1982)); canine kidney cells (MDCK) (ATCC CCL 34 and CRL 6253), HEK 293 (ATCC CRL 1573), WI-38 cells (ATCC CCL 75) (ATCC: American Type Culture Collection, Rockville, Md.), MCF-7 cells, MDA-MB-438 cells, U87 cells, A127 cells, HL60 cells, A549 cells, SP10 cells, DOX cells, SHSY5Y cells, Jurkat cells, BCP-1 cells, GH3 cells, 9L cells, MC3T3 cells, C3H-10T1/2 cells, NIH-3T3 cells, C6/36 cells, human lymphoblast cell lines (e.g. GEX) and PER.C6® cells. The use of mammalian tissue cell culture to express polypeptides is discussed generally in Winnacker, FROM GENES TO CLONES (VCH Publishers, N.Y., N.Y., 1987).
[0582] Exemplary plant cells include, for example, Arabidopsis thaliana , rape seed, corn, wheat, rice, tobacco etc.) (Staub, et al. 2000 Nature Biotechnology 1(3): 333-338 and McGarvey, P. B., et al. 1995 Bio-Technology 13(13): 1484-1487; Bardor, M., et al. 1999 Trends in Plant Science 4(9): 376-380). Exemplary insect cells (for example, Spodoptera frugiperda Sf9, Sf21, Trichoplusia ni , etc. Exemplary bacteria cells include Escherichia coli . Various yeasts and fungi such as Pichia pastoris, Pichia methanolica, Hansenula polymorpha , and Saccharomyces cerevisiae can also be selected.
[0583] Culture Media and Processing
[0584] The methods described herein can include determining and/or selecting media components or culture conditions which result in the production of a desired glycan property or properties. Culture parameters that can be determined include media components, pH, feeding conditions, osmolarity, carbon dioxide levels, agitation rate, temperature, cell density, seeding density, timing and sparge rate.
[0585] Changes in production parameters such the speed of agitation of a cell culture, the temperature at which cells are cultures, the components in the culture medium, the times at which cultures are started and stopped, variation in the timing of nutrient supply can result in variation of a glycan properties of the produced glycoprotein product. Thus, methods described herein can include one or more of: increasing or decreasing the speed at which cells are agitated, increasing or decreasing the temperature at which cells are cultures, adding or removing media components, and altering the times at which cultures are started and/or stopped.
[0586] Sequentially selecting a production parameters or a combination thereof, as used herein, means a first parameter (or combination) is selected, and then a second parameter (or combination) is selected, e.g., based on a constraint imposed by the choice of the first production parameter.
[0587] Media
[0588] The methods described herein can include determining and/or selecting a media component and/or the concentration of a media component that has a positive correlation to a desired glycan property or properties. A media component can be added in or administered over the course of glycoprotein production or when there is a change in media, depending on culture conditions. Media components include components added directly to culture as well as components that are a byproduct of cell culture.
[0589] Media components include, e.g., buffer, amino acid content, vitamin content, salt content, mineral content, serum content, carbon source content, lipid content, nucleic acid content, hormone content, trace element content, ammonia content, co-factor content, indicator content, small molecule content, hydrolysate content and enzyme modulator content. Specific examples of media conditions that will lead to altered levels of GDP-fucose include but are not limited to altering the levels of cobalt, butyrate, fucose, guanosine, and manganese.
[0590] Table 2 provides examples of various media components that can be selected.
[0000]
TABLE 2
amino acids
sugar precursors
Vitamins
Indicators
Carbon source (natural and unnatural)
Nucleosides or nucleotides
Salts
butyrate or organics
Sugars
DMSO
Sera
Animal derived products
Plant derived hydrolysates
Gene inducers
sodium pyruvate
Non natural sugars
Surfactants
Regulators of intracellular pH
Ammonia
Betaine or osmoprotectant
Lipids
Trace elements
Hormones or growth factors
minerals
Buffers
Non natural amino acids
Non natural amino acids
Non natural vitamins
[0591] Exemplary buffers include Tris, Tricine, HEPES, MOPS, PIPES, TAPS, bicine, BES, TES, cacodylate, MES, acetate, MKP, ADA, ACES, glycinamide and acetamidoglycine.
[0592] The media can be serum free or can include animal derived products such as, e.g., fetal bovine serum (FBS), fetal calf serum (FCS), horse serum (HS), human serum, animal derived serum substitutes (e.g., Ultroser G, SF and HY; non-fat dry milk; Bovine EX-CYTE), fetuin, bovine serum albumin (BSA), serum albumin, and transferrin. When serum free media is selected lipids such as, e.g., palmitic acid and/or steric acid, can be included.
[0593] Lipids components include oils, saturated fatty acids, unsaturated fatty acids, glycerides, steroids, phospholipids, sphingolipids and lipoproteins.
[0594] Exemplary amino acid that can be included or eliminated from the media include alanine, arginine, asparagine, aspartic acid, cysteine, glutamic acid, glutamine, glycine, histidine, proline, isoleucine, leucine, lysine, methionine, phenylalanine, proline, serine, threonine, tryptophan, tyrosine and valine.
[0595] Examples of vitamins that can be present in the media or eliminated from the media include vitamin A (retinoid), vitamin B1 (thiamine), vitamin B2 (riboflavin), vitamin B3 (niacin), vitamin B5 (pantothenic acid), vitamin B6 (pyroxidone), vitamin B7 (biotin), vitamin B9 (folic acid), vitamin B12 (cyanocobalamin), vitamin C (ascorbic acid), vitamin D, vitamin E, and vitamin K.
[0596] Minerals that can be present in the media or eliminated from the media include bismuth, boron, calcium, chlorine, chromium, cobalt, copper, fluorine, iodine, iron, magnesium, manganese, molybdenum, nickel, phosphorus, potassium, rubidium, selenium, silicon, sodium, strontium, sulfur, tellurium, titanium, tungsten, vanadium, and zinc. Exemplary salts and minerals include CaCl 2 (anhydrous), CuSO 4 5H 2 O, Fe(NO 3 ).9H 2 O, KCl, KNO 3 , KH 2 PO 4 , MgSO 4 (anhydrous), NaCl, NaH 2 PO 4 H 2 O, NaHCO 3 , Na 2 SeO 3 (anhydrous), ZnSO 4 .7H 2 O; linoleic acid, lipoic acid, D-glucose, hypoxanthine 2Na, phenol red, putrescine 2HCl, sodium pyruvate, thymidine, pyruvic acid, sodium succinate, succinic acid, succinic acid.Na.hexahydrate, glutathione (reduced), para-aminobenzoic acid (PABA), methyl linoleate, bacto peptone G, adenosine, cytidine, guanosine, 2′-deoxyadenosine HCl, 2′-deoxycytidine HCl, 2′-deoxyguanosine and uridine. When the desired glycan characteristic is decreased fucosylation, the production parameters can include culturing a cell, e.g., CHO cell, e.g., dhfr deficient CHO cell, in the presence of manganese, e.g., manganese present at a concentration of about 0.1 μM to 50 μM. Decreased fucosylation can also be obtained, e.g., by culturing a cell (e.g., a CHO cell, e.g., a dhfr deficient CHO cell) at an osmolality of about 350 to 500 mOsm. Osmolality can be adjusted by adding salt to the media or having salt be produced as a byproduct as evaporation occurs during production.
[0597] Hormones include, for example, somatostatin, growth hormone-releasing factor (GRF), insulin, prolactin, human growth hormone (hGH), somatotropin, estradiol, and progesterone. Growth factors include, for example, bone morphogenic protein (BMP), epidermal growth factor (EGF), basic fibroblast growth factor (bFGF), nerve growth factor (NGF), bone derived growth factor (BDGF), transforming growth factor-beta1 (TGF-beta1), [Growth factors from U.S. Pat. No. 6,838,284 B2], hemin and NAD.
[0598] Examples of surfactants that can be present or eliminated from the media include Tween-80 and pluronic F-68.
[0599] Small molecules can include, e.g., butyrate, ammonia, non natural sugars, non natural amino acids, chloroquine, and betaine.
[0600] In some embodiments, ammonia content can be selected as a production parameter to produce a desired glycan characteristic or characteristics. For example, ammonia can be present in the media in a range from 0.001 to 50 mM. Ammonia can be directly added to the culture and/or can be produced as a by product of glutamine or glucosamine. When the desired glycan characteristic is one or more of an increased number of high mannose structures, decreased fucosylation and decreased galactosylation, the production parameters selected can include culturing a cell (e.g., a CHO cell, e.g., a dhfr deficient CHO cell) in the presence of ammonia, e.g., ammonia present at a concentration of about 0.01 to 50 mM. For example, if the desired glycan characteristic includes decreased galactosylation, production parameters selected can include culturing a cell (e.g., a CHO cell, e.g., a dhfr deficient CHO cell) in serum containing media and in the presence of ammonia, e.g., ammonia present at a concentration of about 0.01 to 50 mM.
[0601] Another production parameter is butyrate content. The presence of butyrate in culture media can result in increased galactose levels in the resulting glycoprotein preparation. Butyrate provides increased sialic acid content in the resulting glycoprotein preparation. Therefore, when increased galactosylation and/or sialylation is desired, the cell used to produce the glycoprotein (e.g., a CHO cell, e.g., a dhfr deficient CHO cell) can be cultured in the presence of butyrate. In some embodiments, butyrate can be present at a concentration of about 0.001 to 10 mM, e.g., about 2 mM to 10 mM. For example, if the desired glycan characteristic includes increased sialylation, production parameters selected can include culturing a cell (e.g., a CHO cell, e.g., a dhfr deficient CHO cell) in serum containing media and in the presence of butyrate, e.g., butyrate present at a concentration of about 2.0 to 10 mM. Such methods can further include selecting one or more of adherent culture conditions and culture in a T flask.
[0602] Physiochemical Parameters
[0603] Methods described herein can include selecting culture conditions that are correlated with a desired glycan property or properties. Such conditions can include temperature, pH, osmolality, shear force or agitation rate, oxidation, spurge rate, growth vessel, tangential flow, DO, CO 2 , nitrogen, fed batch, redox, cell density and feed strategy. Examples of physiochemical parameters that can be selected are provided in Table 3.
[0000]
TABLE 3
Temperature
DO
pH
CO 2
osmolality
Nitrogen
shear force, or agitation rate
Fed batch
oxidation
Redox
Spurge rate
Cell density
Growth vessel
Perfusion culture
Tangential flow
Feed strategy
Batch
[0604] For example, the production parameter can be culturing a cell under acidic, neutral or basic pH conditions. Temperatures can be selected from 10 to 42° C. For example, a temperature of about 28 to 36° C. does not significantly alter galactosylation, fucosylation, high mannose production, hybrid production or sialylation of glycoproteins produced by a cell (e.g., a CHO cell, e.g., a dhfr deficient CHO cell) cultured at these temperatures. In addition, any method that slows down the growth rate of a cell may also have this effect. Thus, temperatures in this range or methods that slow down growth rate can be selected when it is desirable not to have this parameter of production altering glycosynthesis.
[0605] In other embodiments, carbon dioxide levels can be selected which results in a desired glycan characteristic or characteristics. CO 2 levels can be, e.g., about 5%, 6%, 7%, 8%, 9%, 10%, 11%, 13%, 15%, 17%, 20%, 23% and 25% (and ranges in between). In one embodiment, when decreased fucosylation is desired, the cell can be cultured at CO 2 levels of about 11 to 25%, e.g., about 15%. CO 2 levels can be adjusted manually or can be a cell byproduct.
[0606] A wide array of flasks, bottles, reactors, and controllers allow the production and scale up of cell culture systems. The system can be chosen based, at least in part, upon its correlation with a desired glycan property or properties.
[0607] Cells can be grown, for example, as batch, fed-batch, perfusion, or continuous cultures.
[0608] Production parameters that can be selected include, e.g., addition or removal of media including when (early, middle or late during culture time) and how often media is harvested; increasing or decreasing speed at which cell cultures are agitated; increasing or decreasing temperature at which cells are cultured; adding or removing media such that culture density is adjusted; selecting a time at which cell cultures are started or stopped; and selecting a time at which cell culture parameters are changed. Such parameters can be selected for any of the batch, fed-batch, perfusion and continuous culture conditions.
EXAMPLES
Example 1
Relationship Between Levels of GDP-Fucose and % Fucosylated Glycans
[0609] The levels of GDP-fucose levels and the degree of protein fucosylation on glycoproteins were analyzed for three different CHO cell lines expressing a representative secreted protein product (CTLA4Ig): CHO cells that are deficient in the enzyme GDP-mannose 4,6, dehydratase (Lec 13.6 A); CHO cells that have lowered levels of GDP-fucose (Lec 2); and wild-type CHO cells. Culture media did not contain free fucose except as indicated for Lec 13.6 A cells cultured in the presence of exogenous fucose supplemented at 0.01 and 1 mM in the culture media. Cells were harvested, and snap frozen, while culture supernatant was harvested and CTLA4Ig harvested by protein A purification for subsequent analysis. Cells were then subjected to nucleotide sugar extraction using standard methods. In short with chloroform:methanol:water (2:4:1), the pellets discarded and the resulting extraction dried down. The dried material was subsequently resuspended in 500 ul of 10% butanol in water and then extracted with 1 ml of 90% butanol in water. The butanol phase was discarded and the aqueous subjected to a second butanol extraction. The final aqueous phase was dried down and the sugar nucleotides further isolated by PGC chromatography eluting off with 25% acetonitrile (v/v) containing 50 mM triethylammonium acetate. For quantification, sugar-nucletides were resolved with RP chromatography.
[0610] Protein products were isolated from culture supernatant by protein A affinity, and subjected to PNGase F treatment to remove glycans. The resulting glycans were isolated by PGC chromatography and subsequently analyzed by MALDI mass spectrometry. The % fucosylation was determined by determining the ratio of the glycans with or without core fucosylation. Results are presented in Table 4. GDP-fucose levels are indicated in peak area as detected by UV.
[0000]
TABLE 4
% of Parental
% Fucosylated
Cell Line
GDP-fucose
Glycans
Wild-type CHO
100
>90
Lec 2
80
>90
Lec 13.6A
61.6
≈20
Lec 13.6A + 1 mM fucose
270
100
Lec 13.6A + 0.01 mM fucose
62.5
45
|
The present invention provides methods and materials useful for monitoring and regulating the glycosylation of glycoproteins that are recombinantly produced from cells. In particular, methods are provided for monitoring and regulating levels of cellular indicators which affect the level of fucosylation produced by cells.
| 2
|
BACKGROUND OF THE INVENTION
Screw compressors used in water cooled chillers are of the oil flooded type. Oil provides a seal between adjacent trapped volumes during the compression process and an oil separator removes oil from the hot, compressed gas downstream of the compression process. At high speeds, the percentage of gas leakage between the rotor and housing and interlobes is small as compared to the inlet flow. This is partly due to the oil film formed between the rotor and housing. Additionally, to reduce drag loses, the amount of oil injected should be kept at a minimum. For screw compressors the loading or flow is directly proportional to speed. At low speeds the sealing at the tips and interlobes is poor which reduces the volumetric efficiency of the compressor.
SUMMARY OF THE INVENTION
Volumetric efficiency is increased at low speeds by increasing the oil flow at low loads to offset the poorer sealing at low speeds. Oil from the cooler or evaporator is injected at the rotor inlet for sealing. An oil-rich layer tends to form at the top of the cooler and an ejector is used to draw oil from the top surface of the cooler. The drive or motive fluid for the ejector is, preferably, taken from the last closed lobe, although the discharge pressure may be used. The last closed lobe pressure is preferred because it is determined by compressor operation whereas discharge pressure is determined by system conditions. The amount of oil injected is optimized for full load operation by proper selection of ejector size. Because, at low loads the oil supply should be increased for better volumetric efficiency, a supplemental oil supply is provided. One approach is to provide a parallel supply path from the ejector which is controlled by a solenoid valve responsive to motor speed. Another approach is to provide a second ejector and supply path to the rotors with a solenoid valve in the second path responsive to motor speed.
It is an object of this invention to improve part load performance of variable speed screw compressors.
It is another object of this invention to increase volumetric efficiency at low speeds by increasing oil flow to the rotors at low speeds. These objects, and others as will become apparent hereinafter, are accomplished by the present invention.
Basically, lubrication supply to the rotors of a variable speed screw compressor is optimized for full load and a supplemental supply path is provided which is opened during low speed operation.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the present invention, reference should now be made to the following detailed description thereof taken in conjunction with the accompanying drawings wherein.
FIG. 1 is a schematic diagram of a closed refrigeration or air conditioning system employing the present invention; and
FIG. 2 is a schematic diagram of a closed refrigeration or air conditioning system employing a modified embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, the numeral 10 generally designates a closed refrigeration or air conditioning system. As is conventional, there is a closed circuit serially including compressor 12 , discharge line 14 connected to the discharge port, condenser 16 , line 18 which contains expansion device 20 , cooler or evaporator 22 and suction line 24 leading to the suction port. Compressor 12 is a multi-rotor, hermetic, screw compressor. Compressor 12 is driven by electric motor 26 which is under the control of inverter 28 through microprocessor or controller 30 .
An oil-rich layer forms an upper layer in cooler 22 and is used for lubricating and sealing the rotors 12 - 2 and 12 - 2 . The lubricant is drawn from cooler 22 and supplied via line 40 to ejector 50 which is sized to supply the maximum required amount of lubricant. Line 52 supplies refrigerant gas at last closed lobe pressure to ejector 50 causing the oil in a refrigerant oil mixture to be drawn from cooler 22 via line 40 and to be supplied to compressor 12 for lubricating and sealing the rotors 12 - 1 and 12 - 2 . Line 52 branches downstream of ejector 50 into lines 52 - 1 and 52 - 2 . Line 52 - 1 contains a restriction 60 sized to provide the proper lubricant flow to the rotors 12 - 1 and 12 - 2 during full load conditions. Line 52 - 2 contains a normally closed solenoid valve 62 and is under the control of controller or microprocessor 34 responsive to the speed of motor 26 via the output of inverter 28 . Microprocessor 30 receives temperature inputs from thermal sensor 32 which senses the outlet chilled water temperature and responsive thereto controls inverter 28 , and thereby compressor 12 . When the motor speed has been reduced sufficiently, solenoid valve 62 is opened by controller 34 to permit more oil to be supplied to the rotors 12 - 1 and 12 - 2 for sealing and lubrication. Typically, the motor sped would be 50-60% of the full load speed when solenoid valve 62 is opened.
Referring now to FIG. 2, system 10 ′ differs from system 10 in dividing line 40 and replacing ejector 50 with two smaller ejectors, 50 - 1 and 50 - 2 , in parallel. Specifically, line 40 divides into lines 40 - 1 and 40 - 2 which are connected to ejectors 50 - 1 and 50 - 2 , respectively. Line 52 divides into lines 52 - 1 and 52 - 2 which recombine into line 52 after supplying refrigerant gas at last closed lobe pressure to ejectors 50 - 1 and 50 - 2 , respectively. Ejector 50 - 1 is sized such that the oil refrigerant mixture drawn from cooler 22 via line 40 - 1 is the proper amount to provide sealing and lubrication of rotors 12 - 1 and 12 - 2 at full load Line 52 - 2 contains normally closed solenoid valve 62 in addition to ejector 50 - 2 . When the speed of motor 26 has been sufficiently reduced by inverter 28 under control of controller 30 , solenoid valve 62 is opened by controller 34 to permit more oil to be supplied to the rotors 12 - 1 and 12 - 2 for sealing and lubrication. Typically, the motor speed would be 50-60% of the full load speed when solenoid valve 62 is opened.
Although preferred embodiments of the present invention have been illustrated and described, other changes will occur to those skilled in the art. It is therefore intended that the scope of the present invention is to be limited only by the scope of the appended claims.
|
Lubrication supply to the rotors of a variable speed screw compressor is optimized for full load and a supplemental supply path is provided which is opened during low speed operation.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATION
This patent application claims the benefit under 35 USC 119(e) of U.S. Provisional Patent Application No. 60/993,203, filed Sep. 7, 2007.
FIELD OF THE INVENTION
The present invention is related to a technique for forming a bioresorbable composite implant in a bone cavity, and in particular to a method comprising forming a hardened orthopaedic paste in a bone cavity under pressure and with a leaking mechanism so that the compressive strength thereof is increased, and inserting another bone filler into an unfilled space in the bone cavity, which has a higher bioresorption rate in comparison with the hardened orthopaedic paste.
BACKGROUND OF THE INVENTION
It is well accepted that bioresorbable orthopedic implants are always the better choice than permanent foreign-body implants, as long as their bioresorption rates, biomechanical properties and variations in biomechanical properties with respect to the resorption processes are appropriately controlled. Among all bioresorbable orthopedic implants, calcium-based implants (calcium phosphate, calcium sulfate, etc), are perhaps the top choice so far.
For the purpose of filling a bone cavity, especially an irregularly-shaped bone cavity, a bone cement paste (for example, a PMMA, calcium phosphate cement or calcium sulfate cement) is often injected into the cavity, wherein the bone cement paste is hardened in-situ. This hardened cement will remain in bone as a permanent implant if it is a permanent foreign-body implant such as PMMA, or gradually replaced by natural bone if it is a bioresorbable material such as calcium phosphate or calcium sulfate. For load-bearing applications, this hardened cement should provide a sufficient strength to withstand the post-operation routine loadings.
Most conventional methods of forming a hardened (set) bone cement in bone cavity involve creating a bone cavity, followed by directly injecting a cement paste into the bone cavity. Such an approach suffers the following major drawbacks among others:
(1) Since the cement paste is directly injected into an environment filled with blood/body fluid, the cement particles are easily dispersed in this environment, especially before the paste is fully set. The dispersed cement particles can penetrate into surrounding tissues, cracks, blood vessels, nerve system, etc. and cause various kinds of clinical complications such as potentially fatal cement embolism. (2) Since the cement paste is hardened in blood/body fluid, the predetermined liquid/powder ratio, which is critical to cement properties, is disrupted in-situ, causing the performance/properties of the cement to degrade. Although applying pressure to the cement during its hardening process can improve the cement strength, surgeons usually avoid applying a high pressure directly to the injected cement paste due to the above-mentioned potential risks of complications. (3) Besides the disruption in liquid/powder ratio, the irregular shape of the hardened cement also decreases the biomechanical properties of the cement and increases the uncertainty/risks of the cement performance (depending on the actual shape and filling condition), especially for bioceramic cements such as calcium phosphate cement and calcium sulfate cement. The decreased strength further causes the cement to more easily disperse/disintegrate.
Another approach to inject an orthopedic implant into a bone cavity involves inserting a container (balloon or pocket) into the cavity; injecting a bone filler (not necessarily a hardenable cement paste) into the container through a tube; and separating the container from the tube with the container and its contained bone filler remaining in bone. One major problem with this approach is that the container left in bone becomes a permanent foreign body which prevents the bone filler from directly interacting with bone tissue to form a biological or even only a chemical or physical bond between the bone filler and bone. Furthermore, most popularly-used containers (balloons) are made from polymers which are not bioactive, bioconductive, or even biocompatible. The negative effects of this permanently implanted container are most obvious when the bone filler is a bioresorbable material, such as a calcium phosphate or calcium sulfate-based material. In this case even a biodegradable polymer container hinders the bioresorption process of the bioresorbable bone filler for a season, especially during the most critical early stage resorption/healing process. Furthermore, most biodegradable polymers do not demonstrate mechanical properties as desired.
An improved method for forming a hardened cement in a bone cavity involves inserting an inflatable, preferably inflatable and expandable, pocket into a bone being treated; injecting a hardenable cement paste into the pocket through a tube which connects and carries the pocket into the bone; allowing the cement paste to harden within the pocket in the bone cavity; opening the pocket; separating the pocket from the hardened cement, and retrieving the opened pocket from the bone with the hardened cement remaining in the bone. Advantages of this method include allowing the hardened cement implant to directly contact the surrounding bone tissue thus enhancing the healing process, and the much higher strength of the hardened cement compared to that of the cement paste directly injected into the bone cavity. This is especially advantageous for bioresorbable implants. A typical example can be found in U.S. Pat. No. 7,306,610 B2.
A further improved method for forming a hardened cement in a bone cavity involves inserting an inflatable, preferably inflatable and expandable, pocket into a bone being treated; injecting a hardenable cement paste into the pocket through a tube which connects and carries the pocket into the bone, therein said pocket is made from a material penetrable to liquid but substantially impenetrable to the powder of said cement paste; allowing the cement paste to harden within the pocket in the bone cavity; opening the pocket; separating the pocket from the hardened cement, and retrieving the opened pocket from the bone with the hardened cement remaining in the bone. A primary advantage of this method is allowing a portion of the liquid contained in the cement paste to be expelled out of the pocket, especially when a pressure is applied unto said cement paste before said cement paste is substantially hardened, so that the powder/liquid ratio of said cement paste in said pocket is increased and the strength of the hardened cement is further increased. This further increase in cement strength is especially advantageous for the relatively weak ceramic, calcium-based cement. Typical examples can be found in U.S. Pat. No. 7,144,398 B2, WO 2004/093733, and WO 2006/138398.
Nevertheless, one disadvantage for the prior art pocket-injection approach is that there exists a portion of the bone cavity which cannot be filled due to the generally irregular shape of the cavity. Although the hardened cement implant may be strong enough to support the restored/expanded bone structure, the remaining (unfilled) cavity can act as a weak spot to potentially induce subsequent local fracturing. Such unfilled space can also induce the undesirable fibrous tissue ingrowth. Another potential problem is that, once the implant resorption process becomes significant, the new bone-incorporated cement implant may become too weak to support the structure. This can potentially cause subsequent fracture/collapse, if the resorption rate of the hardened cement is not carefully controlled.
SUMMARY OF THE INVENTION
The present invention discloses a method for forming a bioresorbable composite implant in a bone cavity, which overcomes most aforementioned difficulties/problems. The primary improvement step of the present invention is inserting a second bone filler with different resorption rate, structure and/or properties into the remaining (unfilled) cavity after the first bone filler (a cement paste) is hardened in a cavity in the bone being treated, wherein the hardened first bone filler and the second bone filler forming a composite implant in the bone cavity.
A method for forming a composite implant in a bone cavity disclosed in the present invention comprises i) forming a first bone filler in a bone cavity; and ii) inserting a second bone filler into an unfilled space in said bone cavity, wherein the first bone filler has a higher compressive strength and slower bioresorption rate in comparison with the second bone filler.
Preferably, the first bone filler comprises a hardened first orthopaedic paste as a major portion thereof, and the second bone filler comprises a hardened second orthopaedic paste as a major portion thereof, wherein the hardened first orthopaedic paste and the hardened second orthopaedic paste are both bioresorbable materials, and the hardened second orthopaedic paste has a porosity 20% higher than that of the hardened first orthopaedic paste. More preferably, the hardened second orthopaedic paste has a porosity 40% higher than that of the hardened first orthopaedic paste.
Preferably, said inserting in step ii) comprises injecting the second orthopaedic paste into the unfilled space in said bone cavity, and letting the second orthopaedic paste harden in the unfilled space.
Preferably, said inserting in step ii) comprises inserting a tube into the unfilled space in said bone cavity through a minimally invasively percutaneous path; injecting the second orthopaedic paste into the unfilled space in said bone cavity through said tube; letting the second orthopaedic paste harden in the unfilled space; and removing said tube from said percutaneous path.
Preferably, the second bone filler is in granular form.
Preferably, the second orthopaedic paste is calcium phosphate cement paste, calcium sulfate cement paste, or bioactive glass-based cement paste. More preferably, the second orthopaedic paste is further doped with a bone morphogenic protein (BMP), a growth factor, or living cells for enhancing bone resorption/healing processes, or the second orthopaedic paste is further doped with calcium phosphate particles, calcium sulfate particles, or bioactive glass particles.
Preferably, the first orthopaedic paste is calcium phosphate cement paste, calcium sulfate cement paste, or bioactive glass-based cement paste. More preferably, the first orthopaedic paste is further doped with calcium phosphate particles, calcium sulfate particles, or bioactive glass particles for improving the compressive strength.
Preferably, the first bone filler and the second bone fillers are both bioresorbable materials, and the second bone filler has a bioresorption rate higher than the first bone filler by at least 50%.
Preferably, said forming in step i) comprises inserting a major portion of a perforated balloon in said bone cavity; injecting the first orthopaedic paste into said perforated balloon, wherein said perforated balloon comprises a neck adapted to be mounted on an end of a tube through which said first orthopaedic paste is injected into the perforated balloon, and leaking perforations, wherein said leaking perforations have a size which is penetrable to liquid contained in said first orthopaedic paste but substantially impenetrable to powder contained in said orthopaedic paste under an expanded condition of said perforated balloon; letting the first orthopaedic paste harden in the perforated balloon under pressure, wherein said liquid contained in said first orthopaedic paste escapes from said perforated balloon through said perforation during said injection and hardening of said first orthopaedic paste; opening the perforated balloon when the first orthopaedic paste hardens or partially hardens; and retrieving the opened balloon from the bone cavity by pulling said tube to leave the hardened or partially hardened orthopaedic paste in the bone cavity.
Preferably, said opening comprises continuously or intermittently injecting a liquid or gas into the perforated balloon containing the hardened or partially hardened first orthopaedic paste therein until the perforated balloon is dilated to exceed a critical size, and thus ruptures.
Preferably, a rupture array is formed on said perforated balloon for initiating said rupture of said perforated balloon when the perforated balloon is dilated to exceed said critical size.
Preferably, a forced-feeding mechanism having a liquid or gas reservoir is connected to another end of the tube, and said liquid or gas is continuously or intermittently injected from the reservoir into the perforated balloon through said tube by applying a force to said forced-feeding mechanism, until the perforated-balloon is dilated to exceed said critical size. More preferably, said forced-feeding mechanism is a syringe.
Preferably, said rupture array comprises pores, dents, notches, grooves or cuts formed on said perforated balloon, which function as weak spots so that said rupture occurs along at least a portion of said weak spots. More preferably, said weak spots form one or more dotted lines.
Preferably, said rupture array is located in a region opposite to said neck of said perforated balloon.
Preferably, said weak spots form one dotted line across an apex of the perforated balloon or more dotted lines intersect at an apex of the perforated balloon.
Preferably, said rupture array comprises pores having a size which is penetrable to liquid contained in said orthopaedic paste but substantially impenetrable to powder contained in said orthopaedic paste under an expanded condition of said perforated balloon. More preferably, said pores constitutes a portion of said leaking perforations. Alternatively, said pores constitutes whole said leaking perforations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic front view of a perforated balloon for entrapping an orthopaedic paste in a bone cavity until the paste is hardened in a bone cavity disclosed in WO 2006/138398.
FIG. 2 is a schematic side view of the perforated balloon shown in FIG. 1 .
FIG. 3 is a schematic side view of a cement-filled balloon under forced-feeding by fluid.
FIG. 4 is a schematic side view showing a representative implementation of forced-feeding by connecting the balloon rear end to a syringe.
DETAILED DESCRIPTION OF THE INVENTION
The present invention discloses a method for forming a composite implant in a bone cavity comprising (a) preparing a first bone filler comprising a cement paste; (b) inserting a pocket into said bone; (c) injecting said first bone filler into said pocket, wherein said injecting is carried out with a means which is able to be operated outside said bone cavity; (d) allowing said cement paste at least partially harden in said pocket, wherein said cement paste in said pocket is optionally under a pressure while said cement paste is hardening in said pocket; (e) opening said pocket, wherein said opening is carried out with a means which is able to be operated outside said bone cavity, and the resulting opened pocket is attached to said means; (f) separating the resulting opened pocket from said hardened cement, wherein said separating is carried out by removing the resulting opened pocket from said bone cavity with the hardened cement remaining in said bone cavity; (g) inserting a second bone filler into said cavity, wherein the hardened first bone filler and the second bone filler forming a composite implant in said bone cavity.
The method of the present invention further comprises preparing a minimally invasively percutaneous path for the pocket to be inserted into the bone being treated.
The method of the present invention further comprises inserting an injection tube into the bone through said percutaneous path, therein the pocket is connected to or near distal end of said injection tube.
The pocket used in the method of the present invention is preferably made from a material penetrable to liquid but substantially impenetrable to the powder of said cement paste under expanded condition.
The pocket used in the method of the present invention preferably comprises at least one perforation through the membrane of said pocket, therein the perforation size can be controlled so that the pocket is penetrable to liquid but substantially impenetrable to the powder of said cement paste under expanded condition.
Step (d) of the method of the present invention preferably further comprises applying a pressure unto said cement paste before said cement paste is substantially hardened, causing a portion of the liquid contained in said cement paste to be expelled out of the pocket, so that the powder/liquid ratio of said cement paste in said pocket is increased.
The pocket used in the method of the present invention preferably comprises a designed pattern (perforation size, number and distribution) of perforations through the membrane of said pocket; therein a first portion of said perforations are able to function as channels through which said a portion of the liquid contained in said cement paste can be expelled out of the pocket; therein a second portion of said perforations are able to function as “weak spots” wherein said opening in (e) can preferentially occur at (along) said weak spots; wherein said first portion of said perforations and second portion of said perforations are optionally the same perforations.
Step (e) of the method of the present invention preferably comprises opening the pocket by means of a cutting mechanism, a thermal softening/melting mechanism, or a “forced-feeding” mechanism; wherein said cutting is conducted unto at least a portion of said pocket with a cutting means, for example, a thin wire or blade; said thermal softening/melting is conducted with an energy directed by an electrically, thermally or optically conductive wire embedded in at least a portion of said pocket; said “forced-feeding” is characterized by, after said cement paste is substantially hardened, further injecting a biocompatible fluid (water, oil, etc) into the pocket at a flow rate greater than that of the fluid leaking out of the pocket to cause said pocket to swell until it ruptures.
The method of the present invention further comprises, prior to inserting a pocket into the bone, creating a cavity and/or restoring at least a portion of height of the bone being treated, wherein the volume of the first bone filler injected into the pocket can be controlled to either avoid further expanding the bone, or to further expand the bone.
At least one of said first bone filler and second bone filler is a synthetic bioresorbable material. Preferably said first bone filler and said second bone filler are both bioresorbable materials. More preferably the second bone filler has a higher bioresorption rate than the first bone filler. Most preferably the second bone filler has a bioresorption rate higher than the first bone filler by at least 50%.
The second bone filler further has a more porous structure than the first bone filler. Preferably the second bone filler has a porosity volume fraction greater than the first bone filler by at least 20%; more preferably by at least 40%.
The first bone filler further has a higher compressive strength than the second bone filler.
The first bone filler material is preferably a viscous, flowable and hardenable calcium-based paste material, e.g., calcium phosphate-based or calcium sulfate-based cement paste; said first bone filler material is optionally doped with a relatively strong and rigid biocompatible phase, such as dense calcium phosphate particles, calcium sulfate particles, or bioactive glass particles, for improving strength.
The second bone filler material can be in granular form, cement paste form, or a granule-cement composite form; said second bone filler is preferably a calcium phosphate, calcium sulfate, or bioactive glass-based material; said second bone filler material preferably has a porous structure with a porosity volume fraction greater than about 50%, preferably greater than 70%; said second bone filler material is optionally doped with a BMP, a growth factor (e.g., a bone marrow or blood-derived growth factor), or living cells for enhancing bone resorption/healing processes.
The second bone filler can be delivered into the unfilled bone cavity through the same percutaneous path or a different percutaneous path.
The bone being treated is preferably a diseased or fractured vertebral body.
When the second bone filler of said composite implant is in granular form, the maximum dimension of the granules is preferably less than 3 mm, more preferably less than 2 mm, most preferably less than 1 mm, capable of being delivered through a minimally invasive percutaneous path or tube.
The bone being treated is preferably a diseased or fractured vertebral body.
Major advantages of this composite bone filler design are listed as follows:
Both first bone filler and second bone filler are bioresorbable materials and eventually the entire composite implant will be entirely replaced by natural bone. The relatively strong first bone filler hardened from a cement paste within a pocket under pressure functions as a primary load-bearer and supports the treated/restored bone structure against collapse or subsequent fracture, while the second bioresorbable bone filler provides a fast bioresorption/healing process for the wounds. The relatively low bioresorption rate of the first bone filler allows the resorption/healing processes associated with the fast-resorbable second bone filler to be substantially completed before the first bone filler starts to be significantly resorbed which may cause the first bone filler to become too weak to support the structure during its resorption process. (Cracks may occur accompanying the resorption process of a bioresorbable implant and thus weaken the implant structure) In the present composite implant design, at the time the first bone filler starts to be significantly resorbed, the second bone filler will have readily been replaced by natural bone which will help bear loads.
In order for the balloon to be ruptured in a predetermined (designed) manner (pattern) after the cement is hardened, “perforation array” is designed, for example the perforation array 210 shown in FIGS. 1 and 2 . The perforation array 210 is used mainly to rupture the inflated balloon 200 with predetermined lines/pattern of breakup, although permeability effect is also provided therein when the pore size is carefully controlled. The perforation array is also designed to keep the entire ruptured balloon to remain attached to the injection tube end after being ruptured. Without this design, it is highly likely that some random pieces of the ruptured balloon are detached from the balloon and left permanently in the bone cavity. Ideally the entire balloon should remain attached to the injection tube after being ruptured and can be entirely withdrawn along with the tube.
The perforation array 210 comprises designed patterns of pores, dents, notches, grooves, cuts, etc. and are made on the surface of at least a portion of the balloon. Such pores, dents, notches, grooves, cuts, etc. can be made by any conventional methods. Preferably, these pores, dents, notches, grooves, cuts, etc. are made at or near the central part of the balloon. Preferably, the “lines of perforation” converge around the apex of the balloon, creating relatively weakened spots where rupturing crack would initiate.
Such parameters as pore size, population, spacing between perforations, number of perforation array, and the array size are to be controlled and optimized to result in a required structural characteristics of the balloon.
Although permeability (draining) effect is provided in the design of the perforation array, in order to more effectively drain water and air out of the balloon as the cement paste is injected to fill the bone cavity, micro-pores 220 can be further incorporated over the surface of the balloon 200 . These micro-pores can be distributed randomly or in a designed manner/pattern and will be progressively enlarged as cement mixture is continually delivered into the balloon.
The perforations of the perforation array 210 and the micro-pores 220 of desired diameters and optionally desired distribution (pattern) can be made mechanically (for example, by needle drilling), chemically (for example, by etching/dissolving) or thermally (for example, by focused heat or laser drilling). The perforations/pores can be made on an empty balloon, a balloon still attached onto a substrate mode (for example, a balloon made by dipping a balloon-shaped substrate mode of a desired size and shape in a PU solution), or a pre-expanded balloon with an infilling material.
As perforations/pores are made on a pre-expanded balloon, the infilling material can be any material which can be delivered into and expand the balloon, and removed from the balloon after perforations are made on the expanded balloon. The infilling material is preferably a high-viscosity powder-liquid mixture paste which will not set/harden in a short period of time after mixing (for example, a CaO powder/water mixture). The balloon can be pre-expanded to any desired size whereas perforations are made. One advantage for perforations/pores made on a pre-expanded balloon is its easier control in perforation quality, since the balloon surface is enlarged during expansion.
As a balloon swells to certain critical size, the internal stresses developed in the stretched membrane will reach the balloon fracture stress threshold. The corresponding strain at balloon fracture can be converted into the rupture volume of the balloon. When balloon is filled with any material which expands the balloon to this critical volume, balloon will fracture spontaneously and the fractured balloon membrane will shrink to its zero-stress state size. Balloon extraction can hence be achieved while leaving the solidified cement deployed in the designated bone cavity.
FIG. 3 shows a cement-filled balloon under forced-feeding by fluid. As the feeding pressure destroys the initial static equilibrium the solidified cement will be lifted up immediately with an inlet flow passage created around the feeding entrance, followed by a filling of the balloon due to the infused fluid volume. Any fluid, gas or liquid, can be used as the filling material so long as it is biocompatible. These fluid fillers first separate the balloon membrane from the solidified cement surface, greatly reducing the contact friction by generating a layer of fluid buffer. Then a further injection of fluid filler will expand the balloon until balloon rupture is accomplished. According to the mass conservation of fluids, the rate of mass increment contained in the balloon closure is equal to the net mass flux convected through the inflow/outflow tracts:
ρ ⅆ V ⅆ t = ∑ i ρ Q i in - ∑ i ρ Q i out ( 2 )
in which, V is the volume and ρ is the density of the fluid while Q i in and Q i out are the inflow and outflow volume flowrates, respectively. For the case illustrated in FIG. 3 , Q i in is the forced-feeding influx and
∑ i Q i out
is the net outflux contributed by all the leakage flows across the micro-pores and perforations in the membrane wall. So long as the volume flux of the inflow is greater than that of the outflow, the balloon will keep on swelling until it ruptures.
FIG. 4 shows a representative implementation by connecting the balloon rear end to a fluid filler such as a syringe 100 having a fluid reservoir 110 . Any decrease of the reservoir volume by pushing the syringe 100 from behind, with sufficiently force and speed, may result in a net volume infusion into the balloon. Balloon will rupture as the accumulated fluid mass increases and the resultant membrane stresses reach the rupture threshold value.
To reduce the risk that a portion (especially the leading/top portion) of ruptured balloon (especially for rupture occurring around the belly/equator portion of the balloon) being trapped in the cavity when the ruptured balloon is retrieved from the cavity site, a thread can be connected to any part of the balloon as a safety device. Since the leading/top portion is one that most easily breaks off the balloon during rupture, the thread can be connected (for example, by glue) to such location. In case a portion of ruptured balloon is broken off, the broken-off piece can be retrieved by the connected wire/thread independently.
A second bone filler is now delivered into the unfilled bone cavity with an injection tube through the same percutaneous path after the ruptured balloon being withdrawn from the bone cavity. The second bone filler is preferably a high-viscosity powder-liquid mixture paste the same as the hardened cement already in the bone cavity, or optionally doped with additional BMP, a growth factor, or living cells for enhancing bone resorption/healing processes. Preferably, the injection tube is kept in the percutaneous path and the injection pressure is maintained for a period of time so that the injected paste hardens or partially hardens in the unfilled bone cavity. The injection tube is then removed from the percutaneous path to complete the implantation of a composite filler in the bone cavity.
|
A method for forming a composite implant in a bone cavity is disclosed, which includes i) forming a first bone filler in a bone cavity; and ii) inserting a second bone filler into an unfilled space in the bone cavity, wherein the first bone filler has a higher compressive strength and slower bioresorption rate in comparison with the second bone filler.
| 0
|
TECHNICAL FIELD
[0001] The present invention relates to a method for dosing and dispensing a laundry detergent into a washing machine, and to the dosing and dispensing device for use therein.
BACKGROUND OF THE INVENTION
[0002] Dispensing devices which are useful for machine washing of clothes are described in, for example, FR-A-2 563 250, published on 25 th Oct. 1985.
[0003] It is known that, in order to obtain a good degree of cleanliness whilst minimizing wastage it is important to dose the right amount of product. This is commonly achieved by embossed dosing lines marks on the dispensing device but these are difficult to read because the lines and the background are made of the same material and color resulting in a low contrast. Accurate dosing is made even more difficult with transparent or translucent liquid products that provide little or no contrast against which embossed dosing lines can be read.
[0004] The requirements of resistance to boil wash and need for transparency have ruled out conventional labelling technology such as wet glue labels, self-adhesive labels, or in mold labels for dosing devices.
[0005] One technology which has been used with success is hot stamping, but this is expensive, requires dedicated equipment and only works with flat surfaces on the device. Hot stamping however does not allow large and multicolour printing on the device and as such is not an adequate means of decoration.
[0006] The aim of the present invention is to provide a dosing and dispensing device which has accurate dosing lines marking and graphics that are resilient to boil wash and retain the transparency of the device where the sleeve is not printed.
SUMMARY OF THE INVENTION
[0007] In a first aspect the present invention provides a method for dosing and dispensing a laundry detergent, preferably a liquid laundry detergent, into a washing machine comprising the steps of
i) measuring a dose of laundry detergent into a dosing and dispensing device comprising a hollow cavity defined by a base and side-walls, wherein the base and/or side walls are at least partly covered by a sleeve, and wherein the sleeve comprises a film of material comprising printed indicia thereupon, wherein the printed indicia are resistant to removal from the film when the dosing and dispensing device is exposed to wash conditions inside a washing machine; ii) placing both the laundry and the dosing and dispensing device containing laundry detergent into a washing machine, and running the washing machine on a selected cleaning cycle; and iii) subsequently reusing the dosing and dispensing device for steps i) and ii).
[0011] In a second aspect the present invention provides a dosing and dispensing device comprising a hollow cavity defined by a base and side-walls, wherein the base and/or side walls are at least partly covered by a sleeve, and wherein the sleeve comprises a film of material comprising printed indicia thereupon, wherein the printed indicia are resistant to removal from the film when the dosing and dispensing device is exposed to wash conditions inside a washing machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a dosing ball suitable for use in the present invention.
[0013] FIG. 2 shows in isomeric view the same ball as in FIG. 1 .
[0014] FIG. 3 shows a sleeve printed with dosing lines suitable for sleeving around the dosing ball shown in FIGS. 1 and 2 .
[0015] FIG. 4 shows the finished device according to the present invention consisting of the dosing ball and printed sleeve.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The invention relates to a decorated reusable dosing and dispensing device for washing machines where the means of marking and decoration is a plastic sleeve. The term “dosing and dispensing device”, or “dosing device” for short, herein should be understood generally as a means for providing measured quantities of fluid products into a washing machine. The term “fluid products” includes liquids or gels as well as flowing materials such as powders or granules.
[0017] The dosing device has a base. By a base it should be understood a part of the device on which the device is left to stand up-right. This part my be flat, or may for example be formed from a moulded tripod, or from a flat ring. Many types of “base” are known in the art, the main feature of such a base being to hold the device in a stable position on a flat supporting surface. The base comprises a base wall. The device also has a major axis which is generally perpendicular to the plane of the base.
[0018] The device also comprises sides. The sides are the surfaces which, in general terms, join the top and the base of the bottle. Typically, when the device is upright, the sides are substantially vertical and perpendicular to the base. The sides may also have a curved or relatively complex shape depending on the device considered. The base and side-walls define a hollow cavity, which is capable of containing a liquid product within the solid walls defining the hollow cavity.
[0019] The device further comprises a top part. The top part is typically the part of the device opposed to the base. The top is commonly the part of the device which is provided with an aperture for dosing the laundry product. The aperture is generally provided without a closure so that the device can be nested on top of a bottle when not used during the washing process.
[0020] The device may be formed by any convenient means, blow-molding being the most commonly used. Preferably the device has an internal volume of at least 20 ml and of less than 500 ml, and more preferably less than 300 ml.
[0021] Further, the device is sleeved. Whilst any process can be used to attach the sleeve around the outside of the dosing device, preferred processes are shrink-sleeving and stretch-sleeving. In these processes the sleeve is generally formed by forming the plastic film essentially into a tube, preferably by folding the film back upon itself and forming a seam, and cutting the tube to form individual sleeves.
[0022] Shrink-sleeving is mostly used in the drinks industry, whereby a sleeve of thermo-plastic material may be stretched or shrunk all around a beverage bottle, thus offering an extended area which may be used for any type of graphics. Typical thermoplastic materials used for stretch or shrink sleeving include polyvinylchloride (PVC); low or high density polyethylene (LDPE, HDPE); polyester teraphthalate (PET); polypropylene (PP) and oriented polypropylene (OPP); polystyrene (PS) and oriented polystyrene (OPS); and mixtures thereof.
[0023] Stretch-sleeving entails placing a stretchable sheath on a reel and forming a tubular sheath made from stretchable plastic material of the dimension required to fit the product. We often find that the use of stretch sleeving for provision of decorative or informative packaging on products has the benefit of increased economy since inexpensive film materials such as low density polyethylene (LDPE) or low density polyethylene/ethyl vinyl acetate (EVA) blends or co-extrusions may be sued for the polymeric film sleeve. Such processes and typical applications are described in US 2004/0182501 or WO 03/037745.
[0024] Shrink-sleeving or stretch-sleeving consists in enveloping a part of the device in a tube-like flexible sleeve. Preferably the material of the sleeve is thermoplastic, and the sleeve is heated to shrink closely around the outer surface of the device or in the case of a stretch sleeve stretched to the dimensions required to fit around the device. The sleeve may be made from a single film of plastic, or laminated in two or more layers. The plastic film may be either coloured or glass clear transparent glossy film which will be printed upon, or, alternatively, in the case of a laminated film, at least one layer of film may be pigmented by the addition of dyes or pigments before or at the point of extruding the laminate. The plastic film may also be decorated with colours, designs, logos, usage instructions, health and regulatory symbols and warnings, and other written or graphical information. Preferably the indicia comprise at least one indication of dosing volume or dosing weight. More preferably the indicia comprise at least one indication of dosing volume or dosing weight positioned within or close to a transparent window in the sleeve in order to facilitate measurement of the desired dose. Accurate dosing is facilitated by the contrast between the dosing indicia and the product to be dosed, especially if the product is a transparent or translucent liquid, i.e. has a light transmittance greater than 25% at wavelength of 410-800 nm.
[0025] Many different printing processes may be used to print on the film, but gravure and flexography are preferred, utilizing continuous web substrate. Gravure is an intaglio process, in that the printing image is formed below the surface of the printing medium. A cylinder is engraved utilizing the art for the particular shrink or stretch sleeve label. Flexography is a relief printing process developed from the letterpress principle. The printing image is produced on a photopolymer plate, in which the image is physically above the non-image area.
[0026] The characteristics on the inks desired in the present invention include visual appearance, durability, color steadfastness and strong adhesion quality. Both water and solvent based inks have been found suitable for application in the present invention. To prevent a “wet” look when a shrink or stretch sleeve label is not printed with a tint coating, anti-wet coating is used to eliminate a spotty or water stain appearance when the sleeve label is applied to a container that contains imperfections (voids) on their surface. These imperfections can trap air between the sleeve label and the container surface, giving rise to the spotty or water stain appearance. Anti-wet coating creates breathable channels, allowing the air to escape during the shrinking phase, and thus eliminating the spotty or water stain appearance. Some label designs may have one or more areas that constitute a window devoid of any ink. The content of the device may be viewed through the one or more windows of the film and through the device wall. In such cases, the inner surface of the window areas may have the anti-wet coating.
[0027] Preferred inks are nitro-cellulosic inks.
[0028] A preferred method, known as reverse printing, is to print the colours on the inside of the sleeve, i.e. the side which will be in contact with the base or side-wall of the dosing device, in order to maintain its glossiness and prevent abrasion and ink transfer to the clothes during the washing process. A particularly preferred method, known as sandwich printing, is to reverse print on to the sleeve material and cover the printed sleeve material on the printed side with another sleeve of the same or slightly lower or higher thickness. The inks are entrapped in between, and protected by, two layers of sleeve material.
[0029] A particular benefit of sandwich printing is that it helps to prevent slipping of the sleeve around the surface of the dosing ball, and as such helps the sleeve to remain in its original position.
[0030] Alternatively, in the case where front “surface” printing is used, then suitable varnishes will be added on top of the inks layers to protect the inks for the wash liquor and clothes and machine drum abrasion. Particularly suitable varnishes are acrylic-based varnishes and ultraviolet-cured varnishes.
[0031] Preferably the sleeve covers at least 30% of the side-walls of the dosing device, and preferably covers at least 50% of the side-walls of the dosing device, and more preferably covers at least 70% of the side-walls of the dosing device.
[0032] In a particularly preferred embodiment of the present invention the sleeve has a cut-out region that is juxtaposed with the pre-treating region of the device. This allows decoration of a dosing device with a pre-treat slit or roll-on applicator.
[0033] A typical device according to the present invention comprises a dosing ball as illustrated in FIGS. 1 and 2 and a sleeve as illustrated in FIG. 3 . The dosing ball 10 shown in FIGS. 1 and 2 comprises a base 11 and side-walls 12 which define a hollow cavity. The hollow cavity is in direct communication with the outside of the dosing ball 10 by means of an open aperture at the top 13 . Viewed from the outside, the three-dimensional shape of the dosing ball 10 is substantially spherical with a flat base 11 and open top 13 .
[0034] FIG. 3 shows a sleeve 20 with indicia 21 marked thereon. In this example the indicia comprise a largely coloured surface 22 and a transparent window 23 . Around the edge of the transparent window dosing lines indicate 50, 60, 75, 90, 100, 120, 125 and 150 ml.
[0035] FIG. 4 shows a dosing and dispensing device 30 according to the present invention comprising the dosing ball 10 shown in FIGS. 1 and 2 with the sleeve 20 shown in FIG. 3 covering the side-wall. The sleeve is brought into close proximity with the side-wall by shrink-sleeving, or, alternatively, by stretch-sleeving. In FIG. 4 the shrunken sleeve 32 is shown covering substantially 100% of the side-wall. The transparent window 33 provides the means for the user to see the level of detergent which is within the hollow cavity of the dosing device, and thus enables the user to measure the desired dose.
[0036] Method of Use. The dosing device of the present invention is filled with detergent, preferably liquid detergent, up to required level indicated by the dosing lines printed on the sleeve. Once the filling operation has been completed and the fabrics have been arranged in the drum of the washing machine, the device filled with detergent is then introduced onto the fabrics present in the drum. Once the machine has been started, the product held in the ball is dispensed into the wash by the rotation of the drum. After washing, the device is retrieved from the drum and ready for the next use. Colors and marking remain intact even after numerous washes.
[0037] Alternatively consumers may wish to remove the sleeve prior to using in the washing machine. This could be because the consumer is washing particularly expensive or delicate garments and wants to eliminate any risk of damage to the garment, for example in case the sleeve detaches in the wash. Alternatively this could be because the consumer wishes to use a drying cycle after the wash cycle and does not wish to look for the dosing ball in the wash load in order to remove it. The sleeved dosing ball may not be compatible with extended drying cycles at high temperature and thus it is important to have the ability to remove the sleeve. In a preferred embodiment of the present invention the sleeve can incorporate a line of weakness, such as a perforation, and appropriate marking to facilitate tearing off of the sleeve before use.
[0038] In a further preferred embodiment of the method of the present invention an additional step is introduced, between steps i) and ii), of pretreating stained or soiled laundry with a portion of the measured laundry liquid.
[0039] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
[0040] All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
[0041] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
|
The present invention relates to a method for dosing and dispensing a laundry detergent, preferably a liquid laundry detergent, into a washing machine comprising the steps of:
i) measuring a dose of laundry detergent into a dosing and dispensing device ( 10 ) comprising a hollow cavity defined by a base ( 11 ) and side-walls ( 12 ), wherein the base ( 11 ) and/or side walls ( 12 ) are at least partly covered by a sleeve ( 20 ), and wherein the sleeve ( 20 ) comprises a film of material comprising printed indicia ( 21 ) thereupon, wherein the printed indicia ( 21 ) are resistant to removal from the film when the dosing and dispensing device ( 10 ) is exposed to wash conditions inside a washing machine; ii) placing both the laundry and the dosing and dispensing device containing laundry detergent into a washing machine, and running the washing machine on a selected cleaning cycle; and iii) subsequently reusing the dosing and dispensing device ( 10 ) for steps i) and ii).
| 3
|
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of priority to Japanese Application No. 2006-321247, filed Nov. 29, 2006, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image obtaining device such as a digital camera, and especially relates to when the settings of the image obtaining device are determined.
2. Discussion of the Background
A self-timer function, which imposes a delay for a predetermined time between an instruction of photographing and a time of photographing, is found on most cameras and permits the photographer to be in the picture. In the case of using the self-timer function, at first a self-timer mode is set on the camera and next a release button is pressed. In the above case, it is no problem that there are multiple subject persons such as in a group photo since a photographer can operate a self-timer photographing after the photographer focuses on any of subject persons other than the photographer. However in the case that the photographer take a photo of the only photographer itself, the photographer must focus on a position which the photographer will be in at a time of photographing, operate the self-timer function, and move to the position during a delay time. This has some problems, for example, whether the photographer can get to the desired position or not, whether there is an object for focusing on, and so on. As a result, the photographer may take a photo which has a lack of sharpness caused by the photographer that cannot get into position accurately, or there are no objects for focusing on instead of the photographer himself. In the case of the subject have no contrast or a recurrent pattern, it is difficult to focus on the subject.
Regarding a self-timer function, Japanese Laid-Open Patent Application No. 2004-336265 discloses that a number of subject people are registered on a camera and the camera take a photo at the time of detecting eyes for subject person. The camera prevent taking a failed photo such that the subject person look away, the subject person closes his eyes, and so on.
Japanese Laid-Open Patent Application No. H8-006154 discloses that a camera performs a distance determination during a delay time of the self-timer function. The operation does not need extra time because a releasing operation has a priority over the distance determination. Moreover, the camera has a focus priority mode and a release priority mode. However Japanese Laid-Open Patent Application No. H8-006154 does not disclose a technology for easily allowing the photographer takes a photo of himself. Further, Japanese Laid-Open Patent Application No. H8-006154 still has a problem that the camera fails to focus accurately in the case that there are cumbersome objects in the subject or there are no objects for focusing on instead of the photographer himself. Moreover, Japanese Laid-Open Patent Application No. H8-006154 has a problem that the camera cannot change a setting such as an automatic focus area and an automatic exposure area.
Further, Japanese Laid-Open Patent Application No. H5-053186 discloses that a camera flashes a light corresponding to photographing range. A photographer can recognize that he is in a photographable position when he sees a flashing light, even in the case that the photographer takes a photo of the photographer himself.
SUMMARY OF THE INVENTION
The present inventors recognized that the above-described background art suffers from taking a photo of a photographer itself.
Therefore, an object of the present invention is to provide a novel imaging pickup apparatus that simplifies a photographing operation having a delaying time such as a self-timer mode or remote control mode and gives good results.
There is an imaging apparatus, which may be a digital camera, for example which includes a face detector which detects a face of a person being photographed, a timer configured to delay a time an instruction is provided until an image is photographed, and a controller configured to operate the face detector during the time in which there is the delay and to change photographing parameters prior to photographing using a result of the face detector.
The invention further includes a method of capturing an image. According to the method, the method includes receiving an instruction to capture an image, running a timer which delays a start of the capture of the image, performing a face detection of a person being photographed while running the timer, setting an image capture parameter using a result of the face detection, and capturing the image after the delay caused by the timer using the image capture parameter which has been set.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a top view of an imaging pickup device according to the present invention;
FIG. 1B is a front view of the imaging pickup device according to the present invention;
FIG. 1C is a back view of the imaging pickup device according to the present invention;
FIG. 2 is a block diagram showing a system configuration in the image pickup apparatus according to the present invention;
FIG. 3A is a finder image indicating a self-timer mode (10 seconds mode);
FIG. 3B is a finder image indicating a self-timer mode (2 seconds mode);
FIG. 3C is a finder image indicating a remote control mode;
FIG. 4 shows a normal AF frame in the imaging pickup device;
FIGS. 5A and 5B show an AF area in the imaging pickup device in the case of succeeding a facial recognition;
FIG. 6 shows a divided digital RGB area in the imaging pickup device;
FIG. 7 shows a facial area setting in the divided digital RGB area when a facial recognition function is operated;
FIG. 8 is a flowchart showing the operation of the invention;
FIG. 9A shows a finder image in the case of recognition two facial areas according to the present invention;
FIG. 9B shows an AF evaluated value characteristics in the case of recognition two facial areas according to the present invention;
FIG. 9C shows a finder image for two people who are close to each other;
FIG. 9D shows AF evaluated characteristic of the image of FIG. 9C ;
FIG. 10 is a flowchart showing a photographing supplementary process in the case of operating a self-timer photographing according to a first embodiment;
FIGS. 11A and 11B are a flowchart showing a photographing supplementary process in the case of operating a self-timer photographing according to a first embodiment;
FIG. 12A shows an angle of view for photographing according to a second embodiment;
FIG. 12B shows a zoom angle of view for a re-recognizing a facial area according to a second embodiment;
FIG. 12C shows the angle of view for photographing after re-recognizing a facial area according to a second embodiment; and
FIG. 13 is a flowchart showing a photographing supplementary process in the case of operating a self-timer photographing according to a first embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings where like reference numerals designate identical or corresponding parts throughout the several views and more particularly to FIG. 1 thereof, there is illustrated a digital camera according to a first embodiment of the present invention. FIG. 1A is a top view of the digital camera, FIG. 1B is a front view of the digital camera, and FIG. 1C is a back view of the digital camera. FIG. 2 is a block diagram showing a system configuration in the digital camera according to the first embodiment.
A top face of the digital camera includes a release switch SW 1 , a mode dial SW 2 , and a liquid crystal display 1 (hereinafter called LCD) shown in FIG. 1A . A front face of the digital camera includes a camera cone 7 , an optical finder 4 , a strobe light emission part or flash 3 , a distance surveying unit or range finder 5 , a remote control receiver 6 may be implemented as an infrared receiver, an ultrasonic receiver, or a radio frequency receiver, for example which receives a command to take a picture and/or begin a delay timer, for example, for two seconds prior to taking a picture. There is also a battery loading part 2 and a cap of the battery loading part 2 shown in FIG. 1B .
In FIG. 1C , there is shown a back face of the digital camera which includes a power switch 13 , a LCD monitor 10 , an AF LED 8 , a strobe light LED 9 , the optical finder 4 , a wide-angle direction zoom switch SW 3 , a telephoto direction zoom switch SW 4 , a self-timer setting and canceling switch SW 5 , a menu switch SW 6 , an up direction and strobe setting switch SW 7 , a right direction switch SW 8 , a display switch SW 9 , a down direction and macro SW 10 , a left direction and image confirming switch SW 11 , an OK switch SW 12 , and a quick access switch SW 13 .
A system configuration of the digital camera is as follows. The digital camera is configured so that the digital camera is controlled by a digital camera processor 104 (hereinafter called processor 104 ) shown in FIG. 2 . The processor 104 includes a CCD1 signal process block 104 - 1 , a CCD2 signal process block 104 - 2 , a CPU block 104 - 3 , a local SRAM 104 - 4 , a USB block 104 - 5 , a serial block 104 - 6 , a JPEG codec block 104 - 7 , a resize block 104 - 8 , a TV signal display block 104 - 9 , and a memory card control block 104 - 10 which are connected each other by a bus, also referred to as a bus line. The digital camera includes a SDRAM 103 for storing RAW-RGB image data, YUV image data, and JPEG image data outside the processor 104 . The SDRAM 103 is connected to the processor 104 by the bus line. The digital camera includes a ROM 108 storing a control program, a RAM 107 , and an embedded memory 120 , connected to the processor 104 by the bus line.
The camera cone 7 includes a zoom optical system 7 - 1 including a zoom lens 7 - 1 a , a focus optical system 7 - 2 including a focus lens 7 - 2 a , an aperture unit 7 - 3 including an aperture 7 - 3 a , and a mechanical shutter unit 7 - 4 including a mechanical shutter 7 - 4 a . The zoom optical system 7 - 1 is driven by a zoom motor 7 - 1 b . The focus optical system 7 - 2 is driven by a focus motor 7 - 2 b . The aperture unit 7 - 3 is driven by an aperture motor 7 - 3 b . The mechanical shutter unit 7 - 4 is driven by a mechanical shutter motor 7 - 4 b . The zoom motor 7 - 1 b , the focus motor 7 - 2 b , the aperture motor 7 - 3 b , and the mechanical shutter motor 7 - 4 b are controlled by a motor driver 7 - 5 . The motor driver is controlled by the CPU block 104 - 3 .
The camera cone 7 includes a photographing lens including the zoom lens 7 - 1 a and the focus lens 7 - 2 a focusing an image onto a CCD 101 which captures an image and is an imaging device or part of an imaging device. The CCD 101 converts the subject image into an image signal and outputs the image signal to an F/E-IC 102 . The F/E-IC 102 includes CDS 102 - 1 , an ADC 102 - 2 , and an A/D converter 102 - 3 , operates a predetermined process to the image signal, converts the image signal into a digital signal, and outputs the digital signal to the CCD1 signal process block 104 - 1 . The predetermined process is controlled by a VD/HD signal output from the CCD1 signal process block 104 - 1 and via a TG 102 - 4 . These components can be constructed in any desired manner, and are not limited to what is disclosed in FIG. 2 , but any desired, known, or conventional structure can be used for obtaining the image.
The CPU block 104 - 3 controls a sound recording operation operated by a sound recording circuit 115 - 1 . The sound recording circuit 115 - 1 records an amplified signal amplified by a microphone AMP 115 - 2 based on instruction. The microphone AMP 115 - 2 amplifies a sound signal converted by a microphone 115 - 3 . The CPU block 104 - 3 controls a sound reproduction operation operated by a sound generating circuit 116 - 1 . The sound generating circuit 116 - 1 reproduces a sound signal recorded on a memory based on instruction and inputs the sound signal to an audio AMP 116 - 2 . The sound signal is output from a speaker 116 - 3 . The CPU block 104 - 3 emits an illumination light from the strobe light emission part 3 by controlling a strobe light circuit 114 . The CPU block 104 - 3 further controls the distance surveying unit 5 .
The CPU block 104 - 3 is connected to a sub CPU 109 which controls an operation to display information at a sub VCD 1 via a LCD driver 111 . The sub CPU 109 is connected to AF LED 8 , a strobe light LED 9 , a remote control optical receiver 6 , an operation key unit including the switches SW 1 to 13 , and a buzzer 113 which may be a speaker or any sound generator of the appropriate sound.
The USB block 104 - 5 is connected to a USB connector 122 , and the serial block 104 - 6 is connected to RS-232C connector via a serial driver circuit 123 - 1 . The TV signal display block 104 - 9 is connected to the LCD monitor 10 via the LCD driver 111 and connected to a video jack 119 via a video AMP 118 . The memory card control block 104 - 10 is connected to a card contact point of a memory card socket 121 .
Before operation of the digital camera according to the present invention is described, the operation of a well-known digital camera is described below. The digital camera boots up into a record mode by setting a mode dial SW 2 to a record mode. When the mode dial SW 2 is set, the CPU detects that a record mode is on, controls the motor driver 7 - 5 , and transfer the camera cone 7 to a position enabling to photograph. The digital camera turns on the CCD 101 , the F/E-IC 102 , and the LCD. When the each element is turned on, the camera is placed in a finder mode.
In the finder mode, a light entering the CCD 101 via a lens is converted to an electric signal, and sent to the CDS 102 - 1 and the A/D converter 102 - 3 as analog signals R, G, and B. The analog signals are converted to digital signals in the A/D converter 102 - 3 , the digital signals are converted to YUV signals in a YUV converter in the SDRAM 103 , and the YUV signals are recorded on a frame memory by a memory controller. The YUV signals are read out by the memory controller, are sent to a TV or the LCD monitor 10 via the TV signal display block 104 - 9 , and are displayed. The above process is operated at 1/30 second intervals, and the display is updated at 1/30 second intervals.
In the finder mode, when the self-timer setting and canceling switch SW 5 is pressed, it is possible to set a self-timer mode shown in FIG. 3 . The self-timer mode has two modes; a 2 seconds mode shown in FIG. 3A , and a 10 second mode shown in FIG. 3B , the 2 second mode operates a photographing process after 2 seconds and the 10 second mode operates a photographing process after 10 seconds. The 2 second mode is switchable to a remote control mode shown in FIG. 3C . When the remote control optical receiver 6 receives a signal from a remote controller, it is possible to start photographing after 2 seconds, or immediately, if desired
An AF (auto focus) system and an AE (auto exposure) system in the digital camera according to the present invention are described below. It assumed that the AF is a function of focusing a camera automatically (auto focusing function), and the AE mode determines an exposure (a combination of an aperture value, a shutter speed, and an ISO sensitivity) of a camera automatically (auto exposure function).
When the release switch SW 1 is pressed, an AF evaluated value indicating a level of focusing in a screen and an AE evaluated value indicating an exposure condition is calculated based on a digital RGB signal imported in a CCD and I/F block of a signal processing IC. An AF evaluated value data is read out by a microcomputer as a characteristic data and used on an AF process. The AF evaluated value data is an integration value and a high-frequency component of the integration value is highest since a edge part of a subject become clear in the case of focusing condition. During the AF process, the digital camera obtains the AF evaluated value at each focusing lens position and detects a maximum, or maxima, ((a) peak position(s)) with the above characteristics. When the AF evaluated value has a plenty of maxima or the largest number of peak positions, the digital camera adopts a most reliable point as a focusing point based on the amplitude of the AF evaluated value at a peak position and a degree of appreciation and declination from a neighborhood value.
The AF evaluated value is calculated from a predetermined range of the digital RGB signal. FIG. 4 shows the predetermined range, which is displayed at the LCD 10 in the finder mode. A center frame of FIG. 4 is the predetermined range. Here the predetermined range is 40% of a horizontal direction and 30% of a perpendicular direction of the digital RGB signal. When a facial recognition function can recognize a face, the predetermined area corresponds to the face shown in FIG. 5 . Even if the digital RGB signal includes multiple faces, the digital camera detects the multiple faces. The digital camera detects up to 4 faces, although more or less faces may be detected, as desired.
The digital camera divides the digital RGB signal into plural areas, for example 16×16 shown in FIG. 6 , and uses brightness data of the plural areas for calculating the AE evaluated value. The digital camera selects several pixels having a brightness value more than a threshold value from the plural areas as a subject pixel, adds up selected brightness values, and multiplies a number of the subject pixels. The digital camera calculates applicable exposure based on a brightness distribution of each area, and amends exposure based on the brightness distribution. Here, for example, when using a facial recognition function, the digital camera selects neighboring areas of an area included in facial recognition area as a subject area, and uses brightness data of the neighboring areas. If the digital RGB signal includes multiple faces, the digital camera selects neighboring areas of an area included in each facial recognition area as a subject area.
The digital camera includes the facial recognition function for the AF process and AE process. The facial recognition function is described below. A facial recognition mode of the digital camera is selected by the menu switch SW 6 , and may be registered or set using the quick access switch SW 13 . During the facial recognition mode, the digital camera periodically performs a facial recognition. A method of detecting a face from a subject image in the facial recognition function is well known and the present invention uses any one of methods below, or any other desired method:
“A Proposal of the Modified HSV Colour System Suitable for Human Face Extraction” vol. 49, No. 6, p. 787-797, 1995. The Journal of the Institute of Television Engineers of Japan, discloses a method that converts a color image into a mosaic image, and picks out a facial area by focusing attention on a flesh color area.
“A Method of picking out a facial area from a still shading scene image” vol. 74-D-II, No. 11, p. 1625-1627, 1991, The Journal of the Institute of Electronics, Information and Communication Engineers, discloses that a method picks up a head region of a front face by using a geometric aspect regarding each part of the head region such as eyes, a mouth, hair and so on.
“A detection of a facial area for a TV telephone and an effect of the detection” 1991-11, 1991, The GAZOH RABO, the image laboratory, discloses that a method picks up a front face by using a contour of a subject person generated by moving an microscopical motion between frames of a moving image.
Next an operation of the digital camera in the first embodiment is described below. The facial recognition process in the finder mode is described below with respect to FIG. 8 .
Since the finder mode is updated at 1/30 second intervals, the facial recognition process is operated so that the facial recognition process is synchronized with the finder mode. In the first step S 8 - 1 , the digital camera starts a flow for the facial recognition process. In the next step S 8 - 2 , the digital camera confirms whether the facial recognition mode is set or not. In the case that the facial recognition mode is set, flow proceeds to step S 8 - 3 , in which the digital camera performs a facial recognition process. In the next step S 8 - 4 , the digital camera sets an AF area based on a result of facial recognition process corresponding to a detected facial area shown in FIG. 5 . When the digital camera does not complete the facial recognition process, the digital camera sets a normal AF area as the AF area. In the next step S 8 - 5 , the digital camera sets a whole area the same as a normal photographing (not the facial recognition mode) because an exposure in a finder changes depending on whether the facial recognition process is completed or not.
In the case that the facial recognition mode is not set, in the next step S 8 - 5 , the digital camera operates the AE process and the process ends. In the case of multiple subjects, peaks of the AF evaluated values may not lap over each, as shown in FIG. 9B , when the facial recognition mode is operated in a situation shown in FIG. 9A . In the above case, the digital camera selects the nearer peak, for example B of FIG. 9B .
FIGS. 9C and 9D illustrate the selection of a face in a situation in which multiple faces are detected. In this case, the face which is more in the center of the image is the face that is chosen. In FIG. 9C , there are illustrated faces C and D, which are a plurality of people. In this figure, it is seen that the face C is more towards a center than the face D.
In FIG. 9D , there is shown an AF evaluated value which shows that the graph for face C is more towards the center of the picture as compared to the AF evaluated value for face D. Thus, if the face towards the center is selected for focusing and/or automatic exposure determination, the face C will be the chosen face. In FIG. 9D , the graph shows an AF evaluated value for the Y axis. However, it is not necessary to use such an AF evaluated value but other values may be used to determine that the face is in the center of thy picture. For example, if the face recognition process determines that the face is in the center, then that face and that facial recognition process may be used to select the AF or the AE settings.
The use of the self-timer mode is described below with respect to FIG. 10 .
In the first step S 10 - 1 , the digital camera judges whether the self-timer mode is the 2 second mode or the 10 second mode. In next step S 10 - 13 , since the 2 second mode is used for stabilizing images on a tripod and since it is assumed that the subject image is in the finder image, the facial recognition process is not operated. In the next step S 10 - 14 , the digital camera judges that 2 seconds has passed. In the next step S 10 - 11 , the digital camera operates the AF process. In the next step S 10 - 12 , the digital camera operates the photographing process and the self-timer photographing ends.
In the case that the self-timer mode is the 10 second mode, in the next step S 10 - 2 , the digital camera starts the 10 second mode. In the next step S 10 - 3 , the digital camera judges whether or not the facial recognition mode is on. In the case that the facial recognition mode is on, in the next step S 10 - 4 , the digital camera operates the facial recognition process for 10 seconds, for example. In the next step 510 - 5 , the digital camera judges whether a face has been detected. In the case that a face has been detected, step S 10 - 6 sets the AF area and the AE area based on the facial area. In the next step S 10 - 7 , the digital camera illuminates the AF fill light LED when the facial recognition process is complete so that the subject person recognizes when the facial recognition process is completed. This is because the subject persons include a photographer generally in the self-timer mode. In the next step S 10 - 8 , the digital camera judges that 10 seconds has passed. The digital camera may illuminate the flash instead of the AF fill light LED. Further, instead of turning on a light to indicate that the facial recognition process is complete, a light may be turned off to indicate the process is complete.
In the next step S 10 - 9 , the digital camera judges whether the facial recognition mode is on or not. In the case that the facial recognition mode is on, step S- 10 operates the AE process based on the facial area and resolves the exposure (the aperture value, the shutter speed, and the ISO sensitivity). In the next step S 10 - 11 , the digital camera operates the AF process based on the facial area. In the case that the facial recognition mode is not on, the digital camera skips the step S 10 - 10 . Finally, in step S 10 - 12 , the digital camera operates the photograph process and records a still image based on the above result. The process of FIG. 10 then ends.
As described above, the digital camera according to the first embodiment does not need to estimate a focus position at the time of photographing, operate a pre-focus process (a distance surveying process which occurs by pressing release button halfway on commonly-used cameras), or start the self-timer mode when pressing the release halfway. In sum, the digital camera avoids troublesome operations and the digital camera starts the self-timer mode facing a suitable direction. The digital camera obtains a photographing result, which focuses a subject face and has a suitable exposure even when the photographer is a subject person and the digital camera reoperates the photographing process quickly because the digital camera detects a face area of a subject person, and operates the AF process and AE process based on the face area for 10 seconds (2 seconds) after the self-timer mode starts. The present invention including this and other embodiments allows a good and quick result using facial detection when the photographer is the only person in the picture as the facial detection process may operate from when a photographing command is received until the photographer can get into the picture. Then, when the delay period is up, a photograph can be taken using the AF and/or AE data obtained during the delay time period based on facial recognition.
Next an operation of the digital camera of the second embodiment is described below, using the same reference symbols as in the first embodiment for the same or equivalent parts as in the first embodiment, and descriptions of the same parts may be omitted.
The self-timer photographing is described below with respect to FIG. 11 .
In the first step S 11 - 1 , the digital camera judges whether the self-timer mode is in the 2 second mode or the 10 second mode. When the self-timer is not in the 10 second mode, flow proceeds to step S 11 - 19 . The 2 second mode is used for stabilizing images when using a tripod and since it is assumed that the subject image is in the finder image, the facial recognition process is not operated. In the next step S 11 - 20 , the digital camera judges that 2 seconds have passed. In the next step S 11 - 12 , the digital camera operates the AF process. Finally, in step S 11 - 13 , the digital camera operates the photographing process and the self-timer photographing ends.
In the case that the self-timer mode is the 10 second mode, in the next step S 11 - 2 , the digital camera starts the 10 second mode. In the next step S 11 - 3 , the digital camera judges whether the facial recognition mode is on or not. When the facial recognition mode is not on, flow proceeds to step S 11 - 8 . In the case that the facial recognition mode is on, in the next step S 11 - 4 , the digital camera operates the facial recognition process for 10 seconds. In the next step S 11 - 5 , the digital camera judges whether a face has been detected. When a face has been detected, flow proceeds to step S 11 - 6 in which the AF area and the AE area are set based on the facial area. In the next step S 11 - 7 , the digital camera illuminates the AF fill light LED to indicate that the facial recognition process is complete and this LED can be seen by the subject person. This is because the subject persons include a photographer generally in the self-timer mode. In the next step S 11 - 8 , the digital camera judges that 10 seconds have passed. The digital camera may illuminate a strobe light or lamp instead of the AF fill light LED.
In the next step S 11 - 9 , the digital camera judges whether the facial recognition mode is on or not. In the case that the facial recognition mode is on, in the next step S 11 - 10 , the digital camera judges whether a face has been detected. In the case that the facial recognition process is completed and a face has been detected, in the next step S 11 - 11 , the digital camera operates the AE process based on the facial area and resolves the exposure (the aperture value, the shutter speed, and the ISO sensitivity). In the next step S 11 - 12 , the digital camera operates the AF process based on the facial area. When the facial recognition mode is not on, the digital camera skips the steps S 11 - 10 and S 11 - 11 .
In the case that a face has not been detected in step S 11 - 10 , the digital camera operates the facial recognition process again after the digital camera changes an angle of view (e.g., whether the lens is zoomed in or out). Hereinafter, an angle of view before being changed is a first angle of view, and an angle of view after being changed is a second angle of view. In the case that the face of the subject person is so small that the digital camera cannot operate the facial recognition process shown in FIG. 12A , step S 11 - 10 determines that no face is detected and flow proceeds to step S 11 - 14 . In step S 11 - 14 , the digital camera operates a zoom process shown in FIG. 12B in order to place the lens in more of a telephoto mode. In the next step S 11 - 15 , the digital camera operates the facial recognition process at the second angle of view (e.g., zoomed in). It is desirable that a difference between the first angle of view and the second angle of view be small because there is no guarantee that the subject person is in a center of the finder image although the difference can be big, if desired. For example the digital camera zooms in 1.25 times compared with a present focal length or setting. In the next step S 11 - 16 , the digital camera judges whether the facial recognition mode is completed or not (e.g., a face is detected). In the case that the facial recognition process is completed and a face has been detected, in the next step S 11 - 17 the digital camera sets the AF area and the AE area so that the AF area and the AE area to correspond to the first angle of view. In the next step S 11 - 18 , the digital camera zooms back to the first angle of view shown in FIG. 12C . The digital camera operates the facial recognition process even under an environment that it is difficult to operate the facial recognition process on by zooming in from the first angle of view, operating the facial recognition process, and zooming back out to the first angle of view. From step S 11 - 18 , flow proceeds to steps S 11 - 11 and S 11 - 12 which have already been described.
In the next step S 11 - 13 , the digital camera operates the photograph process and records an image or images, such as a still image based on above result.
As described above, the digital camera according to the second embodiment does not need to estimate a focus position at the time of photographing, operate a pre-focus process (a distance surveying process which occurs by pressing release button halfway on commonly-used cameras), or start the self-timer mode when pressing the release halfway. In sum, the digital camera avoids troublesome operations and the digital camera starts the self-timer mode facing a suitable direction. The digital camera obtains a photographing result, which focuses a subject face and has a suitable exposure even when the photographer is a subject person and the digital camera reoperates the photographing process quickly because the digital camera detects a face area of a subject person, and operates the AF process and AE process based on the face area for 10 seconds (2 seconds) after the self-timer mode starts. The present invention including this and other embodiments allows a good and quick result using facial detection when the photographer is the only person in the picture as the facial detection process may operate from when a photographing command is received until the photographer can get into the picture. Then, when the delay period is up, a photograph can be taken using the AF and/or AE data obtained during the delay time period based on facial recognition.
Further, the digital camera operates the facial recognition process even in an environment where it is difficult to operate the facial recognition process by zooming in, operating the facial recognition process, and zooming back out to the original focal position, in the case that the face of the subject person is so small that the digital camera cannot operate the facial recognition process.
An operation of the digital camera in the third embodiment is described below, using the same reference symbols as in the first embodiment shown in FIGS. 1 to 7 for the same or equivalent parts as in the first embodiment, and descriptions of the same parts may be omitted. In this embodiment, the facial recognition process uses the finder mode, as described above. Since the finder mode is updated at 1/30 seconds intervals, the facial recognition process is operated so that the facial recognition process is synchronized with the finder mode.
A remote control photographing is described below with respect to FIG. 13 . After starting, step S 13 - 1 judges whether a remote control is operated or not, (e.g., whether the remote control optical receiver 6 receives a signal or not). Other receivers such as radio frequency, ultrasonic, or any other type may be used, if desired. In the case that the remote control receiver 6 receives the signal, in the next step S 13 - 2 , the digital camera judges whether the facial recognition mode is on or not. In the case that the facial recognition mode is on, flow proceeds to step S 13 - 3 in which the digital camera performs the facial recognition process. In the case that the facial recognition process detects a face in step S 13 - 4 , flow proceeds to step S 13 - 5 which sets the AF area and the AE area based on the facial area. In the next step S 13 - 6 , the digital camera illuminates the AF fill light LED to indicate the facial recognition process is complete to the subject person as the subject persons usually include the photographer in the remote control mode. The digital camera may alternatively, illuminate a strobe light or lamp instead of the AF fill light LED. In the next step S 13 - 7 , the digital camera operates the AE process based on the facial area and resolves the exposure (the aperture value, the shutter speed, and the ISO sensitivity). In the next step S 13 - 8 , the digital camera operates the AF process based on the facial area.
In the next step S 13 - 9 , the digital camera starts a 2 seconds timer. In the next step S 13 - 10 , the digital camera judges whether 2 seconds has passed or not. After 2 seconds have passed, in the next step S 13 - 11 , the digital camera operates the photograph process and records a still image based on above result. The process then ends. As an alternative to the 2 second lapse occurring after the facial recognition process, the facial recognition process can occur during the 2 second delay period.
As described above, the digital camera according to the third embodiment does not need to estimate a focus position at the time of photographing, operate a pre-focus process (a distance surveying process which occurs by pressing release button halfway on commonly-used cameras), or start the self-timer mode when pressing the release halfway. In sum, the digital camera avoids troublesome operations and the digital camera starts the self-timer mode facing a suitable direction. The digital camera obtains a photographing result, which focuses a subject face and has a suitable exposure even when the photographer is a subject person and the digital camera reoperates the photographing process quickly because the digital camera detects a face area of a subject person, and operates the AF process and AE process based on the face area for 10 seconds (2 seconds) after the self-timer mode starts. The present invention including this and other embodiments allows a good and quick result using facial detection when the photographer is the only person in the picture as the facial detection process may operate from when a photographing command is received until the photographer can get into the picture. Then, when the delay period is up, a photograph can be taken using the AF and/or AE data obtained during the delay time period based on facial recognition.
The present invention is described based on the first, second and third embodiments. However concrete elements are not limited by these embodiments.
These embodiments operate the AF process and the AE process based on the facial recognition process in the self-timer mode or the remote control mode. However, the present invention may operate using any one of the AF process and the AE process. The present invention may change a set value regarding photographing other than the AF evaluated value and the AE evaluated value. In sum, the present invention operates the facial recognition process during a delay time of the self-timer mode or the remote control mode and changes the set value regarding photographing based on a result of the facial recognition process.
These embodiments select the closest facial area as the AF area and the AE area in the case that that subjects are multiple. However the present invention may select the facial area closest to a center.
These embodiments use an illuminated AF fill light LED to indicate that the facial recognition process is complete. However the present invention may illuminate the AF fill light LED when the facial recognition process is not completed.
Obviously, numerous additional 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 present invention may be practiced otherwise than as specifically described herein.
|
An apparatus and method for capturing images using a delay timer and face detection. After a command is given to begin a photographing process, a face detector determines the location of a face of a person being photographed. A timer counts down a predetermined delay time, for example, corresponding to a self-timer time period. A controller can set the auto focus or auto exposure parameters based on the detected face.
| 6
|
This application claims the benefit of Korean Patent Application No. P2004-110197, filed on Dec. 22, 2004, which is hereby incorporated by reference as if fully set forth herein.
TECHNICAL FIELD
The present application relates to an apparatus and method for manufacturing a liquid crystal display device, and more particularly, to an exposure layout for applying an exposure process to a substrate of a display device such as a liquid crystal display device.
BACKGROUND
Generally, an exposure unit of an apparatus for manufacturing a liquid crystal display device is provided to perform an exposure process by applying ultraviolet radiation to a glass substrate coated with ph otoresist after providing a photo-mask having a predetermined pattern. Before performing the exposure process, the glass substrate is unloaded from a coating unit for coating the photoresist. At this time, there are a plurality of robot arms and conveyors between the coating unit and the exposure unit for conveying the substrate.
FIG. 1 is a block diagram of an exposure layout according to the related art. The exposure layout explains a sequential process for conveying the glass substrate to the exposure unit.
As shown in FIG. 1 , a related art exposure layout is provided with thru-conveyors 11 and 12 , a solvent removing unit 20 , a temperature reduction unit 30 , an in-out turn unit 40 , a titler 50 , a buffer 60 and a plurality of robot arms 71 , 72 and 73 .
The thru-conveyor 11 is provided to load a substrate, and the thru-conveyor 12 is provided to unload the substrate.
Then, the substrate coated with photoresist by a coater 2 is conveyed to the solvent removing unit 20 from the thru-conveyor 11 . The solvent removing unit 20 removes solvent from the substrate coated with photoresist. The solvent removing unit 20 is formed of an oven having a softbake hot plate SHP. The temperature reduction unit 30 is formed of a cool plate CP for reducing a temperature of the substrate unloaded from the SHP 20 . The in-out turn unit 40 changes the progressing direction of the substrate so as to provide the substrate to the next process.
The robot arms 71 , 72 and 73 are positioned between each of the components for loading and unloading the substrate. The robot arms include the first robot arm 71 , the second robot arm 72 and the third robot arm 73 .
The first robot arm 71 receives the substrate coated with photoresist from the coater 2 , and then conveys the substrate to the thru-conveyor 11 . The first robot arm 71 is provided between the coater 2 and the substrate loading side of the thru-conveyor 11 .
The second robot arm 72 receives the substrate unloaded from the thru-conveyor 11 , and then conveys the substrate to the SHP 20 . Also, the second robot arm 72 receives the substrate from the SHP 20 , and then conveys the substrate to the temperature reduction unit 30 . Further, the second robot arm 72 receives the substrate from the temperature reduction unit 30 , and then conveys the substrate to the in-out turn unit 40 .
The SHP 20 is positioned at the substrate unloading side of the thru-conveyor 11 . The second robot arm 72 is positioned among the SHP 20 , the temperature reduction unit 30 and the in-out turn unit 40 , for conveying the substrate to the respective components 20 ; 30 and 40 .
The third robot arm 73 receives the substrate from the in-out turn unit 40 , and then conveys the substrate to the exposure unit 3 . After completing the exposure process, the substrate is conveyed to the in-out turn unit 40 by the third robot arm 73 .
The third robot arm 73 is positioned among the titler 50 , the buffer 60 , the exposure unit 3 and the in-out turn unit 40 , for selectively conveying the substrate to the respective components 50 , 60 , 3 and 40 .
Before performing the exposure process, the substrate is conveyed to the titler 50 by the third robot arm 73 for forming an identification code ID for each substrate.
The buffer 60 includes a cassette for temporarily storing the substrate before being conveyed to the next process. That is, the substrate having the identification code ID is conveyed to the buffer 60 by the third robot arm 73 to be stored temporarily before the exposure unit 3 .
Reference number 4 is a vacuum dry unit VCD for drying a coating layer of the substrate unloaded from the coater 2 under low vacuum conditions. The VCD 4 and the SHP 20 are positioned parallel to the thru-conveyor 11 .
A method for performing the exposure process on the substrate according to the related art exposure layout may be explained as follows.
First, after coating the substrate with photoresist by the coater 2 , the substrate is conveyed to the VCD 4 by the first robot arm 71 . After completing the curing process of the substrate in the VCD 4 , the substrate is conveyed to the thru-conveyor 11 by the first robot arm 71 (S 1 ).
The second robot arm 72 receives the substrate from the thru-conveyer 11 , and then conveys the substrate to the SHP 20 (S 2 ). The SHP 20 removes the solvent from the substrate.
After removing the solvent from the substrate, the substrate is unloaded from the SHP 20 (S 3 ), and then the substrate is conveyed to the temperature reduction unit 30 by the second robot arm 72 . After reducing the temperature of the substrate by the temperature reduction unit 30 , the substrate is unloaded from the temperature reduction unit 30 (S 4 ), and then is conveyed to the in-out turn unit 40 by the second robot arm 72 (S 5 ).
At this point, the in-out turn unit 40 changes the direction of the substrate conveyed by the second robot arm 72 . Then, the third robot arm 73 receives the substrate, which has had its direction changed by the in-out turn unit 40 (S 6 ), and conveys the substrate to the titler 50 .
The titler 50 forms the ID for each substrate. Then, the substrate having the ID is unloaded from the titler 50 (S 7 ) and is conveyed to the exposure unit 3 (S 9 ) by the third robot arm 73 .
If the exposure unit 3 is in an operation mode, the third robot arm 73 conveys the substrate to the buffer 60 so that the substrate may be temporarily stored in the buffer 60 .
After completing the exposure process of the substrate, the substrate unloaded from the exposure unit is conveyed to the in-out turn unit 40 by the third robot arm 73 (S 10 ), and also is conveyed to the thru-conveyor 12 (S 11 ).
In the exposure layout according to the related art, even though the temperature reduction unit is provided so as to adjust the temperature of the substrate before loading the substrate to the exposure unit 3 , it is difficult to maintain the most appropriate temperature for each substrate.
The adjustment of the temperature of the substrate by an additional chamber 5 affects the entire exposure layout, or a portion of the layout, including the in-out turn unit 40 , the third robot arm 73 and the buffer 60 . As a result, it is difficult to adjust precisely the temperature of each substrate.
If the substrate does not have the precise temperature before the exposure process, the dimensions of the substrate may be changed due to the temperature difference. As a result, the position for exposure may be incorrect, and consequently the product may be defective.
Also, the third robot arm 73 performs eight conveyances for the substrate each cycle. Accordingly, a tact time for each cycle is high.
To decrease the tact time for each cycle, another layout for providing an additional robot arm has been proposed. In this case, it is necessary to provide a space for the additional robot arm, and thus the problem of an increased footprint (length of the entire layout) arises. Further, it requires an increase in plant size for the exposure layout.
SUMMARY
An exposure layout of an apparatus for manufacturing a liquid crystal display device that may substantially obviate one or more problems due to limitations and disadvantages of the related art is described herein. The exposure layout may provide a proper temperature of a substrate in an exposure process, decrease a tact time, and minimize a footprint.
An apparatus and method for manufacturing a liquid crystal display device are disclosed. The apparatus includes a thru-conveyor for conveying a substrate, a first robot arm, and a second robot arm. The first robot arm receives the substrate coated with photoresist and conveys the substrate to the thru-conveyor. A hot plate removes solvent from the substrate. A cool plate lowers a temperature of the substrate from which the solvent is removed. A buffer temporarily stores the substrate having the lowered temperature. A second robot arm is arranged among the thru-conveyor, the hot plate, the cool plate and a substrate loading side of the buffer, for loading and/or unloading the substrate. A temperature control unit adjusts a temperature of the substrate unloaded from the buffer. An exposure unit and a third robot arm are arranged among a substrate unloading side of the buffer, the temperature control unit and the exposure unit, for loading and/or unloading the substrate.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a block diagram of an exposure layout according to the related art;
FIG. 2 is a block diagram of an exposure layout according to the first embodiment; and
FIG. 3 is a block diagram of an exposure layout according to the second embodiment.
DETAILED DESCRIPTION
Reference will now be made in detail to preferred embodiments of the exposure layout, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
Hereinafter, an apparatus for manufacturing a liquid crystal display device will be described with reference to the accompanying drawings.
FIG. 2 is a block diagram of an exposure layout according to the first embodiment.
As shown in FIG. 2 , an exposure layout according to the first embodiment may include a thru-conveyor 100 , a first robot arm 710 , a second robot arm 720 , a third robot arm 730 , a hot plate (solvent removing unit) referred to as a softbake hot plate (SHP) 200 , a cool plate 300 , a buffer 600 , a temperature control unit 800 , and an exposure unit 3 .
The thru-conveyor 100 may convey a substrate coated with photoresist. Also, the first robot arm 710 , the second robot arm 720 and the third robot arm 730 may load and/or unload the substrate. The SHP 200 may remove solvent from the substrate coated with photoresist. Then, the cool plate 300 may receive the substrate from which the solvent is removed, and lowers the temperature of the substrate. After that, the buffer 600 may temporarily store the substrate having the lowered temperature before applying the exposure process to the substrate.
In case of the related art, only one side of the buffer may be used for loading and unloading the substrate. However, in case of the present exposure layout, the buffer 600 may have a substrate loading side 610 and a substrate unloading side 620 positioned separately. In particular, the substrate loading side 610 of the buffer 600 may be positioned perpendicular to the substrate unloading side 620 of the buffer 600 .
The temperature control unit 800 may receive the substrate from the buffer 600 and adjust the temperature of the substrate to the exposure process. The temperature control unit 800 may control the temperature of the substrate immediately before applying the exposure process to the substrate. Accordingly, it may be possible to perform a precise exposure process and to prevent a defective exposure caused by deformation of the substrate.
After providing a photo-mask having a predetermined pattern over the substrate coated with photoresist, the exposure unit 3 may apply ultraviolet radiation to the substrate.
The arrangement of the components in the exposure layout according to the first embodiment will now be described in detail.
First, the first robot arm 710 may be provided at the substrate loading side of the thru-conveyor 100 . The SHP 200 may be provided at the substrate unloading side of the thru-conveyor 100 .
From a plan view perspective, the SHP 200 and the thru-conveyor 100 may be positioned in two parallel rows. That is, as shown in FIG. 2 , the SHP 200 may be positioned on the substrate unloading side of the thru-conveyor 100 . Also, a vacuum dry unit VCD (curing unit) 4 may be positioned in front of the SHP 200 along the process direction.
After a coating layer is formed on the substrate in a coater 2 , the VCD 4 may dry and cure the coating layer of the substrate unloaded from the coater 2 under low vacuum conditions.
The second robot arm 720 may be positioned behind the thru-conveyor 100 and the SHP 200 . Also, the CP 300 may be positioned over the second robot arm 720 , from a plan view perspective.
The temperature control unit 800 and the CP 300 may be positioned in two parallel rows.
The third robot arm 730 may be positioned among the substrate unloading side 620 of the buffer 600 , the temperature control unit 800 and the exposure unit 3 .
In particular, from a plan view perspective, the first robot arm 710 , the thru-conveyor 100 , the second robot arm 720 and the buffer 600 may be sequentially positioned along one line. Also, the temperature control unit 800 , the third robot arm 730 and the exposure unit 3 may be sequentially positioned along one line. From a plan view perspective, the third robot arm 730 may be positioned over the buffer 600 . The substrate loading side 610 of the buffer 600 may be opposite to the second robot arm 720 , and the substrate unloading side 620 of the buffer 600 may be opposite to the third robot arm 730 .
In addition, from a plan view perspective, a titler 500 may be positioned over the third robot arm 730 . That is, the titler 500 , the third robot arm 730 and the buffer 600 may be sequentially positioned along the same vertical line.
In the exposure layout according to the first embodiment, the titler 500 may be provided in a location appropriate for conveying the substrate to the next process after completing the exposure process.
A method for performing the exposure process in the exposure layout according to the first embodiment may be explained as follows.
After the substrate is coated with photoresist in the coater 2 , the substrate may be conveyed by the first robot arm 710 . The first robot arm 710 may convey the substrate coated with photoresist to the VCD 4 . After completing the curing of the substrate, the substrate may be conveyed to the thru-conveyor 100 by the first robot arm 710 (S 21 ).
Then, the substrate unloaded from the thru-conveyor 100 may be conveyed to the SHP 200 by the second robot arm 720 (S 22 ). The SHP 200 may remove the solvent from the substrate. Then, the substrate may be unloaded from the SHP 200 (S 23 ), and the substrate may be conveyed to the CP 300 by the second robot arm 720 . After the temperature of the substrate is lowered in the CP 300 , the substrate may be unloaded from the CP 300 (S 24 ), and the substrate may be conveyed to the buffer 600 by the second robot arm 720 (S 25 ).
The substrate may be temporarily stored in the buffer 600 and then unloaded from the buffer 600 (S 26 ), and then conveyed to the temperature control unit 800 by the third robot arm 730 (S 27 ). At this time, the temperature control unit 800 may properly adjust the temperature of the substrate for the exposure process.
After adjusting the temperature of the substrate in the temperature control unit 800 , the substrate may be unloaded from the temperature control unit 800 by the third robot arm 730 , and then the substrate may be conveyed to the exposure unit 3 by the third robot arm 730 (S 28 ). After completing the exposure process, the substrate may be loaded to the titler 500 . Then, after the substrate is unloaded from the tilter 500 (S 29 ), the substrate may be conveyed to the next process.
If the exposure unit 3 is in operation mode, the third robot arm 730 may stop the unloading of the substrate. If the exposure process is finished, the third robot arm 730 may resume unloading the substrate from the buffer 600 .
The components for the exposure layout may be arranged differently.
That is, another exposure layout having a different arrangement of a buffer 700 , a CP 300 and a temperature control unit 800 may be provided.
FIG. 3 is a block diagram of an exposure layout according to the second embodiment.
In the exposure layout according to the second embodiment, as shown in FIG. 3 , a first robot arm 710 , a thru-conveyor 100 , a second robot arm 720 and the CP 300 may be sequentially arranged along one line, from a plan view perspective. Also, the temperature control unit 800 and the CP 300 may be provided in two parallel rows. Also, the buffer 600 , a third robot arm 730 and an exposure unit 3 may be sequentially arranged along one line. From a plan view perspective, the temperature control unit 800 and the third robot arm 730 may be arranged along the same vertical line. That is, from a plan view perspective, the third robot arm 730 may be positioned over the temperature control unit 800 . The buffer 600 and the second robot arm 720 may be arranged along the same line. That is, from a plan view perspective, the buffer 600 may be positioned over the second robot arm 720 .
A method for performing the exposure process in the exposure layout according to the second embodiment is substantially the same as the method for performing the exposure process in the exposure layout according to the first embodiment.
The exposure layout according to the preferred embodiments may have the following advantages.
In the exposure layout according to a preferred embodiment, the temperature of the substrate may be adjusted before loading the substrate into the exposure unit. Accordingly, it may be possible to minimize the incidence of defective exposures of the substrate.
In particular, the third robot arm may perform six conveyances for the substrate each cycle. That is, it may be possible to decrease a tact time for each cycle without providing an additional robot arm.
Also, the buffer has the substrate loading side and the substrate unloading side positioned in different directions. As a result, it may be possible to minimize the footprint or length of the entire layout.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present application covers the modifications and variations of this invention, provided that they come within the scope of the appended claims and their equivalents.
|
An apparatus for manufacturing a liquid crystal display device is disclosed. A first robot arm at a loading side of the thru-conveyor receives a substrate coated with photoresist and conveys the substrate to a thru-conveyor. A softbake hot plate (SHP) at the unloading side of the thru-conveyor removes solvent from the substrate. A cool plate lowers the substrate temperature from which the solvent is removed. A buffer temporarily stores the substrate having the lowered temperature. A second robot arm between the thru-conveyor, the SHP, the cool plate and a loading side of the buffer, loads/unloads the substrate. A temperature control unit adjusts the substrate temperature unloaded from the buffer. A third robot arm between the unloading side of the buffer, the temperature control unit and an exposure unit that exposes the substrate, loads/unloads the substrate.
| 7
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application No. 61/496,862 filed on Jun. 14, 2011, the contents of which are herein incorporated by reference.
TECHNICAL FIELD
[0002] The invention generally relates to advertising over the internet, and more specifically to presentation of an advertisement responsive to a printing request.
BACKGROUND
[0003] The ubiquity of access availability to information using the Internet and the worldwide web (WWW) has naturally drawn the focus of advertisers. The advertisers therefore pay different websites, such as Google® or AOL®, for the placement of their advertisements among these web pages.
[0004] The well-known advertising banner in web pages is generally undesirable to a viewer of a web page as it takes up display space from the web page in which the viewer would rather view useful content. That is, the banners typically reduce the amount of information displayed on a web page present on a client's display. In many cases, the viewer disables the banners or otherwise disables the ability of the browser to display advertisements. For example, all browsers can be configured to block pop-up windows or to render a web page on a user's display without advertisement banners. In addition, a typical web page itself is today cluttered with many advertisements and as a result the user's attention is not given to them.
[0005] It would be therefore advantageous to provide an advertisement space which overcomes the deficiencies of the prior art. It would be further advantageous if such advertisement space would avoid the current typical advertisement clutter.
SUMMARY
[0006] Certain embodiments disclosed herein include a method for providing an advertising item to a client device. The method comprises receiving a printing notification from the client device; selecting an advertising item from at least a database containing a plurality of advertisement items; generating a display window containing the selected advertising item; and sending the generated display window to the client device for display by the client device.
[0007] Certain embodiments disclosed herein also include a system for providing an advertising item to a client device. The system comprises a processing unit; a memory coupled to the processing unit and containing at least instructions executed by the processing unit; a network interface coupled to the processing unit; and a source for providing at least an advertising item responsive of a notification of a printing request received from the client device, the client device being communicatively connected to the system via the network interface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention will be apparent from the following detailed description taken in conjunction with the accompanying drawings.
[0009] FIGS. 1 and 2 are schematic diagrams of a networked system used to describe various embodiments disclosed herein.
[0010] FIG. 3 is a flowchart describing a method for displaying an advertising item responsive to a printing request according to one embodiment.
[0011] FIG. 4 is a screenshot of the display of a web based advertisement according to one embodiment.
[0012] FIG. 5 is a screenshot of the display of an advertisement embedded in a document according to another embodiment.
DETAILED DESCRIPTION
[0013] It is important to note that the embodiments disclosed herein are only examples of the many advantageous uses of the innovative teachings herein. In general, statements made in the specification of the present application do not necessarily limit any of the various claimed inventions. Moreover, some statements may apply to some inventive features but not to others. In general, unless otherwise indicated, singular elements may be in plural and vice versa with no loss of generality. In the drawings, like numerals refer to like parts through several views.
[0014] FIG. 1 depicts an exemplary and non-limiting networked system 100 utilized to describe the embodiments for displaying advertising items responsive to a printing request. A management server 110 stores one or more advertising items in a database 120 . In one embodiment, a plurality of databases each storing one or more advertising items may be used as the database 120 . The database 120 is configured to store and deliver advertising items. The management server 110 further comprises a logic 130 that contains a plurality of instructions embedded in a tangible memory of the management server 110 . Such instruction when executed, for example, by a processor (not shown) of the management server 110 performs the function of displaying an advertising item generated and retrieved from the database 120 as further explained herein below in more detail. In one embodiment, advertising items can also be received from one or more third party providers 140 . For example, the third party providers 140 are publish server of publishers of advertized content. The publisher severs are configured to embed online advertisements in web pages downloaded from web server servers, and further to upload web pages with advertisements to web browsers of client devices. The publisher servers typically receive the advertized content from advertising agencies that set the advertising campaign.
[0015] The management server 110 communicates with a device 180 via a communication network 150 or the Internet 160 . The device 180 is configured to receive an advertising item from the management server 110 . The device 180 may be, but is not limited to, a client agent utility, a client device, a server, a database, a web server hosting a website or a webpage, a data network, and any combination thereof. It should be noted that although one device 180 is depicted in FIG. 1 merely for the sake of simplicity, the embodiments disclosed herein can be applied to a plurality devices 180 .
[0016] According to an embodiment disclosed herein, upon receiving a printing request from the device 180 , the management server 110 selects an advertising item and sends it to the device 180 for display. It should be further understood that a single an advertising item may be comprised from a plurality of advertising items. The advertising item may be, for example, a keyword, an image, a video clip, a text description, another web page, search results retrieved from a search engine, and any combination thereof.
[0017] The operation of the management server 110 is further described with reference to FIG. 2 that depicts an exemplary and non-limiting networked system 200 . A plurality of client devices 210 - 1 through 210 -N are connected to a network 220 . The network 220 includes, but not by way of limitation, a local area network (LAN), a wide area network (WAN), a metro area network (MAN), the Internet, the worldwide web (WWW), wired or wireless, and other types of communication networks, such as the communication network 150 (shown in FIG. 1 ), as well as any combination thereof. The client devices 210 - 1 to 210 -N may be a personal computer (PC), a laptop computer, a mobile device, a smart phone, a tablet computer, and the like. In an embodiment, each client device 210 - i (i=1, . . . , N) includes a monitoring agent (not shown) that is designed to capture print commands on the client device 210 - i and to send a notification of the printing request a document to the management server 110 . The monitoring agent can also send together with the print request information including, but not limited to, an IP address of the client device 210 - i, a URL of a web page that the user requested to print, the type of the application from which the print command was issued, and so on. In one embodiment, the monitoring agent can be realized as an add-on of a software application installed in the client device 210 , a toolbar of a web browser, a browser extension, and so on.
[0018] A plurality of web servers 230 - 1 through 230 -M are also connected to the network 220 . The plurality of web servers 230 - 1 through 230 -M may be implemented as the device 180 shown in FIG. 1 . As noted above, the management server 110 includes the database 120 that stores the advertising items, indexes thereto, and/or advertisement parameters. In one embodiment of the invention the database 120 is connected to a tracking server (not shown) configured to store information respective of the advertising items sent to each of client devices 210 - 1 through 210 -N.
[0019] A plurality of third party providers 240 - 1 through 240 -P are also connected to the network 220 . Each of the third party providers 240 - 1 to 240 -P can generate advertising items.
[0020] A management server, also referred to herein as the server 110 , is also connected to the network 220 and is further equipped with a logic 130 comprised of a plurality of instructions embedded in the tangible memory of the server, that when executed by the server perform the function of displaying an advertising item as further explained herein below in more detail.
[0021] According to various embodiments disclosed herein, the management server 110 causes the display of an advertising item on the display of a client's device 210 - i (i=1, . . . , N) responsive of a print request from a user of the client device 210 - i. In an embodiment, when the client device 210 - i attempts to print from any application executed thereon, such an attempt is captured by the monitoring agent and a notification is sent to the management server 110 . In response, management server 110 generates and delivers an advertising item that is displayed on the display of the client device 210 - i.
[0022] The displayed advertising item may be retrieved from the database 120 and/or a third party provider 240 . In one embodiment, the management server 110 generates a window display which may be, for example, a web page or a display banner in a format of a pop-up window. The window display includes the advertising item. In another embodiment, the management server 110 sends a request to one of the third party providers 240 to generate an advertising item for display by the client device 210 - i. As noted above, a third party provider may be a publisher server that generates a web page containing the advertising items and sends the generated web page to the client device 210 -I or to the management server 110 . In an embodiment, the advertising item in any display form is sent to the client device 210 through the monitoring agent. Thus, the management server 110 allows the display of an advertising item uncluttered by any other content and/or advertisements, thereby capturing the user's attention.
[0023] FIG. 3 depicts an exemplary and non-limiting flowchart 300 describing a method for displaying a web based advertising item linked with the act of printing according to an embodiment. In a non-limiting embodiment, the method is performed by the management server 110 .
[0024] In S 310 , a server, for example the management server 110 , receives a printing notification from a client device, for example, the client device 210 - 1 . As mentioned above, the printing notification can be sent from a monitoring agent installed in the client device. In S 320 , an advertising item is selected by the management server 110 from, for example, the advertising items that are stored in the database 120 . Alternatively or collectively, the advertising item is retrieved from a server 240 (e.g., a publisher server) upon a request from the management server. A selection of an advertising item may be performed in multiple ways including, but not limited to, random selection of an advertising items from a plurality of advertising items; a tailored advertising item selection that fits, for example, a profile of a user of the client device; selection of advertising items based on the printed content, and so on. In S 335 , a display window including the selected advertising item is generated. The display window may be, for example, a pop-up window, in a form of a web page or a display banner that can be displayed in software applications other than a web browser. In S 330 , the generated display window with the selected advertising item is sent to the client device. In S 340 , it is checked whether to continue with the execution, and if so, execution continues with S 310 ; otherwise execution terminates.
[0025] FIG. 4 depicts an exemplary and non-limiting screenshot 400 of the display of a web based advertising item according to an embodiment. A webpage 410 is displayed within a client's web browser on a client device. Upon receiving a printing request from the client's device, a pop-up window 420 appears where the user can select the type of printer to commence the act of printing. In parallel, a display window which is a pop-up window 430 appears containing an advertising item. According to the embodiments disclosed herein, the pop-up window 430 appears responsive to the printing notification that is sent to the management server 110 . The management server 110 selects the advertising item to be displayed and generates the pop-up window, which in this non-limiting example is in a form of a web-page. As noted above, the advertising item in the pop-up window 430 may retrieve from the database 120 and/or a third party provider 240 . It should be appreciated by a person skilled in the art that the location of the window 430 is just an example, as the advertising item can be positioned anywhere on the web page 410 . In another embodiment, the advertising item is embedded in the web page 410 .
[0026] FIG. 5 depicts an exemplary and non-limiting screenshot 500 of the display of an advertising item on a client device according to another embodiment. A document 510 , for example and without limitation, a Microsoft® Word document or Adobe® Acrobat®, is displayed over a client device, such as a client device 210 . Upon receiving a notification about a request for printing by the client device 210 , a pop-up window 520 appears in which the client can select the type of printer to commence the act of printing. In parallel, a display window 530 appears containing an advertising item according to an embodiment of the invention. The display window 530 appears responsive to the printing notification sent to the management server 110 , as explained in more detail hereinabove. In the non-limiting example shown in FIG. 5 , the display window 530 is in a form of a display banner. It should be further understood that the invention is not limited to applications handling documents but may also apply to other applications that may have printing capabilities.
[0027] The various embodiments disclosed herein can be implemented in as hardware, firmware, software, or any combination thereof. Moreover, the software is preferably implemented as an application program tangibly embodied on a program storage unit or computer readable medium consisting of parts, or of certain devices and/or a combination of devices. The application program may be uploaded to, and executed by, a machine comprising any suitable architecture. Preferably, the machine is implemented on a computer platform having hardware such as one or more central processing units (“CPUs”), a memory, and input/output interfaces. The computer platform may also include an operating system and microinstruction code. The various processes and functions described herein may be either part of the microinstruction code or part of the application program, or any combination thereof, which may be executed by a CPU, whether or not such computer or processor is explicitly shown. In addition, various other peripheral units may be connected to the computer platform such as an additional data storage unit and a printing unit. All or some of the servers may be combined into one or more integrated servers. Furthermore, a non-transitory computer readable medium is any computer readable medium except for a transitory propagating signal.
[0028] All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the principles of 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. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure.
|
A method for providing an advertising item to a client device. The method comprises receiving a printing notification from the client device; selecting an advertising item from at least a database containing a plurality of advertisement items; generating a display window containing the selected advertising item; and sending the generated display window to the client device for display by the client device.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains generally to log cutting machines, and more particularly to a mobile apparatus for cutting and sorting firewood.
2. Description of the Background Art
It is common to cut firewood from pre-trimmed poles, trees and the like into lengths which are generally accepted for use in a household fireplace or wood stove. When the wood has a larger than acceptable diameter, it is also common to split the wood into smaller pieces. Saws, splitters and similar wood processing devices are well known. Once the wood is cut and split, it is generally hand sorted according to relative size and stacked in a central location.
Firewood processing devices heretofore developed have been designed primarily for cutting and handling generally straight lengths of wood which have been transported to a processing site. However, an increasing amount of firewood is available as agricultural "waste" which is generated by pruning and removing trees from almond, walnut, apple and other orchards. Such wood is typically bent, twisted and generally gnarly and, therefore, not suitable for processing with existing equipment which requires generally straight lengths of wood. Quite typically, a tree falls over in an orchard and is reduced to trimmed poles and a brush pile by the grower. The brush is removed immediately from the orchard and the poles are piled by the stump of the tree. After enough trees have fallen or have been pruned to generate a truck load of wood, or after a growing season passes, the wood is hauled off and processed. While some trees may yield as much as a cord of finished product, others yield as little as one cubic foot. Rarely does one tree produce a truck load of processed wood.
Furthermore, the waste product wood must be removed from the orchard with a minimum of disruption to normal farming activities. To do so, it is highly desirable to process the wood on site, thereby facilitating loading and removal. However, the wood is unlikely to be found in one central location, but will be scattered throughout the orchard. Therefore, there is a need for an apparatus which can be easily moved through an orchard from location to location and which will cut, sort and load firewood without disrupting the normal farming activities.
SUMMARY OF THE INVENTION
The present invention pertains to a transportable wood processing apparatus for cutting, sorting and loading cut wood which can be moved through an orchard from tree to tree. Instead of bringing the wood to the machine as is done with conventional units, the wood processing apparatus of the present invention is brought to the wood. No input system is required; instead, the wood is loaded onto the apparatus by hand.
The processed wood can be loaded by the apparatus into the same truck that pulls it from location to location through the orchard, or into a trailer which is coupled to the apparatus. As the apparatus is moved from location to location, the configuration of the apparatus is not changed in any way. Therefore, there is no loss in time resulting from set-up or take-down of the apparatus at each location in the orchard. Wood continues to be processed until finished.
By way of example and not of limitation, the wood processing apparatus of the present invention includes a frame which is carried by wheels, and which has a trailer hitch at each end of the frame for coupling to a trailer or a tractor, truck or other transport vehicle. An internal combustion engine powers a hydraulic pump which is in turn coupled to the various operational elements of the apparatus.
Wood which is to be processed by the apparatus is placed on a saw table located at the rear of the apparatus. A hydraulic powered circular saw positioned adjacent to the saw table cross-cuts the wood into lengths which are preset by an adjustable stop. Once the wood is cut, it falls from the saw table onto the lengthwise edge of an adjustable wedge-shaped divider. The lengthwise edge of the divider is laterally offset from that of the saw table such that the cut wood will fall to one side or the other depending upon which side of the divider the center of gravity of the cut wood lies. In this way, the cut wood is sorted according to relative size. Individual conveyors are positioned adjacent to each side of the divider to catch the cut wood as it falls to one side or the other. If the cut wood is too large, it falls into a splitter conveyor on the splitter side of the divider and is carried to a hydraulically powered splitter. Once split, the wood is placed into a loading conveyor which carries the wood to a truck or trailer. Otherwise, the cut wood falls into a feed conveyor on the loading side of the divider and is carried directly to the loading conveyor.
The loading conveyor is pivotally coupled to the frame and extends toward the front of the apparatus with a vertical inclination. In this way, the cut wood falls from the loading conveyor into a truck or trailer coupled to the front trailer hitch. When the processing is complete and the apparatus is to be transported to another job site by way of a highway or at high speeds, the loading conveyor is folded back over the apparatus and locked into a generally horizontal position.
An object of the invention is to provide a transportable apparatus for cutting, sorting and loading wood.
Another object of the invention is to provide for sorting cut wood according to relative size.
Another object of the invention is to provide for splitting cut wood which does not meet the sorting criteria for direct loading.
Another object of the invention is to provide a loading conveyor which can be pivotally folded back over the apparatus when not in use.
Another object of the invention is to provide for processing wood which is not straight.
Another object of the invention is to cut wood into preset lengths.
Another object of the invention is to provide for sorting wood according to relative diameter without the use of moving parts.
Further objects and advantages of the invention will be brought out in the following portions of the specification, wherein the detailed description is for the purpose of fully disclosing preferred embodiments of the invention without placing limitations thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood by reference to the following drawings which are for illustrative purposes only:
FIG. 1 is a perspective view of the apparatus of the present invention showing the loading conveyor in its extended position.
FIG. 2 is a perspective detail view of the sorter divider element of the present invention.
FIG. 3 is a plan view of the apparatus of the present invention showing the loading conveyor in its extended position.
FIG. 4 is a side elevation view of the apparatus of the present invention showing the loading conveyor in its extended position.
FIG. 5 is a side elevation view of the apparatus of the present invention showing the loading conveyor in its folded back position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more specifically to the drawings, for illustrative purposes the present invention is embodied in the apparatus which is generally shown in FIG. 1 through FIG. 5. It will be appreciated that the apparatus may vary as to configuration and as to details of the parts without departing from the basic concepts as disclosed herein.
Referring to FIG. 1, the wood processing apparatus 10 of the present invention includes a frame 12 which is generally supported by wheels 14, 16 which are rotatably coupled to frame 12 and preferably carried by an axle 18 (shown in FIG. 3). Frame 12 generally comprises a network of steel tubing configured and structured to support the various elements of the apparatus.
A guide tongue 20 extends from the front of frame 12 for positioning the apparatus 10 prior to operation. The apparatus can be pushed or pulled into position using guide tongue 20 for directional control. Guide tongue 20 includes a front trailer hitch 22 for coupling to a truck or other vehicle during transportation of the apparatus. A support leg 24 is provided to support guide tongue 20 and to level the apparatus during operation. To assist in uncoupling and coupling front trailer hitch 22 to a vehicle, a hydraulic powered lift foot 26 is also provided to raise and lower guide tongue 20.
Guide tongue 20 and front trailer hitch 22 are primarily for towing the apparatus from location to location. However, in the event that the apparatus becomes obstructed after operation and it is not possible to move forward, an auxiliary tow bar 28 having a rear trailer hitch 30 is provided at the opposite end of frame 12 so that the apparatus can be pulled away from the obstruction. When tow bar 28 is used, support leg 24 is maintained in its extended position and dragged along the surface for support.
A saw table 32 is mounted to frame 12 at the end opposite guide tongue 20, and includes a horizontal lower support member 34 and a vertical upper guide member 36 for supporting and guiding a log or other article of wood to be cut. In operation, an article of wood to be cut placed lengthwise along lower support member 34 with its side abutted against upper guide member 36. A saw 38 having a circular blade 40 is mounted on frame 12 such that blade 40 is positioned at the end saw table 32 and oriented substantially perpendicular to the longitudinal axis between the ends of saw table 32 for cross-cutting an article of wood. Preferably, saw 38 is pivotally coupled to frame 12 on a vertically oriented pivot arm (not shown) such that blade 40 can be moved across the end of saw table 32 laterally to make a cross-cut. Pivotally coupling saw 38 in this manner provides both a reciprocating sliding motion as well as a slight arcuate "swing" to its movement. Alternatively, saw 38 could be slidably coupled to frame 12 for lateral motion without an arcuate swing. While an articulating chain saw or the like could also be employed, a circular saw is preferred for ease of use and making a cleaner cut. In addition, since firewood is commonly cut into various lengths, means is provided to set the length of cut. When a log or the like is placed on saw table 32 to be cut, the user positions the end of the log is abutted against a stop plate 42. Stop plate 42 is attached to an arm 44 which slidably engages a receptacle 46 which is supported by standoff 48 which is mounted to frame 12. The position of arm 44 is adjustable by means of a pin 50 engaging one of several holes 52. Typically arm 44 is configured for adjustment of cut lengths between approximately fourteen inches (35.56 cm) and twenty-four inches (60.96 cm) although other sizes can be easily accommodated.
Referring also to FIG. 2 and FIG. 3, when the end of a log is abutted against stop plate 42 the portion to be cut off will project over the end of saw table 32 above a divider 54. Divider 54 is an elongated generally wedge-shaped structure having an upper lengthwise edge 56 and arcuate sides 58, 60. As can be seen in FIG. 2, upper lengthwise edge 56 is offset laterally from the longitudinal centerline extending between the ends of lower support member 34 in the direction of upper guide member 36. In addition, the vertical position of edge 56 is positioned approximately two inches (5.08 cm) below the vertical position of lower support member 34. Therefore, when the side of a log is abutted against upper guide member 36, the cut portion will fall with its center of gravity to one side or the other of divider 54. In this way, smaller diameter logs will have their center of gravity located on the side of divider 54 which faces toward upper guide member 36 and will fall in the direction of side 58 when cut. Larger diameter logs having their center of gravity located on the side of divider 54 facing away from upper guide member 36 will fall in the direction of side 60 when cut. As can be seen, the amount of lateral offset between saw table 32 and divider 54 will determine the size of logs which will fall to one side of divider 54 or the other. Therefore, divider 54 effectively sorts cut logs and other articles of wood in one of two categories according to relative size.
In the preferred embodiment, the lateral offset between divider 54 and saw table 32 is adjustable so that the relative sorting size can be varied. In this configuration, sides 58, 60 are defined by a lower wedge member 62, and edge 56 is defined by a divider bar 64. In the preferred embodiment shown in FIG. 2, divider bar 64 generally comprises an elongated rectangular bar sandwiched between upper and lower lengths of round stock. While it is preferred that divider bar 64 be generally rectangular in shape, other shapes can be employed without affecting functionality, so long as divider bar 64 forms a generally narrow and elongated edge 56.
Divider bar 64 and lower wedge member 62 are pivotally coupled along their corresponding lengthwise edges so that divider bar 64 can be pivoted toward either side of lower wedge member 62. A locking plate 90 having a plurality of holes 92 is attached to one end of divider bar 64 so that, once the position of divider bar 64 is selected, it can be secured in place at one end with a pin 66 or the like through one of the holes 92. Alternatively, divider bar 64 can be eliminated and divider 54 fashioned as a single wedge-shaped unit which is fixed in position or slidably coupled to frame 12.
A feed conveyor 68 is mounted to frame 12 and positioned such that one end is adjacent to the side of divider 54 facing toward upper guide member 36 in order to "catch" or receive an article of wood falling to that side. The other end of feed conveyor 68 is positioned away from divider 54 and toward the end of frame 12 to which guide tongue 20 is attached. Feed conveyor 68 "feeds" a loading conveyor 70, one end of which is positioned below the end of feed conveyor 68 while the other end extends away from frame 12 at a vertical inclination sufficient for carrying articles of wood to the bed of a truck or to produce a high stack of wood.
A splitter conveyor 72 is mounted to frame 12 and positioned such that one end is adjacent to the side of divider 54 facing away from upper guide member 36 so that it will receive an article of wood falling to that side of divider 54, while the other end of splitter conveyor 72 extends toward the end of frame 12 to which guide tongue 20 is attached and carries the larger articles of wood to a splitter table 74. A splitter 76 is mounted to frame 12 in a position adjacent to splitter table 74 so that the logs can be further processed. Preferably, splitter 76 is mounted to frame 12 using shock absorbing mounts, such as rubber blocks or the like, so that twisting motion resulting from splitting an article of wood is not translated to frame 12. Splitter 76 is also positioned adjacent to the end of loading conveyor 70 which is fed by feed conveyor 68 at a higher elevation so that the split articles of wood can be pushed or dropped into loading conveyor 70.
Referring also to FIG. 4 and FIG. 5, loading conveyor 70 is pivotally coupled to frame 12 with bearings 78, 80 such that it can be extended during operation and folded back over frame 12 during transportation. In its extended position (FIG. 4), loading conveyor 70 is positioned with an inclination sufficient for cut articles of wood to be loaded into a truck or other transport vehicle. In its folded back position (FIG. 5), loading conveyor 70 is folded back over frame 12 in a generally horizontal position and supported by an arm 82. Note that, in rotating loading conveyor 70 between its extended position and its folded-back position, the end of loading conveyor 70 might be obstructed by the ground or other surface on which the apparatus rests. To remove such a restriction, lift foot 26 can be extended to provide sufficient clearance for rotation.
Referring again to FIG. 1 and FIG. 3, in the preferred embodiment the wood processing apparatus 10 is hydraulically powered. An internal combustion engine 84 provides power to a hydraulic pump 86, both of which are mounted on frame 12. Pump 86 is coupled to lift foot 26, saw 38, feed conveyor 68, loading conveyor 70, splitter conveyor 72, and splitter 76 by individual hydraulic lines (not shown). With regard to saw 38, pump 86 powers both the saw itself as well as the pivot mechanism which causes saw 38 to articulate across the end of saw table 32 with a reciprocating motion for cross-cutting an article of wood. Note also that saw 38 can be reciprocated for making a cut by pressing a hip bar 88 which an operator needs only to lean against in order to begin operation. This frees the operator's hands for guiding an article of wood to be cut. Hip bar 88 operates a hydraulic valve which causes saw 38 to move toward the wood. When hip bar 88 is released, saw 38 retracts. Therefore, in operation, hip bar 88 can be used as a direction reversing control as well as to meter the speed of saw movement into the wood.
Rotation of loading conveyor 70 between its extended and folded-back can be effected manually. Preferably, however, rotation is effected with a hydraulic cylinder and chain (not shown) coupled to gear 94 and powered by pump 86. Gear 94 is coupled to loading conveyor 70 and typically sized such that an eight inch (20.32 cm) stroke of the hydraulic cylinder will cause the chain to rotate gear 94 and loading conveyor 70 approximately 147 degrees.
It should also be noted that inclusion both front trailer hitch 22 and rear trailer hitch 30 provides for flexible operation. Since loading conveyor 70 will carry wood to the front of the apparatus when in its extended position, the wood is normally dropped into a truck or other vehicle which is pulling the apparatus from location to location. When the truck is fully loaded, it can be uncoupled from front trailer hitch 22 and replaced with an empty truck. Alternatively, a tractor or the like could be coupled to rear trailer hitch 30 for pulling the apparatus from the opposite direction. In this configuration, it is possible to couple one or more trailers to front trailer hitch 22 onto which the cut wood can be loaded from loading conveyor 70. When a trailer is full, it can be uncoupled and replaced with an empty trailer.
Accordingly, it will be seen that this invention presents a wood processing apparatus which is convenient to operate, easy to move from one location to another, and which provides for sorting as well as cutting logs and other articles of wood. Although the description above contains many specificities, 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.
|
Disclosed is a transportable wood processing apparatus (10) for cutting, sorting and loading firewood and the like. A frame (12) is carried by wheels (14, 16) and includes a guide tongue (20) and trailer hitch (22) for moving the apparatus from location to location. A stop plate (42) sets the length of firewood which is cut by a reciprocating saw (38). A divider (54) is laterally offset from saw table (32) such that the cut firewood will fall either to side (58) or side (60) and be sorted according to relative size depending upon which side the center of gravity of the firewood lies. The cut firewood either falls into a feed conveyor (68) which then feeds a loading conveyor (70) for loading a vehicle or, if too large for direct loading, falls into a splitter conveyor (72) and is carried to a splitter table (74) for splitting with splitter (76). After being split, the firewood is placed into loading conveyor (70). Loading conveyor ( 70) is pivotally coupled to the frame (12) such that it can be rotated between an extended position for operation and folded back over frame (12) during movement from location to location.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Application Ser. No. 61/242,577, filed Sep. 15, 2009, and U.S. Provisional Application Ser. No. 61/235,536, filed Aug. 20, 2009, each of which is hereby incorporated by reference herein in its entirety, including any figures, tables, and drawings.
FIELD OF INVENTION
[0002] This invention relates to a cap that fits on the end of a flexible or rigid endoscope that can be used to contain, control and shape ionized plasma and remove tissue coagulum for purposes of efficiently and precisely treating diseases and abnormalities that involve tissue layers.
BACKGROUND OF THE INVENTION
[0003] Argon plasma coagulation (APC) is a monopolar non-contact electrosurgical method that transfers electrical energy to tissue by means of ionized non-thermal, inert gas plasma (Ginsberg et al. ( 2002 )). Resistance in an electrical conductor produces heat. As tissue is heated by current flow, its electrical resistance increases. Electrical current flowing through the argon plasma and into tissue seeks the path of least resistance in accordance with the laws of electrophysics. This permits a superficial tissue injury effect that is free of mechanical contact artifacts and that is primarily a function of the shape of the ionized plasma, the stability of the distance over which the plasma must conduct current from its ignition source to the target tissue, and the homogeneity of the target tissue conductivity. Examples of endoscopic and argon plasma devices are described in U.S. Pat. Nos. 7,517,347; 6,210,410; and 6,063,084; and in published U.S. patent applications 2009/0024122 and 2007/0034211. Refinement of argon plasma tissue treatment methodology will improve the uniformity and superficiality of tissue layer thermal treatments and permit utilization of the therapeutic effects of active charged and uncharged molecules produced by the plasma.
BRIEF SUMMARY OF THE INVENTION
[0004] The subject invention concerns a series, set, or collection of caps which can be fitted onto the distal end of a flexible or rigid endoscope. In one embodiment, as shown in FIGS. 1A and 1B , a cap of the invention comprises a generally cylindrical cap body having a distal end portion with a distal end opening and having a proximal end portion with a proximal end opening which can operably connect with the distal end of an endoscope. The wall of the cap body can optionally comprise one or more venting holes in the distal end portion of the cap body. A cap of the invention can optionally comprise a conduit on the exterior or the interior of the cap body for containing, for example, fluid, gas and/or ignition device wiring. In one embodiment, the wall of the distal end portion of the cap body is hollow, such that the distal end portion comprises an inner wall and an outer wall defining an internal hollow space in the cap body. In a specific embodiment, the conduit is directly and operably connected to the internal hollow space in the cap body. In a further embodiment, one or more fluid or gas delivery ports can be provided on the inner wall of the distal end portion having the internal hollow space.
[0005] The subject invention provides methods of ionized plasma tissue layer treatment utilizing a generally cylindrical cap of the invention fitted on the end of a flexible or rigid endoscope to facilitate low power non-thermal plasma ignition and maintenance, plasma confinement, and plasma behavior control. The invention encompasses specific modifications in cap shape, diameter, length, open end bevel or edge profile, gas delivery, venting, and plasma ignition device positioning for purposes of minimizing plasma ignition and maintenance power requirements, facilitating control of plasma behavior, and debridement of tissue coagulum, which are all important aspects of the new method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIGS. 1A-1C illustrate various embodiments of a cap of the invention having an angled cap wall and external conduit for routing of gas and ignition device wiring.
[0007] FIGS. 2A and 2B illustrate various embodiments of a cap of the invention with shouldered cap wall.
[0008] FIG. 3 illustrates an embodiment of a cap of the invention with spherical cap wall.
[0009] FIGS. 4A-4C illustrate various embodiments of a cap of the invention with beveled open cap end.
[0010] FIG. 5 illustrates an embodiment of a cap of the invention with hollow distal cap end wall for multiple fluid or gas delivery ports.
[0011] FIGS. 6A and 6B illustrate various embodiments of a cap of the invention with attached electromagnetic devices to produce osculation of the ferromagnetic ignition device support or direct shaping of plasma.
[0012] FIG. 7 illustrates an external conduit.
[0013] FIGS. 8A and 8B illustrate various embodiments of a cap of the invention with probe based gas delivery and ignition systems.
[0014] FIGS. 9A-9E illustrate distal end cap edge profiles that can enhance tissue debridement.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The subject invention concerns a series, set, or collection of caps which can be fitted onto the distal end of a flexible or rigid endoscope. In one embodiment, as shown in FIGS. 1A and 1B , a cap of the invention comprises a generally cylindrical and/or conical shaped cap body 10 having a distal end portion 12 with a distal end opening 14 and having a proximal end portion 16 with a proximal end opening 18 which can operably connect with the end of an endoscope 20 . An annular rib 17 can optionally be provided on the interior of the proximal end portion 16 (see, for example, FIG. 7 ). The annular rib 17 can act as a stop for preventing the endoscope from being inserted beyond a certain point in the proximal end portion 16 of the cap body 10 . The distal end portion 12 and the proximal end portion 16 are generally provided in a coaxial orientation. Typically, the diameter of the distal end opening 14 is larger than the diameter of the proximal end opening 18 . In one embodiment, the cap body 10 is conical shaped. In a specific embodiment, the wall of the cap body 10 tapers from the proximal end to the distal end such that the distal end portion 12 of the cap body 10 is conical shaped, as shown in FIGS. 1A-1C . In another embodiment, the distal end portion 12 of the cap body 10 has a generally U-shaped appearance, having a generally angular or curved shoulder 15 , as shown in FIGS. 2A and 2B . In another embodiment, the distal end portion 12 of the cap body 10 has a generally globe, spherical, or round shape, as shown in FIG. 3 . The distal end opening 14 of cap body 10 can be of any desired angle, including from 0 to more than 45 degrees (see, for example, FIGS. 4A-4C ) such that the plane of the distal end opening 14 is oblique to the insertion direction of the endoscope. The wall 19 of the cap body 10 can optionally comprise one or more venting holes 22 in the distal end portion 12 of the cap body 10 . In another embodiment, the wall 19 of the cap body 10 does not comprise any venting holes (see, for example, FIG. 1C ) regardless of the shape or construction of the distal end portion 12 of the cap body 10 .
[0016] A cap of the invention can also optionally comprise a conduit 24 on the exterior and/or the interior of the cap body 10 for containing, for example, fluid, gas and/or ignition device wiring 23 , and/or a wash tube for cleaning an ignition device 25 , etc. The conduit 24 can extend in an orientation substantially axially along the exterior of the cap body 10 . The conduit 24 can be releasably attached (via e.g., a strap 27 ) to the endoscope 20 or to cap body 10 , or it can be more permanently attached, for example, by way of bonding, adhesive, or welding. The conduit 24 can be composed of a rigid or flexible material. In one embodiment, the wall of the distal end portion 12 of the cap body 10 is hollow, such that the distal end portion 12 comprises an inner wall 32 and an outer wall 34 defining an internal hollow space 30 in the cap body, as illustrated in FIG. 5 and FIG. 6A . In a specific embodiment, the conduit 24 is directly and operably connected to the internal hollow space 30 .
[0017] A cap of the invention can also optionally comprise a releasably locking or securing means in the cap body 10 for locking or securing the cap in place when attached to the endoscope.
[0018] As illustrated in FIGS. 9A-9E , the cap of the invention can have a rounded edge 52 , a square or flat edge 54 , or an internal tapered edge 56 , or an external tapered edge 58 , or an internal and external tapered edge 59 on the distal end portion 12 of the cap body 10 .
[0019] Caps of the invention can also comprise a plasma ignition device 60 provided inside of the distal portion of the cap body for producing an ionized plasma. Any suitable plasma ignition device in the art can be utilized with the subject invention. In one embodiment, a plasma ignition device is provided on a support 62 . The support 62 can comprise, for example, an insulated or uninsulated ferromagnetic metal current conductor. Caps of the present invention can also include an electromagnetic device 70 attached to or embedded in the wall of the distal portion of the cap body 10 or positioned in sufficient proximity to the cap body 10 so as to provide an operator of the endoscope the ability to manipulate or adjust the shape of a cap confined plasma through the use of electromagnetic fields generated by the device (see, for example, FIGS. 6A and 6B ). Any suitable electromagnetic device capable of generating an electromagnetic field for control of cap confined plasma can be utilized with the subject invention. In a further embodiment, one or more gas or fluid delivery ports 40 can be provided on the inner wall 32 of the distal end portion 12 having the internal hollow space 30 , wherein the conduit 24 can be indirectly or directly and operably connected to the hollow space 30 and in communication therewith. Caps of the invention can also include a probe deflection shelf 80 attached to an inner wall 32 of the distal portion of the cap body 10 , wherein the probe deflection shelf 80 can position a tip of a probe 90 toward the center of a field defined by the boundaries of the cap body. As shown in FIG. 8B , an endoscope for use with a cap of the invention can optionally comprise an objective lens 100 , an air and/or water jet 102 , and one or more lightguides 104 .
[0020] A cap of the invention can be constructed of any suitable material, including for example, plastic, glass, metal or metal alloy, ceramic, etc. In one embodiment, a cap of the invention is constructed from a clear plastic material such as (but not limited to) polyethylene, polycarbonate, and polyurethane. The material selected for cap construction will depend on the degree of desired distal end stiffness and other variables associated with a particular component configuration. In a specific embodiment, a cap of the invention is made of a clear or translucent plastic material.
[0021] Endoscopic caps of the invention are contemplated to include all variations in cap diameters, length and shape, cap open end bevels and edge profiles, cap associated gas delivery and venting mechanisms, and plasma ignition device positions and configurations in the cap, which can be employed to shape and stabilize an ionized plasma generated within or adjacent to the cap for any therapeutic purpose in humans or animals. Therapeutic treatments specifically contemplated within the scope of the invention include, but are not limited to, tissue de-vitalization, coagulation, carbonization, vaporization or tissue layer surface chemical reactions supported by active ionic and molecular products produced by the cap associated non-thermal ionized plasma (Fridman et al. (2005)). Additionally, the invention includes any device or devices capable of generating an electromagnetic field in the vicinity of the cap constrained or associated ionized plasma through integration of an electromagnetic device or devices into the design of the cap, through attachment of the electromagnetic device or devices to the cap, or through positioning of the electromagnetic device devices in proximity to the cap in such a manner that the generated electromagnetic field can influence the ionized plasma, its' ignition device, or the ignition device supporting mechanism. Finally, the invention includes any modification to the cap edge profile (such as squaring or angling) or to the cap open end shape the purpose of which is to enhance or facilitate debridement of tissue coagulum.
[0022] The varying degree of desiccation and thickness of coagulum, which builds up during the plasma coagulation process using APC for Barrett's epithelium, progressively impairs uniformity of tissue conductivity and hence diminishes the precision and uniformity of treatment effect. It was observed that use of a cap of the invention to periodically scrape off coagulum (debridement) during the treatment process greatly improved the uniformity and precision of the treatment effect and permitted ionized plasma ignition and maintenance with the use of extremely low treatment power settings. It was further observed that it was much easier to stabilize the distance between the plasma ignition source (the tip of the probe) and the target tissue during treatment with a cap of the invention fitted onto the endoscope. This innovation, using a cap of the invention on an endoscope, permitted successful ablation of Barrett's epithelium utilizing power settings of about 1 to 20 Watts. These power settings were 40% (or less) of the power settings currently recommended for treatment of Barrett's epithelium by two different APC generator manufacturers and 17% (or less) of the published power settings for high power ablation of Barrett's esophagus or epithelium. It was further observed that relatively large areas of epithelium could be removed with little or no post procedure pain or squealae. Furthermore, the use of very low power settings to ignite and drive the ionized plasma resulted in a translucent plasma which permitted near complete visualization of the target tissue during treatment, a circumstance not possible with any other tissue ablation technology including standard APC methodology, which creates a blindingly bright plasma. The ability to visualize the target tissue during treatment greatly enhances the precision of treatment.
[0023] Design modifications with respect to cap length, diameter, and shape provide significant further improvements in the ability to stabilize the distance between the probe tip and the target tissue during treatment. Furthermore, different methods of delivering gas to and venting gas from the cap and positioning of the plasma ignition device further enhance control of the ionized plasma behavior and further minimize the power necessary to ignite and maintain the plasma. For instance, by connecting the gas delivery system and ignition device to the cap, rather than passing these system components through the accessory channel of the endoscope in the form of a probe, the ignition device at the tip of the probe can be positioned ideally with respect to tissue surface and cap walls so as to maximize plasma flow to the target tissue and minimize episodic plasma flow to the cap walls ( FIGS. 1A-1B , 2 A- 2 B, 3 , and 4 A- 4 C). Additionally, the endoscope accessory channel is free for other uses such as coagulum removal because it no longer need be used as a conduit for the probe. The need to periodically remove the probe from the endoscope accessory channel to physically clear coagulum from its tip during treatment is also eliminated. In addition, cap design to include a probe deflection shelf to better center the probe with respect to the treatment field ( FIGS. 8A and 8B ) can preserve the current probe-through-the-scope methodology whose major advantage is the real-time ability to alter probe-tissue distance. Uniformity of plasma effect can be provided by routing argon gas into a hollow cap and delivering it to the cap confined treatment space through a multiported system ( FIG. 5 ). Real time adjustments to the shape of a cap confined plasma can be provided through the use of electromagnetic fields generated by devices incorporated into the cap or placed adjacent to it ( FIGS. 6A and 6B ). Real time electromagnetic plasma shaping provides for an unprecedented level of therapeutic control.
[0024] Iterative removal of accumulated coagulum is an integral part of making low power generator settings work for APC tissue layer ablation and is hence an integral and novel aspect of cap design. Current open cap end edge profiles are generally rounded to avoid tissue injury. In one embodiment, open cap end edge profiles are squared or are configured with internal or external tapered lips ( FIGS. 9A-9D ) to enhance the ability of the caps to successfully remove tissue coagulum (debridement).
[0025] As shown in FIGS. 6A and 6B , additional embodiments of the cap can include multiple gas port associated ignition devices arrayed circumferentially around the distal end of the cap which can be fired in rapid sequence.
[0026] As shown in FIGS. 8A and 8B , the same basic modifications (gas venting holes and probe deflection shelf) can be utilized with angled and spherical embodiments. The probe deflection shelf is positioned such that when the cap is attached to the endoscope and properly oriented the shelf will position the tip of the probe toward the center of the field as defined by the boundaries of the cap without obstructing the view from the endoscopes objective lens.
[0027] The subject invention also concerns an endoscope comprising a cap of the invention.
[0028] The subject invention also concerns kits comprising, in one or more containers, an endoscopic cap of the invention. In one embodiment, the cap is provided sterile in a container or package. In one embodiment, the cap is provided as a disposable, one use product. In one embodiment, a kit of the invention includes instructions or packaging materials that describe how to install and/or how to use a cap on an endoscope in a patient. Containers of the kit can be of any suitable material, e.g., glass, plastic, paper, metal, etc., and of any suitable size, shape, or configuration. As noted above, the container and the cap provided therein can be provided in a sterile form.
[0029] The subject invention also concerns methods of using an endoscope comprising a cap of the invention. In one embodiment, a method of the invention comprises introducing an endoscope of the invention into the body of a person or animal. The endoscope can then be utilized, for example, for tissue debriding, devitalizing, ablating (polyps, malignant tumors, etc.), coagulating, carbonizing, hemostasis (bleeding ulcers, etc.), and/or vaporizing. In one embodiment, the present invention can be used to treat a premalignant condition (e.g., Barrett's esophagus) or a malignant condition (e.g., esophageal cancer).
[0030] The methods of the present invention can be used in the treatment of humans and other animals. The other animals contemplated within the scope of the invention include domesticated, agricultural, or zoo- or circus-maintained animals. Domesticated animals include, for example, dogs, cats, rabbits, ferrets, guinea pigs, hamsters, pigs, monkeys or other primates, and gerbils. Agricultural animals include, for example, horses, mules, donkeys, burros, cattle, cows, pigs, sheep, and alligators. Zoo- or circus-maintained animals include, for example, lions, tigers, bears, camels, giraffes, hippopotamuses, and rhinoceroses.
[0031] All patents, patent applications, provisional applications, and publications referred to or cited herein are incorporated by reference in their entirety, including all figures and tables, to the extent they are not inconsistent with the explicit teachings of this specification.
[0032] It should be understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and the scope of the appended claims. In addition, any elements or limitations of any invention or embodiment thereof disclosed herein can be combined with any and/or all other elements or limitations (individually or in any combination) or any other invention or embodiment thereof disclosed herein, and all such combinations are contemplated with the scope of the invention without limitation thereto.
REFERENCES
[0033] U.S. Pat. No. 7,517,347
U.S. Pat. No. 6,210,410 U.S. Pat. No. 6,063,084 U.S. published patent application 2009/0024122 U.S. published patent application 2007/0034211 Fridman, A., Chirokov, A., and Gutsol, A. (2005) “Non-thermal atmospheric pressure discharges” J. Phys. D: Appl. Phys., 38:R1-R24. Ginsberg, G., Barkun, A., Bosco, J., Burdick, J. S., Isenberg, G., Nakao, N., Petersen, B.,
[0040] Silverman, W., Slivka, A., and Kelsey, P. (2002) “The argon plasma coagulator” Gastrointestinal Endoscopy, 55(7):807-810.
|
The subject invention concerns caps that fit on the end of an endoscope. Endoscopic caps of the invention can provide for the control and shaping of an ionized inert gas plasma for purposes of efficiently and precisely burning and removing tissue layers. The device can be used in the treatment of premalignant and malignant conditions, such as Barrett's esophagus and early esophageal cancer, as well as other therapeutic applications.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a method of and apparatus for decontaminating garments and soft goods, and more specifically, to the removal of radioactive particulate matter, chemical agents, toxins and/or biological agents as well as regularly encountered soiling materials from garments or other items of cloth, paper and rubber.
2. Brief Description of the Prior Art
A patent which purports to teach a method of decontaminating radioactive garments through the use of a dry cleaning solvent is U.S. Pat. No. 3,728,074. This system depends entirely on the filtration of nuclear particulates from the dry cleaning solvent as the dry cleaning solvent is circulated through the contaminated garments. Therefore, since the radioactive particulates are captured entirely by the filters, it is presumable necessary to replace those filters often. Also, this system operates under positive pressure and includes an expansion bag. Any leak in the system or rupture of the expansion bag will result in radioactive particulates being discharged to the atmosphere.
There is also in the prior art a method which seems to teach the cleaning of radioactive particulate material from industrial workers protective clothing through the use of a conventional laundry wash. This wash entails a standard 30 to 45 minute water washing using commercial detergent followed by a separate drying cycle of usually 60 minutes in a conventional hot air or other type textile clothes dryer. This system although effective in producing a clean looking garment, normally is so inefficient that from 20 to 35% of the clothing must be rewashed because insufficient radioactivity has been removed to permit reuse of the protective article. Moreover, this method generates quantities of radioactively contaminated wash water which must be diluted to safe concentrations before it is released or evaporated to a concentrate and then drummed and buried in an radiation waste burial facility. This makes the method very costly and time consuming.
There is little in the prior art dealing with the removal of chemicals or toxins such as pesticides and chemical warfare agents such as tabun, sarin, soman or mustard gas from articles of protective clothing. This is also the case with garments contaminated with biological contaminants. The military currently decontaminates protective articles contaminated with chemical agents through the use of high temperature steam. Although the article is decontaminated of chemical agents in this manner, it is also usually no longer suitable for reuse. Also, this method does nothing to deactivate or destroy the agent.
Accordingly, it is an object of the present invention to provide a method of and apparatus for decontaminating garments contaminated with radioactive particulates which dislodges such radioactive particulates by using a dry cleaning solvent.
Another object of the present invention is to provide a method and apparatus which captures and contains radioactive, chemical and biological contaminants removed from the garments.
A further object of the present invention is to provide a method of an apparatus for decontaminating radioactively contaminated garments in a single apparatus which also serves to dry the garments after completion of the wash cycle.
Another object of the present invention is to provide a method of and apparatus for decontaminating garments contaminated with pesticides and chemical agents such as those used in chemical warfare (e.g. HD, GD, GA, GB).
Further, it is an object of the present invention to provide a method of and apparatus for decontaminating garments contaminated with biological and toxin contaminants including anthrax, salmonella, botulinum, a mycotoxin commonly referred to as yellow rain and other viruses and bacteria which can be potentially used in warfare or terrorist activity.
A further object of the present invention is to provide a method and apparatus for decontaminating garments which limits the amount of contaminated waste generated.
Further, it is an object of the present invention to provide a method and apparatus which is self contained and relatively easy to transport so that it may be taken from site to site.
Another object of the present invention is to provide a method and apparatus which operates under negative pressure so that, should leaks develop, no contaminants will be discharged to the atmosphere.
A further object of the present invention is to provide a method of an apparatus for decontaminating garments having radioactive, chemical and biological contamination in a quick and efficient manner.
Further, it is an object of the present invention to provide a method and apparatus which can be operated on a continuous basis for relatively long periods.
Briefly stated, the foregoing and numerous other features, objects and advantages of the present invention will become readily apparent upon reading the detailed description, claims and drawings set forth hereinafter. These features, objects and advantages are accomplished by circulating a dry cleaning solvent through the articles to be decontaminated while the articles are being agitated so that particulate and chemical contaminants which may be radioactive, chemical and/or biological in nature may be dislodged or dissolved and removed from the garments.
After an initial wash cycle, the dry cleaning solvent containing suspended particulate and dissolved contaminants is dumped from the drum housing which provides agitation to the garments, into a distillation means. Chemical agents including pesticides and nerve, blister, and other incapacitating or killing agents such as sarin and mustard are also removed from the garments during this initial wash cycle because they are all highly soluble in the dry cleaning solvent, preferably trichlorotrifluoroethane referred to herein as the solvent.
Located in the distillation means is a neutralizing agent which serves to deactivate biological contaminants, chemically break down chemical contaminants to nontoxic or less toxic substances and to prevent the migration of chemical contaminants with the solvent while the distilling is being performed. During the second phase of the wash cycle, an initially contaminate free volume of dry cleaning solvent is continuously circulated through the agitating drum housing in which the contaminated garments are placed in a closed loop arrangement. The closed loop includes a filter for the removal of additional particulates dislodged from the garments and an adsorber which preferentially adsorbs chemical agents which have been dissolved in the dry cleaning solvent during this phase of the wash cycle.
Between the second phase of the wash cycle and the drying cycle, there is a rinse cycle. Residual solvent absorbed in the garments is extracted by pumping a quantity of clean solvent through the drum thereby rinsing the garments of the residual solvent.
During the drying phase, hot solvent vapor is circulated through the drum housing in closed loop fashion by a fan. A portion of the hot solvent vapor being circulated is run through a condenser and returned to the fan so that the vapor being circulated through the drum housing is not saturated thereby facilitating more rapid drying.
Solvent vapor generated in the distillation means is collected and condensed and returned to the secondary solvent tank in pure liquid phase.
In other words, the invention comprises the use of a drum housing similar to that used in conventional dry cleaning systems and the use of trichlorotrifluoroethane as the dry cleaning solvent. The solvent not only serves to dislodge contaminating particulate matter, but also solubilizes various pesticides and chemical agents used in chemical warfare. The contaminated solvent is then drained from the drum housing to a distillation means which serves a dual function. The first function of the distillation means is to distill pure solvent from the contaminated solvent dumped therein while the second function of the distillation means is to serve as a container for a neutralizing agent which destroys or deactivates both chemical and biological contaminants. The neutralizing agent is comprised of a mixture of calcuim hypochlorite or sodium hypochlorite and sodium hydroxide or potassium hydroxide. The concentration of calcium or sodium hypochlorite must be greater than 10% and the concentration of sodium hydroxide or potassium hydroxide must be greater than 1.0 Normal.
The biological contaminants coming in contact with this neutralizing agent are destroyed. The chemical contaminants coming in contact with this neutralizing agent are chemically broken down to either nontoxic or less toxic substances. The density of the neutralizing agent is less than the density of solvent and further the neutralizing agent is nonmiscible in solvent, because the neutralizing agent has a polar chemical configuration. Therefore, the neutralizing agent will float as a layer on top of any solvent dumped to the distillation means. Any chemical agent attempting to migrate from the distillation means with the solvent vapor must first pass through this layer of neutralizing agent. Upon contacting the neutralizing agent layer, the chemical contaminants are broken down to heavier components which settle out in the distillation means assuring that no contaminants migrate from the distillation means with the solvent vapor. The solvent vapor thus generated is then condensed and collected and placed in readiness for the next wash load.
Given the relatively small size required for the apparatus, making it not unreasonable to transport, and that washings may be performed consecutively, the invention is particularly adaptable to use by the military for decontaminating the protective garments of soldiers, and the like, at or near the place of battle.
Garments currently used by the military for protection against chemical warface contain a layer of activated carbon which serves to adsorb any chemical agents coming in contact with the garment thereby preventing the chemical agents from contacting the wearer of the garment. Since there is currently no effective or efficient method of stripping off chemical agents adsorbed by the activated carbon impregnated in the garment, once the garment becomes contaminated, it must be replaced. The invention disclosed herein allows the activated carbon contained in the garment to be cleansed of chemical agents and therefore be reused.
The entire wash and dry cycle of the present invention can be performed in less than 45 minutes. Thus, it is entirely feasible that mobile dry cleaning decontamination units can be used in battle field conditions to regenerate the protective quality of the garments worn under those type of conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram and schematic view of the apparatus constructed according to the present invention.
FIG. 2 is a diagram showing the sequence of operations of the parts of the invention during the wash and dry cycles.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning first to FIG. 1, there is shown a schematic illustration of a dry cleaning system constructed according to the present invention. Such arrangement is unique in its ability to remove and contain multiple forms of contamination as well as in its ability to render inactive many contaminants otherwise harmful to human life.
The dry cleaning apparatus of this invention includes a rotatable cleaning cage or drum 10 wherein garments contaminated with radioactive particulate matter, toxin contaminants, chemical contaminants and/or biological contaminants. The chemical contaminants may be pesticides or those types of nerve agents and blister agents used by the military in chemical warfare. They include: HD (mustard gas), GD, GA, GB and VX. The types of biological or toxin contaminants encountered may include salmonella, botulinum, anthrax and a mycotoxin commonly referred to as yellow rain.
The garments are cleaned in the drum 10 by placing within drum 10 an initial charge of dry cleaning solvent and agitating the garments by imparting to drum 10 a rotational movement of alternating direction. This action coupled with the garments submersion in the dry cleaning solvent, trichlorotrifluoroethane, serves to loosen and dislodge particulate contaminants and dissolve the chemical contaminants. The dry cleaning solvent is supplied by primary solvent tank 12 in fluid communication with drum 10. A pump 14 is used to force the solvent from the primary solvent tank 12 through conduit 16, isolation valve 18, bag filter 20, conduit 22, adsorbers 24, conduit 26 and into the top of drum 10.
This initial wash phase consists of a closed loop agitation with a finite quantity of solvent. Before beginning the secondary wash phase, the initial wash phase may be repeated one or more times. This reiteration of cycles may be accomplished by manual or automatic control.
Disposed in the bottom of drum 10 is an outlet conduit 28 which permits withdrawal of the dry cleaning solvent together with any radioactive particulate matter, chemical agents and/or biological and toxin agents removed from the garments during the wash cycle. At the completion of the initial wash cycle, motorized ball 30 opens allowing drum 10 to drain and the solvent and contaminants are communicated through conduit 28, motorized ball 30 and conduit 34 to still tank 36. Also, at the conclusion of the initial wash cycle, an extract motor imparts to drum 10 a rapid, one directional, spin to aid in draining the contaminated solvent from drum 10. Most of the contaminants (approximately 93%) are removed by the initial phase of the wash cycle. For heavily contaminated garments, it may be necessary to repeat the initial phase of the wash cycle.
Contained within still tank 36 is an approximately 2" thick layer of neutralizing agent comprising a mixture of concentrated bleach and caustic having a pH of approximately 12. The neutralizing agent can be made by starting with a quantity of water as a base and adding to the water either calcium hypochlorite or sodium hypochlorite to create at least a 10% solution of either. Then dissolve solid sodium hydroxide or potassium hydroxide in the concentrated bleach solution so that the solution has at least a 1.0 Normal hydroxide present. The neutralizing agents are introduced to still tank 36 from a neutralizing agent tank 38 through a motorized ball valve 40 and a conduit 42. Motorized ball valve 40 is operated by level controller 43 so that a minimum 2" thick layer of neutralizing agent is present in still tank 36 at the beginning of each wash. These neutralizing agents are not miscible with the dry cleaning solvent because they are polor in chemical configuration and therefore, the layer of neutralizing agents will float on top of the solvent and contaminants flushed from drum and into still tank 36.
Still tank 36 is maintained at a temperature of approximately b 118° F. which is the boiling point of trichlorotrifluoroethane. As the solvent boils within the still tank 36, the resulting vapor must first pass through and thereby contact the layer of neutralizing agent riding on top of the liquid solvent. Any chemical agents attempting to migrate with the solvent vapor will be chemically oxidized by the neutralizing agent and will ultimately end up as residue on the bottom of the still tank 36 in a much less toxic form after distillation is complete. The neutralizing agents also serve to destroy the biological and toxin contaminants. It is important that no contaminants be permitted to migrate with the solvent vapor from the still tank 36 as this would cause a recontamination of the garments during a later phase of the process and could also create a vapor hazard to the operator when he opens drum 10 at the completion of the cycle. Note that the agents used in chemical warfare can kill even in the parts per million range.
The resulting contaminant free solvent vapor is then communicated by convection through Viton lined conduit 44 to condenser 46. Condensate generated by condenser 46 is communicated through conduit 48 to water separator 50 by gravity. The solvent is then communicated through conduit 52 to secondary solvent tank 54. Water separated from the dry cleaning solvent by water separator 50 is communicated through conduit 56 to the still tank 36 so as to eliminate moisture contamination of the now clean solvent generated by distillation.
During the secondary phase of the wash cycle, motorized ball 30 closes and motorized ball 32 opens and pump 14, again taking suction from primary solvent tank 12, pumps solvent in a continuous fluid circuit comprised of pump 14, conduit 16, bag filter 20, conduit 22, adsorbers 24, conduit 26, drum 10, conduit 28, motorized ball valve 32, conduit 62, liquid level control structure 64, conduit 70 and back to primary solvent tank 12. During the secondary phase of the wash cycle, as in the initial phase, movement to drum 10 is imparted by the wash motor generating a rotational movement of alternating direction.
As the solvent flows through filter 20, particulate contaminants, both radioactive and biological in nature, are removed from the solvent. Similarly, chemical contaminants dissolved in the solvent are adsorbed in adsorbers 24. The preferred adsorbent is Fullers Earth, but it is also possible to use activated silica, activated alumina, activated carbon or diatomaceous earth as the adsorbent. Uncontaminated solvent enters drum 10 dislodging particulate contaminants not removed during the initial wash cycle and dissolving chemical contaminants not dissolved during the initial wash cycle. A level of liquid solvent in drum 10 is maintained by liquid level control structure 64 which contains a weir 66 so situated so as to maintain the desired level.
There are weep holes at the base of weir 66 so that all dry cleaning solvent may be drained from drum 10 when pump 14 is de-energized at the completion of the secondary phase of the wash cycle. Before exiting the liquid level control structure 64, the dry cleaning solvent must first pass through macro particle separator 68 thereby removing gross particulate contaminants from the dry cleaning solvent. From the macro particle separator 68 the dry cleaning fluid is transmitted via conduit 70 to primary solvent tank 12 thus completing a continuous fluid circuit.
In an alternative arrangement, macro particle separator 68 could be located immediately after drum 10 and before motorized ball 30 and 32 and serve the identical function while also protecting motorized ball 30 and 32 from being plugged with debris flushed from drum 10.
At the completion of the secondary phase of the wash cycle, the wash motor is de-energized and the extract motor is re-energized. The resulting rapid spinning of drum 10 aids in the removal of liquid solvent from the drum and adsorbed in the garments. Clean solvent is then transmitted to drum 10 via conduit 60 by pump 56 taking suction from secondary solvent tank 54 via conduit 58. The clean solvent is pumped to drum 10 in the manner described above, then drained from drum 10 via conduit 28 into primary solvent tank 12 while the extract motor is operating in order to facilitate a rinse cycle thereby insuring that no contaminants remain on the garments or within the drum 10.
During the drying stage of operation, fan 74 is energized. Fan 74 takes solvent vapor from liquid level control structure 64 via plenum 72 and transmits the solvent vapor through duct 76, heater 78, duct 80, drum 10, duct 82 and back to liquid level control structure 64, thus completing a continuous vapor circuit. The function of heater 78 is to heat the solvent vapor entering drum 10 to facilitate the drying of the garments contained in drum 10 by causing the evaporation of any liquid solvent remaining in drum 10.
There is a side stream continuous vapor circuit also originating with fan 74. In this side stream continuous vapor circuit, fan 74 circulates solvent vapor through duct 76, line 84, condenser 46, conduit 86, conduit 72 and back to fan 74. The purpose of circulating this side stream through condenser 46 is to desaturate the solvent vapor being circulated through drum 10. Thus, the liquid solvent remaining in drum 10 is continuously evaporated by the passage of hot, unsaturated solvent vapor through drum 10, thereby drying the garments within.
In an alternative embodiment, all of the vapor being circulated through the drum 10 during the drying cycle could also be circulated through the condenser 46. This would desaturate the entire vapor stream being circulated and, therefore, dry would be accomplished more rapidly. However, this alternative embodiment would require greater energy consumption.
There is a pressure equalization system connected to primary solvent tank 12 comprised of comduit 87, carbon column 88, HEPA filer 90 and solenoid valve 92. At the very onset of operation of the process, when pump 14 is actuated and begins pumping dry cleaning solvent from primary solvent tank 12, the pumping of the dry cleaning solvent will cause some vaporization of the dry cleaning solvent meaning that there will be some gaseous expansion within the system. Therefore, simultaneously with the actuation of pump 14, solenoid valve 92 opens. This allows air and dry cleaning solvent vapor to flow through conduit 87 and into carbon column 88 where the solvent vapor and any trace quantities of chemical agent are adsorbed by the activated carbon. The high efficiency particulate air filter 90 prevents the escape of particulate contaminants to the atmosphere. Filter 90 is designed to remove 99.7% of all particles greater than 0.3 microns in size. Therefore, what actually escapes to the atmosphere through solenoid valve 92 is the air that was originally contained within the system and most if not all of the air is expelled during the brief time (approximately 15 seconds) that solenoid valve 92 remains open.
When condenser 46 begins condensing solvent vapor received from still tank 36, a partial vacuum within the system is created and from that point on, the entire process is operated under a partial vacuum. Operating under a partial vacuum yields a number of advantages to the invention. First, the rate of distillation in still tank 36 is enhanced. Second, the time required for the drying cycle is shortened. Third, should the apparatus develop any leaks, those leaks will cause atmosphere to flow into the apparatus rather than contaminants to flow into the atmosphere thus obviating the escape of toxic or hazardous materials.
When the process has been run through completion, the door to drum 10 cannot be opened without first equalizing the pressure within and without the apparatus. Therefore, solenoid valve 92 is again actuated, opening for a brief period. Air is allowed to rush back into the system through solenoid valve 92, hepa filter 90 and carbon column 88. As the air flows across carbon column 88, solvent adsorbed therein is stripped off thereby partially regenerating the activated carbon.
FIG. 2 shows a motor control sequence for automatically actuated equipment used in the apparatus once operation is started. Review of FIG. 2 in conjunction with FIG. 1 will promote a better understanding of the order of operation of the process.
First, contaminated garments are placed in the drum 10. Pump 14, solenoid valve 92 and the wash motor to drum 10 are simultaneously actuated with solenoid valve 92 remaining opened for only a brief period and pump 14 remaining energized long enough to place an initial charge of dry cleaning solvent within drum 10. Shortly before (15 seconds) the completion of the initial phase of the wash cycle, motorized ball valve 30 opens thereby beginning the draining of drum 10. At the completion of the initial phase of the wash cycle, the wash motor of drum 10 is de-energized and the extract motor is energized thereby facilitating additional draining of drum 10 through motorized ball valve 30. After approximately 30 seconds, the extract motor de-energizes and the wash motor re-energizes. Also, at this point, motorized ball valve 30 closes and motorized ball valve 32 opens and pump 14 re-energizes. Pump 14 is now pumping dry cleaning solvent in a closed fluid circuit originating and ending with primary solvent tank 12. As the dry cleaning solvent is continuously circulated through drum 10, bag filter 20 and adsorbers 24, the remaining trace contaminants not removed in the initial phase of the wash cycle, are thus removed in this secondary phase of the wash cycle. At the completion of the secondary phase of the wash cycle, the wash motor and pump 14 de-energize and the extract motor to drum 10 re-energizes to facilitate the draining of the solvent remaining in drum 10 to primary solvent tank 12. One minute later, pump 56 begins pumping uncontaminated solvent from secondary solvent tank 54 through drum 10 which in turn drains to primary solvent tank 12. This is, in essence, a rinse cycle. At the completion of the rinse cycle, the quantity of solvent contained within primary solvent tank 12 is at its original level. At the completion of the rinse cycle, the extract motor to drum 10 de-energizes and the wash motor re-energizes. Also, at this point, fan 74 and heater 78 energize thus beginning the drying phase of the process. The heater 78 will de-energize shortly before the fan 74, allowing cool solvent vapor to be circulated through drum 10 thus cooling the garments. At the completion of the drying phase of the process, the wash motor to drum 10 and the fan 74 will de-energize and the motor operated ball valve 32 closes. Simultaneously, solenoid valve 92 opens thereby equalizing the pressure within and without the system.
At this point, drum 10 may be opened and the garments removed. Also, distillation within still tank 36 is complete and therefore, the quantity of solvent contained in secondary solvent tank 54 has been returned to its original level. Thus, the apparatus is immediately ready to receive another load of contaminated garments.
It should be noted that an alternate embodiment could be practiced which does not contain the still tank 36. In such case, the garments would be cleaned by continuously circulated solvent through the bag filter 20, adsorbers 24 and drum housing 10. However, in such an embodiment, since the bag filter 20 and the adsorbers 24 would be required to remove all of the contaminants, they would have to be sized much larger and would have to be replaced frequently.
From the foregoing, it will be seen that this invention is one well adapted to attain all of the ends and objects hereinabove set forth, together with other advantages which are obvious and which are inherent to the apparatus.
It will be understood that certain features and subcombinations are of utility and may be employed with reference to other features and subcombinations. This is contemplated by and is within the scope of the Claims.
As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
|
Garments contaminated with radioactive, toxin, biological and/or chemical contaminants are deposited in a cleaning drum and the drum is agitated during a wash cycle. A dry cleaning solvent is added to the drum during the initial wash cycle and then drained to a distillation means. Within the distillation means, there is a neutralizing agent which deactivates the biological and toxin contaminants and chemically breaks down the chemical contaminants removed with the dry cleaning solvent from the cleaning drum. Dry cleaning solvent is then continuously added to the drum during the secondary wash cycle and continuously removed from the drum. After the dry cleaning solvent is removed from the drum, and before it is pumped back to the drum, the dry cleaning solvent is filtered to remove remaining trace particulate contaminants. The dry cleaning solvent is also passed through an absorber where remaining trace chemical contaminants dissolves in the dry cleaning solvent are removed. The garments are then rinsed by circulating contaminant free dry cleaning solvent through the drum. After rinsing, the garments are dried by circulating hot, unsaturated dry cleaning solvent vapor through the drum.
| 3
|
RELATEDNESS OF THE APPLICATION
[0001] This application is a divisional of U.S. Ser. No. 09/925,832, filed Aug. 8, 2001, entitled “Methods for Detecting and Extracting Gold,” now U.S. Pat. No. 6,686,202, incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates generally to the use of non-naturally occurring specific gold-binding proteins or peptides for use in analytic, exploration or recovery methods in the gold mining industry.
BACKGROUND OF THE INVENTION
[0003] Gold is one of the rarest precious metals on earth. It occurs naturally as the reduced metal (Au°) or associated with quartz or pyrites as telluride (AuTe 2 ), petzite (AuAg) 2 Te or sylvanite (AuAg)Te 2 . The electronics and space industries use gold's properties of electrical conductivity and heat reflection. Gold has applications in radar equipment, home computers, satellites and space exploration. Gold is also used in considerable quantities in the form of gold leaf (having a thickness of less than 0.2 μm) for sign writing and book binding lettering. Gold film has been used in glass windows to reflect heat. Liquid gold is a suspension of very finely divided gold particles in vegetable oil that is used in the decoration of china articles. Gold salts are used for toning in photography, and in coloring glass.
[0004] Most frequently gold in nature is dispersed in low concentration throughout large volumes of material, usually rock. Gold deposits occur in belts across the earth's crust in various forms: placers or quartz veins in sedimentary or indigenous formation, blanket or pebble beds or conglomerates, or as base metal ore associations. Gold occurs in ore bodies described as lodes or veins, replacement deposits, contact (skarn) deposits, volcanogenic deposits, deposits associated with intrusive activity (such as ‘porphyry’ systems and breccia pipes) and deposits associated with ferruginous sediments (banded iron formations) and cherts. Gold bearing veins are found in rocks of all compositions and geologic ages, deposited in cavities and associated with rocks such as slates or schists. Lode deposits consist of gold particles contained in quartz veins or country rock. Lode deposits usually are mined in deep underground mines using a variety of methods, although sometimes lode deposits are surface mined. The blanket or reef-type deposits are deposits in which the gold exists in quartz conglomerates. Disseminated gold deposits have three identifying characteristics. The gold mineralization is fairly evenly distributed throughout the deposit rather than being concentrated in veins (as in lode deposits) or in pay-streaks (as in placer deposits); the deposits consist of in place materials rather than transported materials; and the disseminated deposits are less flat. Generally, these types of deposits are mined using surface mining techniques.
[0005] Gold also exists in secondary ore deposits. All rock outcrops exposed at the surface of the earth are subjected to the natural elements of weathering and erosion, causing eventual breakdown of rock into fragments which are carried away by wind, water or ice. The fragments are then redeposited in river systems, lakes or in the sea. During the erosive cycle, the heavier and more durable gold is concentrated into rich deposits, even though the original rock may have contained low values. Residual deposits of gold are found close to the gold bearing outcrop after the other rock fragments have weathered and been carried away. Eluvial deposits are formed when gold or gold bearing rock fragments have been transported short distances from their source (generally by gravity) and have been concentrated within the soil horizon. Alluvial deposits are formed by the concentration of gold particles within stream systems, under the action of running water. Beach placers, where gold is concentrated in beach sands by wave action, are a type of alluvial deposit. Leads are former stream courses, containing gold, where barren sands have covered the original passage of the stream. Deep leads are gold deposits in former stream beds which have been covered with basaltic lava. Nuggets are formed, either as rich fragments of primary deposits which have been transported and deposited in a sedimentary environment, or a chemical accretion of small gold particles into larger fragments. Some nuggets may have formed through the chemical action of host soils or sediments on a gold solution. Placer deposits are flat-laying deposits composed of unconsolidated materials, such as gravel and sands, in which the gold particles occur as free particles ranging in size from nuggets to fine flakes. They are the result of erosion and transport of rock. Placer deposits most commonly are mined using water based surface methods, including hydraulic methods, dredging and open pit mining. These deposits usually are not mined in underground operations.
[0006] Methods for recovering gold from its ores (termed “beneficiation methods”) are extremely expensive and labor and heavy machinery intensive. Gold is one of the least reactive metals on earth. It does not combine with oxygen or with nearly any other chemicals, no matter how corrosive. Some gold ores are free milling and allow the separation of coarse gold using methods that depend on the high specific gravity of gold. All other commonly used methods depend on the use of cyanide which is highly toxic, hazardous to the environment and difficult to remove. Basically, the first step in all methods is to subject the ore to cyanide leaching followed by a gold recovery process. The three known methods for extracting gold from the cyanide leach solution are the “Merrill-Crowe” or zinc dust precipitation process, the carbon-in pulp process, and the carbon in-leach process. Other gold recovery processes use gravity methods to extract the high proportion of free gold and flotation-roasting leaching to extract the remaining gold.
[0007] Cyanide and cyanide by-products from cyanide leaching operations are responsible for several environmental impacts, including air and water pollution and solid waste disposal contamination. Free cyanide and various cyanide complexes are the by products of current leaching methods. Although cyanide will degrade, for example in a surface stream exposed to ultraviolet light, aeration and complexing with various chemicals present in the stream water, in-stream degradation is a wholly unsatisfactory approach to removing cyanide from the environment. Cyanide solutions are often kept in open ponds and frequently birds or other animals are exposed and killed by the toxic material.
[0008] Air pollution with cyanide also is an unavoidable result of prior art methods for heap-leaching of gold. Cyanide solutions are sprayed onto the heaps, the cyanide drifts and contaminates the surrounding environment. As is the case with cyanide released into water, eventually the cyanide is degraded by ultraviolet light, but not until after it has adversely affected the environment. The EPA directs considerable efforts and expense in regulating cyanide releases into the air and water. Chronic cyanide toxicity due to long-term exposures to low levels is also a health factor to be considered, and the effects such exposures are not presently well known. For these reasons there has been a long standing need for gold mining processes which do not pollute the environment with cyanide and cyanide byproducts.
[0009] Gold recovery from secondary sources such as electronic scrap and waste electroplating solutions, as well as recovery from primary sources such as leach solutions is also an important technology. Various processes such as carbon adsorption, ion exchange, membrane separation, precipitation, and solvent extraction have been used for isolation of metal ions, including gold.
[0010] Recently, methods for the utilization of naturally occurring proteins or biologic materials in analytic or gold recovery, including microbial biomass, as an adsorbent for metals have been studied. Bontideau et al., Anal. Chem. 70:1842-1848 (1997) is a physical chemical study of the two-dimensional binding properties between a naturally occurring protein and a gold substrate. The arrangement and enzymatic activity of a myosin sub-fragment were characterized with special focus on the direct attachment of the thiol groups of cysteines in the protein to the gold substrate.
[0011] The current process for gold recovery includes treatment with cyanide to form a gold cyanide complex. U.S. Pat. No. 5,378,437 of Kleid et al teaches the use of cyanide-secreting microorganisms that also absorb the cyanide gold complex once formed.
[0012] A large body of research exists that describes, as an alternative to cyanide, the utilization of biomass to recover gold from aqueous solution or suspension. U.S. Pat. No. 4,789,481 of Brierley describes an improvement over the basic biomass extraction process whereby the biomass—in this case Bacillus subtilis —is treated with a caustic solution prior to use. U.S. Pat. No. 4,769,223 of Volesky et al., is directed to the biomass process where the biomass is derived from the growth of the marine algae of the genus Sargassum . U.S. Pat. No. 5,567,316 of Spears et al., describes a process for recovering metals from solutions using an immobilized metalloprotein material. There is no suggestion that this process would be useful for the recovery or detection of gold.
[0013] Different processes of enrichment of gold-containing ore are known in the art. Flotation is one of the most widely used of these processes. In this method, separation is accomplished by treating ground ore with chemical reagents that cause one fraction to sink to the bottom of a body of water and the other fraction to adhere to air bubbles and rise to the top. The flotation process was developed on a commercial scale early in the 20th century to remove very fine mineral particles that formerly had gone to waste in gravity concentration plants. Most kinds of minerals require coating with a water repellent to make them float. By coating the minerals with small amounts of chemicals or oils, finely ground particles of the minerals remain unwetted and will thus adhere to air bubbles. The mineral particles are coated by agitating a pulp of ore, water, and suitable chemicals; the latter bind to the surface of the mineral particles and make them hydrophobic. The unwetted particles adhere to air bubbles and are carried to the upper surface of the pulp, where they enter the froth; the froth containing these particles can then be removed. Unwanted minerals that naturally resist wetting may be treated so that their surfaces will be wetted and they will sink. Processing the flotation concentrate in order to recover gold is simpler and cheaper than treatment of total ore stock. Current flotation technology, however, still does not recover all of the gold that is present, especially the gold in finely-dispersed ore. At least one attempt has been made to improve the flotation process using a microorganism culture. Cormack, et al., Gold Extraction Process for Bioflotation, WO 97/14818. In this method, a microorganism culture is introduced into flotation tails and the mixture is agitated.
[0014] Most reported research in the area of protein/gold interactions describes the adsorption of gold or other metals by proteins in a non-specific fashion. Ishikawa & Suyama, Recovery and Refining of Au by Gold-Cyanide Ion Biosorption Using Animal Fibrous Proteins, App. Biochem. and Biotech., 1998, 70-72:719-728, is typical. Animal fibrous proteins which were insoluble and stable in water, such as chicken feather protein and hen eggshell membrane, adsorbed gold in a non-specific fashion. In this reference, eggshell membrane was utilized in a column and was able to remove very low concentrations of gold from aqueous solution. Another typical reference which provides generic disclosure of protein/gold or protein/metal ion interactions is Alasheh & Duvnjak, Adsorption of Copper by Canola Meal, J. Hazardous Mat., 1996, 48:83-93. Niu & Volesky, Gold-cyanide Biosorption with L-cysteine, J. Chem. Tech. and Biotech., 2000, 75:436-442, describe the chelation properties of a particular amino acid. In this reference, biomass was “loaded” with L-cysteine by contacting dried, protonated biomass with a solution of L-cysteine, and resulted in the ability of the biomass to adsorb higher concentrations of gold-cyanide. The authors postulate that the enhanced binding probably results from binding the gold-cyanide complex to the cysteine NH 3 + , while the cysteine COO − binds to positive charges on the biomass.
[0015] Brown, Nat. Biotech. 199715:269-72, herein incorporated by reference in its entirety, has engineered a fusion protein including E. coli alkaline phosphatase and an engineered gold binding peptide domain. The identification of the gold binding domain involved fusion of a combinatorial library of peptide repeat sequences to an outer membrane protein of E. coli. Cells were selected for their ability to attach to Au beads. The Au-binding domains that appeared to have high specificity and affinity for Au were then engineered as fusion peptides to the E. coli enzyme alkaline phosphatase (referred to as gold-binding protein or GBP). The attachment of the Au-binding domain to the enzyme provided a convenient means to follow (quantify) binding to Au surfaces. With respect to applications of this novel material, the article was principally concerned with studies on metal protein interactions. Woodbury et al., Biosensors and Bioelectronics, 13:1117-1126 (1998), is directed to the general application of the gold-binding peptides suggested by Brown. The biosensors described in the Woodbury et al. reference utilized the gold-binding peptides to attach recognition elements to the gold sensor surface. Detection of binding events to the recognition element is performed by surface plasmon resonance (SPR). Although the gold-binding peptide and its affinity to gold is an element of this article, the gold-binding peptides affinity to gold is not exploited for analytic or gold recovery applications.
SUMMARY OF THE INVENTION
[0016] The present invention provides methods for detecting gold in ore samples, using a gold-specific protein for binding to the sample. Such methods may be qualitative or quantitative. In one embodiment, the method is a direct-binding method. In another embodiment, the non-specifically bound gold-binding protein is proteolyzed and detected. The methods have been adapted for a high-throughput format, such as a multiwell plate.
[0017] The present invention also provides methods for extracting gold from a mineral suspension containing gold and magnetite, using a magnetite-binding gold-specific protein to form a magnetic complex and extracting gold using a magnetic field.
[0018] The present invention also provides flotation methods for extracting gold from a mineral suspension, using a gold-specific protein with a hydrophobic tail as a flotation reagent.
BRIEF DESCRIPTION OF THE FIGURES
[0019] [0019]FIG. 1 shows localization of gold with the “rock blot”.
[0020] [0020]FIG. 2 shows a comparison of UW 96 well assay with fire assay using core split chips.
[0021] [0021]FIG. 3A shows a film analysis of 96 well plate assay where the exposure to film was a 10 second exposure.
[0022] [0022]FIG. 3B shows a film analysis of the same 96 well plate assay where the exposure to film was a 10 minute exposure.
[0023] [0023]FIG. 4A displays the results of each 96 well plate assay specificity sample along with a high and low ore standard. The “trp” and “adj” labels represent the signal from the trypsinized sample and then a background adjusted result.
[0024] [0024]FIG. 4B displays the results of a 50/50 mix of the specificity sample and the high (7.59 g/t) ore standard.
[0025] [0025]FIG. 5 show the results of the film analysis in a graphical form.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The present invention is directed to the use of non-naturally occurring specific gold-binding proteins or peptides in all areas of the mining industry including prospecting, exploration and development, actual mining, such as surface mining and underground mining, sustainable mining, sampling, concentration, beneficiation, and environmental remediation. In particular embodiments of the invention, uses include locating gold in field samples with intact or proteolyzed proteins, recovering gold with a magnetic gold-binding protein, and recovering gold via flotation with a gold-binding protein suitable as a flotation reagent. A magnetic gold-binding protein can be generated by techniques known to those skilled in the art, for example, by derivatizing magnetic beads with the gold-binding protein. Further embodiments include recovering gold using chemotactically sensitive microbes producing gold-binding protein and methods for determining the source of metal ions in streams, rivers, and drainage basins by using immobilized gold-binding proteins in these locations.
[0027] The gold binding proteins of the present invention are proteins that have a high specificity and affinity for gold. The preferred gold-binding proteins of the present invention are those identified as described by the methods in Brown, Nat. Biotech. 199715:269-72, and most preferably are the proteins set forth in Brown. However, the present invention is not limited to such proteins and specifically includes any gold-specific binding protein defined as a having high specificity and affinity for gold, obtained by any method. For example, the present invention includes monoclonal antibodies specific for metal ions including gold ions that are described in U.S. Pat. No. 5,503,987 to Wagner, et al, incorporated by reference herein in its entirety. In fact the present invention also extends to any other gold-specific binding, non-naturally occurring ligand to gold, be it a protein, polypeptide, peptide, protein fragment, oligonucleotide, carbohydrate, antibody, chelating agent, magnetic agent, hydrophobic agent, or combination thereof, that can be used in the methods of the present invention. As an example, in one embodiment of the invention, gold-binding protein is associated with magnetic beads to generate a magnetic gold-binding protein reagent. In another embodiments, a gold-binding protein is modified with hydrophobic tails to generate a hydrophobic gold-binding protein suitable as a flotation reagent. Additionally, methods of the present invention include the use of other proteins, such as the monoclonal antibodies specific for metal chelates as are described in Meares, et al., U.S. Pat. No. 4,722,892, incorporated by reference herein in its entirety.
[0028] I. Field System for Mineral Exploration (“Rock Blot”)
[0029] The present invention is directed toward a method for locating gold in field samples with a protein having high specificity and affinity for gold. As used herein, Au-specific protein or gold-specific protein refers to a protein having high specificity and affinity for gold. In one embodiment, the method is useful in characterizing the distribution of gold within deposits. Samples are first treated with blocking reagents well known in the art (e.g., protein, detergents) to prevent the Au-specific protein from binding to sites that have general affinity for protein. The sample is then exposed to an Au-specific protein. In a preferred embodiment, the Au-specific protein is alkaline phosphatase (AP) engineered with a Au-binding domain, or AP Au . AP Au is also referred to as GBP (gold-binding protein). The sample is washed and the location of the bound AP Au is determined by using a detectable substrate for alkaline phosphatase, for example, using standard ELISA techniques. In a preferred embodiment, the substrate is a luminescent substrate, detected by exposing overlaid film to light generated by the AP Au and a substrate that generates light when hydrolyzed by AP Au . Other suitable substrates are well-known to those skilled in the art. Examples of suitable substrates include 5-bromo-4-chloro-3 indolyl phosphate (BCIP), utilized in U.S. Pat. No. 5,354,658, and p-nitrophenyl phosphate, a water-soluble substrate. Indirect detection methods are also useful in the present invention, for example, a sandwich ELISA.
[0030] [0030]FIG. 1 shows the results of a typical assay. This assay has been termed a “rock blot” by the inventors. A rock section with visible Au was provided to serve as both a sample and control. The exposed areas of the film clearly line up over the Au deposits in the sample. The details of the protocol are included in Example 1.
[0031] II. High-throughput Gold Detection Protocol
[0032] The present invention also provides methods to quantify the surface area of Au exposed on ore samples in a high-throughput assay. The basic method is similar to the “rock blot,” but incorporates additional steps to reduce background signal generated by the reaction of the mineral matrix with the preferred luminescent substrate. In this assay, GBP was allowed to bind to a milled ore sample. The AP domains bound to the areas of the ore matrix that bound protein nonspecifically, while the Au-binding domain more specifically binds Au. Following this initial binding, the samples were treated briefly with a proteolytic agent cleaving the protein, and releasing into the supernatant any GBP bound only through its Au-binding domain. As used herein, proteolytic agent refers to a reagent that is capable of chemically or otherwise splitting proteins into smaller peptide fractions and amino acids. Proteolytic agents useful in the present invention include proteolytic enzymes such as proteases, peptidases, and proteinases. Examples of proteolytic enzymes are Lys C, Arg C, Asp N, Glu C, trypsin, chymotrypsin, pepsin, thermolysin, and proteinase K. Non-enzymatic proteolytic agents include cyanogen bromide (CNBr) and formic acid (COOH). In a preferred embodiment, the proteolytic agent is trypsin. The alkaline phosphatase cleaved from the Au-binding domain and released into the supernatant was removed from the matrix-containing reaction and was quantified by measuring the activity of the alkaline phosphatase. A very sensitive assay for alkaline phosphatase involves cleavage of the substrate LUMI-PHOS® Plus (Lumigen, Inc., Southfield, Mich.) to produce light, which is quantified in a luminometer.
[0033] Experiments with milled ore samples containing high or low levels of Au led to the development of incubation and wash conditions that differentiated high Au containing samples from samples with low levels of Au.
[0034] The need to examine high numbers of samples required the development of a high-throughout analysis (96 well plate assay). “Saw chips” from a core-split were used to compare the plate assay with a standard fire assays of one-half of the core.
[0035] The fire assay is a potentially highly precise and accurate method for the total determination of Au and other precious metals in samples. It is typically used on ore-grade samples. The fusion, or “melt” is done in a furnace at high temperatures; hence the term “fire” assay. Samples are mixed with fluxes including lead-oxide, fused at 1050° C., cupeled to recover a dore bead, nitric acid parted to separate the precious metal then analyzed by either gravimetric, atomic absorption, or other analytical method. The fire assay does have drawbacks, however. First, the sample size is relatively large, requiring about one “assay ton” of pulverized sample, i.e. 29.84 grams of material. Second, certain types of ore contain elements that may interfere with the result. A good fire assayer knows how to modify the composition of the flux to avoid these problems, thus highly skilled and experienced assayers are necessary to achieve high quality results in a fire assay for gold.
[0036] [0036]FIG. 2 shows the results of a comparison of the fire assay with the GBP assay (average of three replicates) using a three point sample average smoothing. Overall, there was an excellent agreement between the results of the fire assay and the plate assay, particularly for samples from the upper region of the core. Application of the 96 well plate assay shows that replicate assays had small variance between replicates and differentiates between milled samples with high or low Au content.
[0037] In another embodiment, suitable for use in the field, the 96 well plate is exposed to film, as it would be much more convenient to analyze film in the field than carry out luminometer determinations. A POLAROID® film result can be scanned with a simple PC scanner device and the results quantified. Normal film can be scanned by a simple densitometer. In another embodiment, normal film or X-ray film is used, and, once exposed and developed, is taped the bottom of a 96 well plate and analyzed in a plate reader at 500 nM. The results of a sample quantitation are shown in Table 1 below and in FIG. 3. In the sample plate, eight replicate well sets were used, and enzyme concentration was reduced by one-half for twelve steps. FIG. 3A shows a film exposed for 10 seconds, and FIG. 3B shows the same experiment with a film exposure of 10 minutes. These procedures are detailed in Example 2.
TABLE 1 Absorbance Values from Molecular Devices Plate Reader for 96-Well Plate 1 2 3 4 5 6 7 8 9 10 11 12 (10 second exposure) A 2.105 2.538 2.802 1.202 0.708 0.409 0.272 0.218 0.206 0.202 0.193 0.190 B 1.306 2.615 2.226 1.204 0.713 0.390 0.261 0.206 .202 .194 0.195 0.189 C 1.893 2.737 2.261 1.326 .767 0.412 0.272 0.209 0.197 0.192 0.190 0.191 D 0.291 2.618 2.164 1.237 0.703 0.362 0.249 0.199 0.193 0.184 0.186 0.192 E 2.107 2.571 2.254 1.307 0.722 0.399 0.264 0.214 0.195 0.182 0.186 0.187 F 1.674 2.632 2.196 1.257 0.700 0.390 0.257 0.203 0.2 0.188 0.188 0.179 G 2.036 2.552 2.118 1.173 0.729 0.422 0.270 0.209 0.195 0.190 0.187 0.181 H 2.209 2.572 2.214 1.333 0.728 0.401 0.278 0.222 0.193 0.188 0.183 0.182 (10 minute exposure) A 3.858 3.846 3.724 3.620 3.651 3.505 3.332 2.850 2.120 1.119 0.469 0.279 B 3.527 3.560 3.575 3.494 3.416 3.374 3.186 2.614 1.794 0.915 0.351 0.255 C 3.477 3.522 3.457 3.495 3.376 3.408 3.185 2.708 1.709 0.858 0.307 0.242 D 3.669 3.648 3.592 3.595 3.527 3.340 3.219 2.530 1.560 0.725 0.309 0.237 E 3.824 3.754 3.702 3.712 3.641 3.520 3.299 2.889 1.603 0.773 0.323 0.232 F 3.719 3.826 3.798 3.693 3.652 3.516 3.378 2.765 1.898 0.943 0.387 0.258 G 3.661 3.732 3.651 3.602 3.554 3.476 3.37 2.846 1.657 1.024 0.384 0.275 H 3.791 3.823 3.841 3.880 3.733 3.653 3.414 3.065 2.066 1.048 0.521 0.307
[0038] A number of different mineral samples were tested using the plate assay to determine the levels of nonspecific binding. Table 2 contains the raw data. FIG. 4 depicts the averages listed on the table in graphical form. FIG. 4A displays the results of each specificity sample along with a high and low ore standard. The “trp” and “adj” labels represent the signal from the trypsinized sample and then a background adjusted result. FIG. 4B displays the results of a 50/50 mix of the specificity sample and the high (7.59 g/t) ore standard.
TABLE 2 Raw data from specificity assay: trp ave trp− ave adjusted Sample only Calcopyrite 3954 3710 3832 3538 3409 3474 359 Pyrite 0.75 0.91 1 1.53 1.48 2 −1 Arsenopyrite Aresenic I - Not 2402 2444 2423 2900 2727 2814 −391 canada 229 262 246 31.3 69.9 51 195 Silicon Dioxide 1068 913 991 1078 596 837 154 Calcite 34.6 96 65 157 165 161 −95 Soda Feldspar 441 582 511 381 280 330 181 Calcopyrite on Dol 162 163 162 149 192 170 −8 Feldspar Sericite I 380 386 383 245 203 224 160 Pseudomorph 3153 2680 2917 665 661 663 2254 Cerussite 0.62 12 6 5.36 5.54 5 1 Low 286 224 255 155 253 204 52 Hi 7990 8104 8047 565 206 385 7662 Sample spiked with 50% high Au ore Calcopyrite 5229 5244 5237 1279 1402 1341 3896 Pyrite 265 132 198 110 80.3 95 103 Arsenopyrite Aresenic I - Not 4315 4966 4641 2308 1514 1911 2730 canada 2388 2473 2431 320 302 311 2119 Silicon Dioxide 3285 3040 3163 673 1070 872 2291 Calcite 1496 1323 1410 195 320 258 1152 Soda Feldspar 3082 2940 3011 610 543 576 2435 Calcopyrite on Dol 321 601 461 330 76.3 203 258 Feldspar Sericite I 2406 2613 2510 414 206 310 2199 Pseudomorph 4992 5528 5260 985 965 975 4285 Cerussite 135 148 142 166 132 149 −7 Low 286 224 255 155 253 204 52 Hi 7990 8104 8047 565 206 385 7662
[0039] III. Gold Recovery System (Magnetic Separation).
[0040] It is a further object of this invention to provide a method for the recovery of gold from a liquid containing a magnetic mineral. In this method, a magnetic mineral binding reagent including a gold-specific protein is added to the sample to form a complex of magnetic mineral and gold. When a magnetic field is applied to the sample, the complex is removed from the rest of the solution, allowing the recovery of the gold. The magnetic mineral binding reagent and the gold-specific protein may be associated by covalent or non-covalent means.
[0041] In a preferred embodiment, the liquid is a slurry containing magnetite and fine gold. Magnetite, sometimes called magnetic iron, is an oxide of iron (Fe 3 O 4 ) occurring in isometric crystals, also massive, of a black color and metallic luster. It is readily attracted by a magnet and sometimes possesses polarity, in which case it is called lodestone. As there is often a significant quantity of magnetite in the gold-processing stream, and a substantial amount of fine Au is lost during processing, this method provides a solution to the problem of this lost Au. In the case of ores with low magnetite, the method may be used upon addition of magnetite to the slurry.
[0042] In order to test the concept, Au beads (≈3 μm diameter) were coated with GBP and rabbit anti-alkaline phosphatase antibodies. The coated beads were in turn bound to magnetic beads coated with goat anti-rabbit antibodies. The complex was readily pulled to the wall of a micro-centrifuge tube in the presence of a magnetic field, while the controls stayed suspended and gradually settled to the bottom of the tube.
[0043] In one embodiment, a reagent with both gold-and magnetite-binding domains is added to bind gold and the natural magnetite, then the complex is extracted using magnetic means.
[0044] In another embodiment, a GBP bound to a magnetic particle is used. Methods for generating protein-bound magnetic particles are described in U.S. Pat. No. 6,033,878, herein incorporated by reference in its entirety.
[0045] In another embodiment, magnetic mineral binding reagent is a microbial cell expressing two different metal binding domains on its surface, one for gold and one for magnetite. In another embodiment, different cells, each expressing a different domain can be cross-linked to provide the reagent. Another way to achieve this aim is to make a fusion protein with both binding domains.
[0046] IV. Gold Flotation
[0047] In another embodiment, the present invention provides a gold flotation reagent. In one embodiment, the gold flotation reagent is a hydrophobic reagent comprising a gold-specific protein. As used herein, hydrophobic moiety refers to a substance that repels or is insoluble in water. The hydrophobic moiety may be any hydrophobic moiety. Simple hydrophobic moieties such as a C 5 tail are suitable, as well as larger and more complex hydrophobic groups. Suitable hydrophobic groups include those derived from the organic acids butanoic acid, maleic acid, valeric acid, hexanoic acid, phenolic acid, cyclopentanecarboxylic acid, benzoic acid, and the like. Other suitable hyrdrophobic moieties include protein domains consisting of the hydrophobic amino acids alanine, valine, leucine, isoleucine, phenylalanine, tyrosine, and tryptophan. Naturally-occurring proteins with such hydrophobic tails or domains are known to those skilled in the art, as are methods for the creation of fusion proteins with such hydrophobic domains.
[0048] The ability of a gold-specific protein to act as a flotation reagent is evidenced by an experiment with a modified gold-specific protein. GBP was modified with valeric anhydride to create a GPB with C 5 hydrophobic tails (C 5 -GPB). After binding to gold particles, valeric anhydride was added to acylate the bound GBP. Mineral oil was then added. After mixing, followed by separation of the oil and water layers, it was found that the C 5 -GBP bound to gold resided at the oil water interface. The experiment shows that gold bound to C 5 -GBP possesses sufficient hydrophobic character to be used in a flotation process.
[0049] V. Use of Microbes to Extract and Deliver Metals from Ores.
[0050] In another embodiment, the present invention provides a method to recover very small gold from crushed samples or from samples with free particles of sub micron to micron size gold. In one embodiment, the method utilizes microbial strains that express gold binding domains on their surfaces. The cells are directed to deliver the bound Au to the destination by taking advantage of their ability to swim up a concentration gradient of attractant (chemotaxis). Microbial cells have very efficient chemotaxis systems. Use of two phase aqueous systems should be useful for such separations. For example, an E. Coli cell that expresses an extracellular gold binding protein domain will bind small particles of gold. The cell will then follow a chemical gradient (e.g., a gradient of the sugar ribose or amino acid aspartate or other chemoattractants) to the collection destination.
[0051] VI. Use of High Affinity Binding Proteins for Mineral Exploration.
[0052] The present invention also provides a method for determining the source of metal ions in streams, rivers, and drainage basins. In general, streams, rivers, and drainage basins are monitored for the presence of metal ions of interest. Determining the location of metal ions in various locations will allow one to track the course of the ion from its destination in a drainage basin backwards to its source. The approach involves placement of small dialysis sacs, immobilized proteins or similar devices in streams and rivers of a drainage basin for fixed times. The sacs containing proteins that bind metal ions with very high affinities are removed and analyzed for content of mineral ion.
EXAMPLES
Example 1
Field System for Mineral Exploration (“Rock Blot”)
[0053] A sample (rock) suspected of containing gold was obtained. The surface of the rock was blocked with a 50 μg/ml solution of alkaline phosphatase (P2991) diluted in TTBS (100 mM Tris pH 7.4, 0.5 M NaCl, 0.1% TWEEN® 20 (Polyoxyethylenesorbitan monolaurate)), mixing gently for four hours. The rock was then washed with TTBS buffer, 3×. FITC-GBPAP (Fluoresceinated Gold Binding Protein, 11 μg/ml in PBS) at a concentration of 0.18 μg/ml was added, and incubated for six hours with a rocking mixer. After incubation, the rock was rinsed three times with 6 ml TTBS. The rock was blocked by incubating in dry milk solution in (10% w/v in TTBS) for 30 minutes, followed by three washes with 10 ml TTBS each. Primary antibody (Anti-Fluorescein IgG, Monoclonal, 15 μg/ml in TTBS, Mouse anti-F, 1/10 Dilution of stock) was added, and the rock was incubated at room temperature overnight with gentle shaking. A VECTASTAIN® kit (Vector Laboratories, Inc., Burlingame, Calif.) was used to bind biotinylated secondary antibody (horse anti-mouse) and avidin-labeled alkaline phosphatase.
[0054] Substrate solution was prepared in glass containers by dissolving 5 mg of 4-iodophenol and 20 mg of luminol (5-amino-2,3-dihydro-1,4-pthalazinedione) into 0.5 ml DMSO and adding solution of 0.5 ml 1 M Tris HCl pH 8.5, 21.5 ml ddH 2 O (double glass distilled H 2 O), and 2.5 ml 5 M NaCl. 62.5 μl of H 2 O 2 was placed in a separate glass tube.
[0055] The detection reaction was initiated in a darkroom. The rock was placed into the into the tris/salt solution face up without shaking. Luminol solution was added to the H 2 O 2 solution, mixed, and them immediately added to the petri dish. After two minutes, the solution were drained away from the rock. The rock surface was covered with plastic wrap and then exposed to Polaroid Type 57 high speed film for 1, 2, 4 , 8, 16, 30, and 60 seconds. The film was developed to observe results of the blot.
Example 2
High-Throughput Analysis Protocol (96 Well Plate Assay)
[0056] A. Ore samples were puck milled (or powdered by another fashion to the extent of puck milling). Using a 5 mg scoop, samples were transferred into the wells of the 96 well filtration plate (MULTISCREEN® 96 well filtration and assay plate (Millipore, #MAHVN4510). 100 μl of gold binding solution (GBP in Buffer T (50 mM Tris, pH=8, 10 mM CaCl 2 , 40 mM NaCl, 1% TRITON® X-100 (t-octylphenoxypolyethoxyethanol)), standardized according to EXAMPLE 2B) was added to each well with a multipipettor. The plates were covered with sealing tape (Fisher Scientific #MATAHCL00) and vortexed for 30 min in a Vortex Mixer with 96 well plate attachment (Fisher Scientific #12-812, 96-attachment is #12-812D). The plate was washed with 200 μl Buffer T fifteen times on a Vacuum Manifold for MULTISCREEN® plates (Millipore Corp.). 100 μl of trypsin (Sigma Chemicals #T8642, TPCK treated) solution (100 μl/ml, in buffer T) was added to each well with a multipipettor. The plate was covered again, and vortexed for 5 min. The cover was then removed and blotted with a paper towel to remove excess moisture. 25 μl of trypsin inhibitor (Sigma Chemicals #T9003, from soybean) solution (1 mg/ml in buffer T) was added to each well to stop the reaction, and mixed briefly on the lowest setting (uncovered) on the vortex mixer. The entire volume of each well was transferred to a new filter bottom plate (using a 96 well syringe pipettor from Midwest Scientific, St. Louis, Mo.). A standard 96 well plate was placed into the chamber of the vacuum manifold, and the contents of the filter plate were vacuumed through to the top filter plate and into the receiver plate.
[0057] For a direct luminescent measurement, five μl of the filtrate is transferred to a 0.5 ml EPPENDORF® tube containing 95 μl of LUMI-PHOS® Plus (luminescent alkaline phosphatase substrate) (Lumigen, Inc., Southfield, Mich. #P-701). The solutions are mixed well and incubated for 1 hour. After 1 hour the tubes are read individually in the luminometer with an adaptor for 0.7 ml Eppendorf tubes. (Turner Designs TD-20/20).
[0058] The reaction may also be detected by film. In this case, 95 μl of LUMI-PHOS® Plus is added to each well of an opaque 96 well plate. Five μl of the sample in the standard (clear) 96 well plate is transferred to its corresponding location on the opaque plate and mixed with the vortex mixer on the lowest setting for a few seconds. The plate is incubated at room temperature for one hour and then exposed to Polaroid Type 57 high speed film for several time intervals.
[0059] B Standards Assay
[0060] To test a new preparation of GBP for efficacy, test several concentrations of GBP with the low gold fire assayed standard (0.02 g/ton) and high gold fire assayed standard (7.59 g/ton) from PD and pick the GBP concentration, that provides the best signal to noise between the two samples. The GBP concentrations were varied between 0.001 and 0.01 mg/ml to start. Optimal protein concentration is determined by maximizing the signal with the high concentration gold sample while keeping the non-specific signal from the low gold concentration ore at a low value.
[0061] C. Specificity Assay
[0062] The procedure for this assay was the same as that in Example 2A, with the following changes. The Gold Binding Protein Solution is in PKT(50) buffer (10 mM KH 2 PO 4 , 50 mM KCl, 1% Triton X-100, pH≅3.95 (Unadjusted)) instead of Buffer T. The concentration of the GBP was at 200 μg/ml. The samples were covered in sealing tape and vortexed on high for 10 min. After the vortex step the wells were washed with Tris Calcium Buffer (1 mM CaCl 2 , 11 mM Tris pH 8.0, pH=8.2 Unadjusted) rather than Buffer T (using the 8-pipettor, 10 washes of 200 μl). Trypsin volume was changed from 100 μl to 200 μl. Concentration remained same at 100 μl/ml. The plate was covered and vortexed for 4 min. The transfer step was eliminated; and the contents were vacuumed through into the receiver plate. Luminometer incubation volume and time were slightly adjusted. 5 μl of filtrate sample was added to 100 μl of Lumi-Phos Plus and incubation time was shortened to 40 min.
Example 3
Gold Recovery System (Magnetic Separation)
[0063] DYNABEADS® M-280 Tosyl-activated (Dynal A. S., Oslo, Norway, Prod.No.: 142.04) (200 μl, 2 mg) are uniform, superparamagnetic, polystyrene beads coated with a polyurethane layer. The polyurethane surface is activated by p-toluenesulphonyl chloride to provide reactive groups for covalent binding of proteins (e.g. antibodies) or other ligands containing primary amino or thiol groups. The beads are washed with 1 ml 0.1 M Na Borate, pH 9.5. 40 μl goat-anti-rabbit IgG (1 μg/μl) were added to 200 μl 0.1 M Na Borate containing 2 mg beads. The beads and the antibody were incubated at room temperature on a rotating shaker overnight. A control reaction contained control beads but no antibody. The beads were washed once with 1 ml Buffer D (PBS+0.1% BSA) then once with 0.5 ml Buffer D. The mixture was blocked overnight in buffer E (0.2 M Tris pH=8.5+0.1% BSA). Wash with 1 ml PKT Buffer (10 mM KH 2 PO 4 , pH 7.0, 10 mM KCl, 1% Triton X-100). Gold beads (20 μl of a 1 mg/ml suspension, 1.5-3.0 micron, Aldrich Chemical Co. #32658-5), were mixed with 30 μl PKT and 50 μl 1.11 mg/ml GBP in 50 mM Tris pH=8.0, (final concentration is 0.5×PKT (10 mm KCl)) and incubated overnight at room temperature on a rotating shaker. The overnight incubation ensures maximum bead coverage. The beads were washed 4 times with 1 ml PKT buffer.
[0064] Anti Alkaline Phosphatase Antibody (polyclonal, Harlan Sera-Lab #ENZ-020) (1.2 mg in 120 μl PKT) was added to the GBP-Au bead solution and incubated with gentle mixing for four hours. After incubation, the beads were washed twice with 1 ml PKT buffer. Twenty μg of the resulting beads (Au plus GBP plus anti AP) were mixed with the Dynabeads and incubated with rotation for one hour. After mixing the solutions, a magnetic field is applied with a Dynal MPC-P-12 Magnetic particle concentrator for 0.5 ml Eppendorf Tubes (Prod.No: 120.10). Gold beads without GBP attached were used as a control.
Example 4
Gold Flotation
[0065] Colloidal gold (1 ml, Sigma, #G1402, 5nM,) was added to three 1.5 ml Eppendorf tube and the tubes centrifuged for fifteen minutes in a microcentrifuge at 12,000 rpm. The supernatant was removed and one tube of the colloid was resuspended in a solution of GBP (0.333 mg/ml in 50 mM Tris pH=8.0). Two other control tubes were resuspended in ddH 2 O only. The tubes were incubated on a rotating mixer overnight to allow binding to occur. The tubes were centrifuged for fifteen minutes in a microcentrifuge at 12,000 rpm to remove excess GBP, and the colloid was resuspended in 1 ml phosphate buffer (pH=6)(43.85 ml 0.2 M NaH 2 PO 4 , 6.15 ml 0.2 M Na 2 HPO 4 ) three to four times. Valeric anhydride (2 μl, Sigma #V-6127) was added to the tube with GBP and to one of the control tubes. Mineral oil (100 μl) was added to each tube and the tubes vortexed for 2-3 minutes. The tubes were allowed to settle and the oil and water to separate.
Example 5
GBP binding Using 1.5-3.0 Micron Spherical Au Particles
[0066] A. Preparation of Gold Beads. 10 mg of 1.5-3.0 micron Au powder (Aldrich Chemical #32.658-5) was suspended in 1 ml of 10% Hydrofluoric acid (HF) and incubated on a rotating mixer at room temperature overnight (to clean any organic debris from the beads). The beads were washed by spinning at 10,000 RPM in a microfuge for 1 minute. The supernatant was decanted and the gold beads resuspended in 1 ml PKT(50) at pH=7.0. The wash procedure was repeated four times, with the beads in a final volume of 1 ml. The beads were vortexed vigorously and 10 μl of this suspension was immediately pipetted to another 1.5 ml Eppendorf tube, yielding 100 μg of Au beads per tube.
[0067] B. Gold bead assay. 500 μl of GBP solution at 10 μg/ml in PKT(50) buffer, pH=7.0 was added to the gold containing tube and incubated for 30 minutes at room temperature on a rotating mixer (the tube was rotated end over end because the beads settle rapidly). After 30 minutes, the beads were washed three times as described above in EXAMPLE 3A.
[0068] C. Trypsinization. The final pellet was resuspended in 200 μl trypsin solution (10 μg/ml trypsin (Sigma Chemicals #T8642, TPCK treated) in trypsin buffer (10 mM Tris pH=8.0, 10 mM CaCl 2 )). After five minutes on the mixer, the Au beads were spun down again. The supernatant was assayed for AP activity by adding 5 μl of the supernatant to 100 μl Lumi-Phos® Plus and then reading in the luminometer after a 30 minute incubation.
Example 6
GBP Binding Using Gold-Coated Slides
[0069] This procedure is an improvement on the Au bead assay for determination of GBP binding ability. Using a gold-coated slide in place of the Au beads greatly reduces the variability that was previously observed, most likely due to a much more uniform and reproducible surface.
[0070] A. PNPP assay. For determination of GBP-AP alkaline phosphatase activity, 10 μl of GBP solution was added to 1 ml of the PNPP (p-Nitrophenyl Phosphate, Sigma #104-0, 52 mg in 50 ml 50 mM Tris pH 8.0). The change in absorbance was measured at an O.D. of 600 nM. Slope was multiplied by 100 to yield PNPP units per ml.
[0071] B. Gold slide assay. A glass slide (1 5×4 mm) was incubated in a 1.5 ml Eppendorf tube containing 1 ml of GBP solution. The concentration of GBP was around 10 μg/ml in PKT(50) buffer. The incubation was at room temperature on a shaking incubator for 30 minutes. The slide was removed and rinsed with ddH 2 O. The slide was placed into a 1.5 ml Eppendorf tube containing 1 ml Lumi-Phos® Plus and incubated on shaking incubator for 30 min. 100-500 μl samples were analyzed in a Turner TD 20-20 Luminometer.
|
Methods for detecting gold and quantitating gold in ore samples utilizing a gold-specific protein are provided, including methods for multiple sample handling. Also provided are methods for extracting gold from mineral suspensions utilizing a magnetic mineral binding reagent and gold-specific protein, or hydrophobic reagent and gold-specific protein in conjunction with a flotation reagent.
| 2
|
BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] This invention is related to downhole tools used in drilling oil or gas wells. Such tools include, for example, sleeves, stabilizers and drill bits.
[0003] 2. Description of Related Art
[0004] Currently downhole tools such as sleeves, stabilizers and drill bits used for various purposes during the course of drilling an oil or gas well are formed as a single piece unit. Such an array of tools is shown in WO2009/073656 A1. The sleeves, stabilizers and drill bits typically include a plurality of spiral vanes with fluid passageways between them to allow for upward flow of drilling fluid. The pitch of the vanes is selected according to the conditions at the bottom of the well and the composition of the well bore at any given vertical or horizontal position. Various portions of the tool are subject to uneven wear which requires replacing the entire unit. Also, the pitch of the vanes once manufactured is fixed in a given unit and can not be altered to create customized fluid flow in different applications associated with a downhole tool used in forming and/or completing wells.
BRIEF SUMMARY OF THE INVENTION
[0005] The invention of this application is forming downhole tools in segmented discrete portions. This allows for replacing worn portions of the tool with a new segment rather than replacing the entire unit. This saves time and materials. This also allows for the ability to adjust the flow path of the fluid around the tool by providing segments having vanes with different pitch angles and blade thicknesses. Thus the operator of the drilling rig can vary the flow characteristics depending on varying conditions within the well.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0006] FIG. 1 is an elevation view of a tool according to an embodiment of the invention.
[0007] FIG. 2 is a perspective view of the tool showing two of the segments separated.
[0008] FIG. 3 is a longitudinal cross sectional view of the tool.
[0009] The drawings are intended to illustrate the various aspects of the invention and are not intending to be limiting, nor are they necessarily drawn to scale.
DETAILED DESCRIPTION OF THE INVENTION
[0010] As shown in FIGS. 1 and 2 , the sleeve or stabilizer 10 according to an embodiment of the invention includes a hollow core member 21 having an upper threaded portion 12 which is known in the art as an API connector. Threads are provided at 14 for connection to an interiorly threaded portion of a tubular member which may be the drill tube. Breaker slots 16 are also provided for gripping by an appropriate bit breaker. Also shown in FIG. 1 is a plurality of stabilizer or sleeve segments 20 . Although four are shown it is understood that any number of segments may be provided in accordance with the invention. Each segment includes plurality of vanes 22 , 24 , 26 and 28 respectively. The segments are mounted on the core member which extends from top portion 12 to bottom portion 30 . The lower portion of the core member may be internally threaded as shown in FIG. 3 to receive a connection portion of another tool such as a drill bit. Lower collar member 32 may be provided with internal threads that engage threads on the lower exterior portion of core member 21 . In lieu of threads, lower collar member 32 may be welded to core member 21 . Upper and lower collar members 18 and 32 serve as transition members between the core and the segments 20 . They may be provided with vanes 19 and 30 that line up with the vanes 22 and 28 of the adjacent segments.
[0011] FIG. 2 illustrates a way to attach the segments to core 21 and to each other. For preventing rotation of the segments with respect to each other, recesses 40 may be provided the top surface of the vanes as shown in FIG. 2 . Pins 43 shown in FIG. 3 are adapted to fit within recesses 40 in the lower surface of an adjacent vane. To prevent rotation of the segments about core member 21 , holes 42 are formed in the passageways between the vanes and extend to the inner surface of the segments. A suitable set screw, welded pin, press weld pin, threaded pin or any other known securing means can be inserted into the hole for securing the segment to the core member 21 . It is understood that there are many other techniques and mechanisms that could be used to attach the various components to each other, all of which could be used in the context of this invention. Upper collar member 18 may be welded to core member 21 or secured to it by any well-known arrangement.
[0012] FIG. 3 illustrates an arrangement of the segments and collars on the core. The core includes an upper connection portion 12 known as an API connector and a lower integral portion 21 formed as a hollow cylindrical body. Upper collar member 18 and segments 20 have an internal diameter slightly greater than the external diameter of cylindrical portion 21 of the core so that they can slide over the outer surface of core portion 21 .
[0013] The exterior lower surface of core portion 21 has inwardly extending threads 46 that are adapted to fit corresponding threads 47 provided on the interior surface of lower collar 32 . The lower interior portion of core member 21 has threads 45 that are adapted to receive a standard API connector. In lieu of a threaded connection, lower collar member 32 may simply be welded to core member 21 .
[0014] To assemble the sleeve or stabilizer, top collar 18 is positioned onto core member 21 . Segment members 20 are then fitted on core 21 with the pins 45 aligning with the holes 40 in adjacent segments. A set screw or pin is then inserted through holes 42 to secure the segments to the core member 21 . Finally lower collar is threaded or welded to the lower portion of the core thereby capturing the segments on the core member between the upper and lower collar members.
[0015] If during use one of the segments experiences more wear than the other, the drill string can be withdrawn from the well and only the worn segment need be replaced.
[0016] Also, it is contemplated that a plurality of segments with different pitch angles could be provided at the well site to allow the drill operator the flexibility to choose among several options depending on the drilling conditions. Each segment could also have a different pitch angle and blade thickness.
[0017] Although the present invention has been described with respect to specific details, it is not intended that such details should be regarded as limitations on the scope of the invention, except to the extent that they are included in the accompanying claims.
|
A downhole tool includes a plurality of segments positioned on a core member. This construction is particularly suitable for sleeves, stabilizers and drill bit gage pads used in the formation of oil and gas wells. Worn or damaged segments can be replaced without the need for replacing the entire unit. The segments may include spiral vanes for directed fluid upwardly to the well head.
| 4
|
FIELD OF INVENTION
This invention relates to weighing apparatus and is especially concerned with platform weighing scales.
BACKGROUND
A problem experienced with platform scales of the type which supports the platform on inboard load cells is the difficulty in removing a defective load cell for repair or replacement.
SUMMARY AND OBJECTS OF INVENTION
A major object of this invention is to provide a novel construction for easily removing inboard platform-supporting load cells.
The foregoing object is accomplished by detachably securing a force-transmitting or transferring member in an aperture or opening which is formed through the platform and by so arranging the load cell beneath the force transfer member that its force receiving element is engaged by the force transfer member to receive the load-induced force which is transferred by the force transfer member. The force transfer member is upwardly removable from the top of the platform so that upon removing it, the load cell may be withdrawn upwardly through the platform aperture which is made large enough to pass the cell.
To reduce the ground-to-platform height of a low profile scale incorporating the principles of this invention, the foregoing force-transfer member is formed with a downwardly opening well which receives the load cell button or force-receiving nose of the load cell. In this manner, the load cell button is nested at least partially within the force transfer member which preferably has a relatively short axial length.
In the preferred embodiment of this invention the above-mentioned force-transfer member is a leveling element such as an externally threaded screw which is threaded in the load cell-removal aperture and which is selectively axially displaceable. With this construction each load cell-supported corner of a rectangular platform may independently be raised or lowered to level the platform and thereby accommodate the installation of the scale on an uneven floor or other uneven support surface. Additionally, adjustment of the leveling screws serve to uniformly distribute the scale's dead load which is carried by the platform-supporting load cells.
In this invention, therefore, the leveling screws or other equivalent, axially displaceable members are each effective to facilitate the removal of the load cells, to adjust the level of the platform, to adjust the distribution of dead load on the load cells, and to transfer the weight of an applied load from the platform to the load cells.
It will be appreciated that the combined leveling and load cell removal construction described above is advantageously applicable to load cell platform scales other than the low profile type.
Thus a further object of this invention is to provide a novel platform scale construction in which a selectively displaceable member provides for the transfer of force from the load-receiving platform to the load cell, is selectively removable to effect the removal of the load cell, and is adjustable to level the platform.
DESCRIPTION OF DRAWINGS
FIG. 1 is a plan view of a low profile type platform scale which incorporates the principles of this invention;
FIG. 2 is a side elevation of the scale assembly shown in FIG. 1 as seen from lines 2--2 of FIG. 1;
FIG. 3 is a section taken substantially along lines 3--3 of FIG. 1;
FIGS. 4 and 5 are sections respectively taken substantially along lines 4--4 and 5--5 of FIG. 1;
FIG. 6 is a section taken substantially along line 6--6 of FIG. 1; and
FIG. 7 is a section taken substantially along line 7--7 of FIG. 1; and
FIG. 8 is a section taken substantially along line 8--8 of FIG. 1.
DETAILED DESCRIPTION
Referring to drawings and particularly to FIGS. 1-6, the platform weighing scale incorporating the principles of this invention comprises a platform or deck structure 20 and platform-supporting load cells 22, 23, 24 and 25.
In the illustrated embodiment structure 20 comprises a rectangular load-receiving platform or deck 30 which is formed by a suitable structural plate and which is directly supported at each corner by one of the load cells 22-25. For the pitless installation shown in FIGS. 1 and 2, a ramp structure 32 provides access to platform 30. Although a rectangular platform is shown in the illustrated embodiment, it will be appreciated that the various features of this invention may be employed with different platform configurations if desired.
Structure 20 rests upon load cells 22-25 which are inboard of and hence vertically beneath platform 30. In this embodiment, each load cell 22-25 is restrained against horizontal movement relative to platform 30. The scale support surface is indicated at 33 in FIG. 2. Load cells 22-25 may be of any suitable type. For application in low profile platform scales load cells 22-25 may be of the conventional pancake compression type which is responsive to an applied load to produce a d.c. signal voltage whose magnitude is a function of the weight of the load. The overall height of such pancake type load cells generally ranges from about 1 inch to about 13/8 inches. Other types of load cells or transducers, such as hydraulic load cells, may be utilized with this invention. If desired, an unshown system may be employed to restrain horizontal movement of the assembly of load cells 22-25 and platform structure 20.
If desired, retainers, such as those indicated at 60, 66 and 70, may be employed for all or selected ones of load cells 22-25. In this embodiment, load cells 22-24 are removably seated in upwardly opening apertures or openings in retainers 60, 66 and 70 respectively. The previously mentioned, unshown horizontal restraint system, if employed, may be connected to retainers 60, 66 and 70 to restrain horizontal motion of the assembly of the load cells and platform structure 20.
An example of such a horizontal restraint system is described in United States patent application Ser. No. 534,087 filed on even date herewith for LOW PROFILE PLATFORM WEIGHING SCALE, and assigned to the asignee of the instant application.
In this embodiment, the force attributable to a load on platform 30 is transferred to load cells 2-25 respectively by load cell removal assemblies 80, 81, 82 and 83 (see FIG. 1). Assembly 80, as shown in FIG. 5, comprises an externally threaded leveling screw 86 and a leveling screw retainer block 88. Retainer block 88 is rigidly fixed to the underside of platform 30 as by welding and has an internally threaded through bore 90. Bore 90 is in axial alignment with an aperture 92 which is formed through platform 30.
Leveling screw 86 is threaded into bore 90 and is coaxially formed with a downwardly opening well 94 which interfittingly receives the load cell button 96 of load cell 22. A close clearance is provided between load cell button 96 and the sidewall of well 94. Load cell button 96 seats against the closed inner end of well 94 and is nested and thus captured in well 94 to reduce the floor-to-platform height of the scale.
With this construction, force attributable to the weight of the load on platform 30 is transferred through retaining block 88 and leveling screw 86 to the force-receiving load cell button 96. The reception of load cell button 96 in well 94 confines load cell 22 against horizontal displacement relative to platform 30.
Assemblies 81-83 are of the same construction as that just described for assembly 80. Accordingly, like reference numerals have been applied to designate like parts of assemblies 81-83.
As shown in FIGS. 3-6 each retaining block 88 cooperates with the aperture-defining wall of platform 30 to define a shallow recess or well 120 which receives the head of leveling screw 86 so that the top face of screw 86 is at a level which is lower than the flat load-receiving surface of platform 30.
The diameter of each bore 90, as well as the diameter of each aperture 92, is larger than the greatest dimension of each load cell 22-25 in a horizontal plane to facilitate the convenient removal of each load cell upwardly through its associated bore 90 and apreture 90 upon the removal of the leveling screw 86.
The top end wall of each leveling screw is advantageously formed with suitable non-circular sockets 121 for receiving a suitable tool to selectively thread leveling screw 86 up and down in bore 90. With this construction, each leveling screw may be threaded upwardly to remove it from the platform structure which comprises the assembly of platform 30 and retaining blocks 88. After the leveling screw is removed, each load cell (22-25) may easily be removed from the scale simply by lifting it upwardly through bore 90 and aperture 92. Each of the load cells 22-25 is therefore conveniently removable in this fashion for repair or replacement without having to jack up or lift the platform and without requiring the removal of any part other than the leveling screw itself.
In addition to providing the load cell-removal capability, each leveling screw 86 is selectively threadable up and down in bore 90 to raise or lower its associated corner of platform 30. In this manner, leveling screws 86 are adjustable to level platform 30 and thus facilitate the installation of the scale on an uneven floor or other scale support surface.
Additionally, the scale's dead load carried by each of the load cells 22-25 is individually and selectively adjustable by selectively threading the leveling screws 86 up or down. The dead load carried by load cells 22-25 is the weight of platform structure 20.
From the foregoing it will be appreciated that leveling screws 86 each perform multiple functions. First, they each provide for the transfer of load-induced force from platform 30 to load cells 22-25. Second, they are each removable to facilitate the removal of load cells 22-25 from the scale. Finally, they are each selectively adjustable to level platform 30 and also to adjust the dead load carried by each load cell.
The foregoing novel construction for facilitating the removal of load cells 22-25 and/or leveling platform 30 may also be employed in load cell platform scales which are not of the low profile type.
If desired, a pair of platform-clamping and anti-tipping assemblies 122 (FIG. 7) and 123 (FIG. 8) may be employed. Assemblies 122 and 123 are effective to restrain platform 30 against tipping when a load is so positioned on platform 30 that its weight is not uniformly distributed among load cells 22-25. For example, a load applied at any one of the corners of platform 30 will tend to tip platform structure 20 because it merely rests on the force-receiving elements or buttons of load cells 22-25 and is not vertically fixed to cells 22-25 or any other part. Additionally, assemblies 122 and 123 are each selectively manipulatable to rigidly clamp platform assembly 20 in place to prevent it from tilting or falling down upon removing any one of the load cells 22-25.
As shown in FIG. 7, assembly 122 includes an anchor bolt 54 (which may be of the masonry type) and a suitable snubber or bumper member which may be in the form of an internally threaded washer 124. The upper end portion of anchor bolt 54, which is threaded, coaxially extends through a circular aperture or bore 125 in a support ledge 126 and partially through a circular aperture 127 which is formed through platform 30. Support ledge 126, which is welded or otherwise rigidly joined to deck 30 on the underside thereof, may be formed from a suitable structural plate and is counterbored to form an annular shoulder 128 at the bottom of a recess 214. The uniformly diametered, cylindrically smooth side wall, which delimits recess 214, provides a smooth continuation of the aperture 127. A protective cap or cup 216 covers the upper end of anchor bolt 54 and provides a closure for the open upper end of aperture 127.
In normal use or operation of the scale, washer 124 is threaded on the upper end of anchor bolt 54 in such a manner that it is spaced vertically above shoulder 128 in the manner shown in FIG. 7. However, should an applied load tend to upwardly tip platform 30 in the region of assembly 122, shoulder 128 will seat against the flat bottom face of washer 124 to restrain tipping of platform structure 20.
As shown in FIG. 8, assembly 123, which is of the same construction as assembly 122, includes an anchor bolt 56 and a washer 124a. Associated with assembly 124 is a protective cap 216a and a support ledge 126a which are of the same construction as cap 216 and support ledge 126 respectively. Accordingly, like reference numerals suffixed by the letter "a" have been applied to designate like portions of support ledge 126a and cap 216a.
Cap 216a seats in and covers the circular aperture 127a which is formed through deck 30 and which corresponds to aperture 127. Thus, the construction and relationship of aperture 127a, assembly 123 and support ledge 126a are the same as that described for aperture 127, assembly 122 and support ledge 126.
Like washer 124, washer 124a is normally threaded on the upper end of anchor bolt 56 so that it is spaced vertically above and does not seat against shoulder 128a during normal use of the scale. Should an applied load tend to upwardly tip platform 30 in the region of assembly 123, shoulder 128a will seat against the bottom of washer 124a to restrict and restrain the tipping movement.
By selectively threading either or both of the washers 124 and 124a downwardly to positions where they firmly seat on shoulders 128 and 128a respectively, platform 30 will rigidly and vertically be clamped against movement between each washer and the rigid upper ends of the force-receiving elements or buttons of load cells 22-25. Thus, prior to the removal of any one of the load cells 22-25 either or both of the washers 124 and 124a may be tightly threaded down to firmly seat on shoulders 128 and 128a to rigidly clamp platform assembly 20 vertically in place, thereby preventing it from tilting or falling down when any one of the load cells 22-25 is removed.
The weight-representing output voltages developed by load cells 22-25 may be applied to a conventional circuit to provide a read-out of the weight of the load on platform 30. The weight read-out may be in digital form or in analog form.
If platform 30 tends to tilt when one of the load cells 22-25 is removed with this invention, it will be appreciated that structures other than assemblies 122 and 123 may be employed to restrain tipping. For example, a temporary support may be positioned beneath the corner at which the load cell is to be removed. Assemblies 122 and 123, however, are advantageous because of the previously mentioned reasons and because they are a unitary part of the scale assembly.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
|
A platform weighing scale having a load receiving platform structure positioned over and resting on a multiplicity of load cells and having a load cell-removing aperture in registry with each load cell whereby each load cell is upwardly removable through its associated load cell removal aperture.
| 6
|
FIELD OF THE INVENTION
[0001] The present invention relates to work lamps and more particularly to a non-fragile work lamp with improved characteristics.
BACKGROUND OF THE INVENTION
[0002] Conventionally, a work lamp is used in an environment where the lighting position is liable to change such as automobile repairing station. It is often found that the work lamp is collided with other object or fallen on the ground. However, most previous work lamps are fragile, thus causing inconvenience to workers. Therefore, improvement is desirable in order to overcome the above drawback of prior art.
SUMMARY OF THE INVENTION
[0003] It is an object of the present invention to provide a non-fragile work lamp comprising: a protective sleeve; a lamp device received in the protective sleeve, the lamp device including a first base at one end, the first base including an on/off switch, a rear connection member for electrically connecting to a power source, and a first recess; a first socket in the first recess; a lamp having one end secured to the first socket; a plurality of first radial elastic members having one ends fixed on the surface of the first socket for preventing the first socket from contacting the inner wall of the first recess; a first axial elastic member having one end fixed on the rear side of the first socket; a second base at the other end projected beyond the protective sleeve the second base including a second recess; an auxiliary shell member in the second recess with the other end of the lamp secured thereto; a plurality of second radial elastic members having one ends fixed on the surface of the auxiliary shell member for preventing the auxiliary shell member from contacting the inner wall of the second recess; a second axial elastic member having one end fixed on the front side of the auxiliary shell member; an elongate half cylindrical member connected between the first and second bases for receiving the lamp; a second socket in the front of the auxiliary shell member for receiving a bulb; and a plurality of third radial elastic members having one ends fixed on the surface of the second socket for preventing the second socket from contacting the inner wall of the second recess; and a cap secured to the second base.
[0004] According to one aspect of the present invention, the rear connection member is a hose having a clamp or a magnet at the free end.
[0005] According to another aspect of the present invention, there is provided a battery case enclosing the rear connection member and being electrically connected to the rear connection member.
[0006] According to still another aspect of the present invention, the auxiliary shell member is formed of a heat resistant material.
[0007] The above and other objects, features and advantages of the present invention will become apparent from the following detailed description taken with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is an exploded view of a first preferred embodiment of work lamp according to the invention;
[0009] [0009]FIG. 2 is a sectional view of the assembled FIG. 1 work lamp;
[0010] [0010]FIG. 3 is a perspective view of a second preferred embodiment of work lamp according to the invention; and
[0011] [0011]FIG. 4 is a perspective view of a third preferred embodiment of work lamp according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] Referring to FIGS. 1 and 2, there is shown a work lamp constructed in accordance with the invention comprising a protective sleeve 10 and a lamp device 20 received in the protective sleeve 10 . Lamp device 20 comprises a first base 21 at one end, a second base 22 at the other end, and an elongate half cylindrical member 23 connected between the first and second bases 21 and 22 . First base 21 comprises an on/off switch 210 on the surface, a threaded rod 211 projected rearward for electrically connecting to a power source and a first recess 212 . A lamp 24 is secured to first socket 25 . A plurality of radial elastic members (e.g., spring) 26 have one ends fixed on the surface of first socket 25 for preventing first socket 25 from contacting the inner wall of first recess 212 . An axial elastic member (e.g., spring) 26 has one end fixed on the rear side of first socket 25 . Second base 22 comprises a second recess 220 . An auxiliary shell member 27 is provided in second recess 220 . The front end of lamp 24 is inserted in and secured to auxiliary shell member 27 . Auxiliary shell member 27 is formed of heat resistant material such as bakelite. Similarly, a plurality of radial elastic members (e.g., spring) 26 have one ends fixed on the surface of auxiliary shell member 27 for preventing auxiliary shell member 27 from contacting the inner wall of second recess 220 . An axial elastic member (e.g., spring) 26 has one end fixed on the front side of auxiliary shell member 27 . Lamp 24 is provided in the elongate half cylindrical member 23 . The front end of second base 22 is projected beyond protective sleeve 10 . A second socket 280 is in the front of auxiliary shell member 27 for receiving a bulb 28 . Also, a plurality of radial elastic members (e.g., spring) 26 having one ends fixed on the surface of second socket 28 for preventing second socket 28 from contacting the inner wall of second recess 220 . A cone 29 is put on bulb 38 . A piece of glass 290 is provided on the front end of cone 29 . A cap 30 is threadedly secured to the front end of second base 22 . The provision of first socket 25 and auxiliary shell member 27 can prevent lamp 24 from shaking in an operating state. Further, the provision of second socket 25 can prevent bulb 24 from shaking in the operating state. This ensures the work lamp of the invention to be non-fragile.
[0013] Referring to FIG. 3, there is shown a second preferred embodiment of work lamp according to the invention. The difference between first and second preferred embodiments is that the threaded rod 211 is replaced by a hose 40 having a clamp 41 (or a magnet 42 ) provided at the free end so as to fasten to a suitable work place.
[0014] Referring to FIG. 3, there is shown a third preferred embodiment of work lamp according to the invention. The difference between first and third preferred embodiments is that the threaded rod 211 is replaced by a cylindrical battery case 50 with a predetermined number of cells stored therein.
[0015] While the invention has been described by means of specific embodiments, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope and spirit of the invention set forth in the claims.
|
A work lamp comprises a protective sleeve, a cap, and a lamp device received in the protective sleeve including two sockets and an auxiliary shell member all supported by a plurality of elastic members, thereby ensuring the work lamp to be non-fragile while operating.
| 5
|
TECHNICAL FIELD
[0001] The present application is a continuation of application Ser. No. 11/383,742, filed May 16, 2006 (U.S. Pat. No. 7,489,801), which is a continuation of application Ser. No. 10/132,060, filed Apr. 24, 2002 (U.S. Pat. No. 7,046,819) which claims benefit of provisional application No. 60/286,701, filed Apr. 25, 2001. Each of the above patent documents is hereby incorporated herein by reference.
BACKGROUND
[0002] Digital watermarking is a process for modifying physical or electronic media to embed a machine-readable code into the media. The media may be modified such that the embedded code is imperceptible or nearly imperceptible to the user, yet may be detected through an automated detection process. Most commonly, digital watermarking is applied to media signals such as images, audio signals, and video signals. However, it may also be applied to other types of media objects, including documents (e.g., through line, word or character shifting), software, multi-dimensional graphics models, and surface textures of objects.
[0003] Digital watermarking systems typically have two primary components: an encoder that embeds the watermark in a host media signal, and a decoder that detects and reads the embedded watermark from a signal suspected of containing a watermark (a suspect signal). The encoder embeds a watermark by altering the host media signal. The reading component analyzes a suspect signal to detect whether a watermark is present. In applications where the watermark encodes information, the reader extracts this information from the detected watermark.
[0004] Several particular watermarking techniques have been developed. The reader is presumed to be familiar with the literature in this field. Particular techniques for embedding and detecting imperceptible watermarks in media signals are detailed in the assignee's co-pending application Ser. Nos. 09/503,881 (now U.S. Pat. No. 6,614,914), 60/278,049 and U.S. Pat. No. 6,122,403, which are hereby incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a diagram illustrating a digital watermark embedder.
[0006] FIG. 2 is a diagram illustrating a digital watermark detector compatible with the embedder of FIG. 1 .
DETAILED DESCRIPTION
[0007] This disclosure describes a method for encoding a digital watermark into an image signal that is robust to geometric distortion. The digital watermark is adapted to the host image signal in which it is embedded so as to be imperceptible or substantially imperceptible in the watermarked image when displayed or printed. This digital watermark may be used to determine the geometric distortion applied to a watermarked image, may be used to carry auxiliary information, and may be used to detect and decode a digital watermark embedded in a geometrically distorted version of a watermarked image. Because of its robustness to geometric distortion, the digital watermark is useful for a number of applications for embedding auxiliary data in image signals, including still pictures and video, where the image signal is expected to survive geometric distortion.
[0008] This method may be adapted to other types of media signals such as audio.
[0009] The digital watermarking system includes an embedder and a detector. The embedder embeds the digital watermark into a host media signal so that it is substantially imperceptible. The detector reads the watermark from a watermarked signal.
[0010] FIG. 1 is a diagram illustrating a digital watermark embedder.
[0011] The embedder encodes a reference signal into a particular transform domain of the host media signal, called the encoded domain. The embedding of the reference signal may use a secret key. Also, the encoded reference signal can be embedded so that it is dependent on the host signal by using some attributes of the host signal to create the encoded reference signal. For example, a hash of attributes of the host media signal may be used as a key to encode the reference signal in the encoded domain. The hash is preferably robust to manipulation of the host signal, including changes due to embedding the digital watermark, so that it can be derived from the watermarked signal and used to decode the embedded watermark. Examples of hashes include most significant bits of image samples, low frequency components (e.g., low frequency coefficients, a low pass filtered, sub sampled and/or compressed version of the host signal or signal attributes).
[0012] The following describes a digital watermark embedder and detector for images. First, the embedder creates the reference signal in the encoded domain. The encoded domain is a transform domain of the host image. In this particular example, the relationship between the spatial domain of the host image and the encoded domain is as follows. To get from the image to the encoded domain, the image is transformed to a first domain, and then the first domain data is transformed into the encoded domain.
[0013] The embedder starts with a reference signal with coefficients of a desired magnitude in the encoded domain. These coefficients initially have zero phase. Next, the embedder transforms the signal from the encoded domain to the first transform domain to recreate the magnitudes in the first transform domain.
[0014] The selected coefficients may act as carriers of a multi-bit message. For example, in one implementation, the multi-bit message is selected from a symbol alphabet comprised of a fixed number of coefficients (e.g., 64) in the encoded domain. The embedder takes a desired message, performs error correction coding, and optional spreading over a PN sequence to produce a spread binary signal, where each element maps to 1 of the 64 coefficients. The spreading may include taking the XOR of the error correction encoded message with a PN sequence such that the resulting spread signal has roughly the same elements of value 1 as those having a value of 0. If an element in the spread signal is a binary 1, the embedder creates a peak at the corresponding coefficient location in the encoded domain. Otherwise, the embedder makes no peak at the corresponding coefficient location. Some of the coefficients may always be set to a binary 1 to assist in detecting the reference signal.
[0015] Next, the embedder assigns a pseudorandom phase to the magnitudes of the coefficients of the reference signal in the first transform domain. The phase of each coefficient can be generated by using a key number as a seed to a pseudorandom number generator, which in turn produces a phase value. Alternatively, the pseudorandom phase values may be computed by modulating a PN sequence with an N-bit binary message.
[0016] Now, the embedder has defined the magnitude and phase of the reference signal in the first transform domain. It then transforms the reference signal from the first domain to the perceptual domain, which for images, is the spatial domain. Finally, the embedder adds the reference signal to the host image. Preferably, the embedder applies a gain factor to the reference signal that scales the reference signal to take advantage of data hiding characteristics of the host image. For examples of such gain calculations see the patent documents incorporated by reference above.
[0017] In one implementation, the first transform domain is a 2D Fourier domain computed by taking an FFT of a block of the host image. The encoded domain is computed by performing a 2D transform of the first transform domain. To create the reference signal, the magnitude of the coefficients of the encoded domain are set to desired levels. These coefficients have zero phase. This signal is then re-created in the first domain by taking the inverse FFT of the reference signal in the encoded domain. Next, the embedder sets the phase of the signal in the first domain by generating a PN sequence and mapping elements of the PN sequence to coefficient locations in the first domain. Finally, the embedder computes the inverse FFT of the signal, including its magnitude components and phase components, to get the spatial domain version of the reference signal. This spatial domain signal is scaled and then added to the host signal in the spatial domain. This process is repeated for contiguous blocks in the host image signal, such that the embedded signal is replicated across the image.
[0018] The host image and reference signal may be added in the first transform domain and then inversely transformed using in inverse FFT to the spatial domain.
[0019] The embedder may use a key to specify the magnitudes of the coefficients in the encoded domain and to generate the random phase information of the reference signal in the first transform domain. The locations and values of the coefficients of the reference signal in the encoded domain may be derived from the host image, such as by taking a hash of the host image. Also, a hash of the host image may be used to compute a key number for a pseudorandom number generator that generates the pseudorandom phase of the reference signal in the first transform domain.
[0020] The above embedding technique may be combined with other digital watermarking methods to encode auxiliary data. In this case, the reference signal is used to correct for geometric distortion. Once the geometric distortion is compensated for using the reference signal, then a message decoding technique compatible with the encoder extracts the message data. This auxiliary data may be hidden using the techniques described in the patent documents reference above or other known techniques described in digital watermarking literature.
[0021] FIG. 2 is a diagram illustrating a digital watermark detector compatible with the embedder of FIG. 1 .
[0022] The detector operates on portions of a signal suspected of containing a digital watermark that has been embedded as described above. First, it creates a specification of the magnitudes of the reference signal in the encoded domain. If the magnitudes were specified by a key, the detector first reads the key or derives it from the watermarked signal. It then constructs a copy of the magnitudes of the reference signal in the encoded domain and uses it to align the watermarked image. If the magnitudes were specified by encoding an N bit message in selected ones of the 64 coefficients, then a proxy for the reference signal is created as a series of peaks at all 64 locations.
[0023] To align the watermarked image, the detector transforms the image into the first transform domain and sets the phase to zero. It then transforms the magnitudes of the watermarked image in the first domain into the encoded domain. In the encoded domain, the detector correlates the copy of the reference signal constructed from the key or N bit message with the magnitude data of the watermarked image transformed from the first domain.
[0024] The detector may use any of a variety of correlation techniques, such as matched filtering or impulse filtering, to determine affined transformation parameters (e.g., rotation, scale, differential scale, shear), except translation, based on the magnitude data in the encoded domain. Examples of some correlation techniques are provided in the patent documents referenced above. One technique is to transform the magnitude information of the reference signal and watermarked image data to a log polar space using a Fourier Mellin transform and use a generalized match filter to determine the location of the correlation peak. This peak location provides an estimate of rotation and scale.
[0025] After finding the rotation and scale, the detector aligns the watermarked image data and then correlates the phase of the aligned watermarked image with the phase of the reference signal. The detector may correlate the watermarked image data with the pseudorandom carrier signal used to create the random phase, or the random phase specification itself. In the case where the pseudorandom phase of the reference signal is created by modulating a message with a pseudorandom carrier, a part of the message may remain constant for all message payloads so that the constant part can be used to provide accurate translation parameters by phase matching the reference phase with the phase of the aligned watermarked image.
[0026] Once the watermarked image is aligned using the above techniques, message data may be decoded from the watermarked image using a message decoding scheme compatible with the embedder. In the particular case where an N bit message is encoded into the magnitude of the reference signal in the encoded domain, the message decoder analyzes the 64 coefficient locations of the watermarked data in the encoded domain and assigns them to a binary value of 1 or 0 depending on whether a peak is detected at the corresponding locations. Then, the decoder performs spread spectrum demodulation and error correction decoding (e.g., using a technique compatible with the embedder such as BCH, convolution, or turbo coding) to recover the original N bit binary message.
[0027] In the particular case where the N bit message is encoded into the pseudorandom phase information of the reference signal, the decoder correlates the phase information of the watermarked signal with the PN carrier signal to get estimates of the error correction encoded bit values. It then performs error correction decoding to recover the N bit message payload.
[0028] The same technique may be adapted for audio signals, where the first domain is a time frequency spectrogram of the audio signal, and the encoded domain is an invertible transform domain (e.g., 2D FFT of the spectrogram).
CONCLUDING REMARKS
[0029] Having described and illustrated the principles of the technology with reference to specific implementations, it will be recognized that the technology can be implemented in many other, different, forms. To provide a comprehensive disclosure without unduly lengthening the specification, applicants incorporate by reference the patents and patent applications referenced above.
[0030] The methods, processes, and systems described above may be implemented in hardware, software or a combination of hardware and software. For example, the auxiliary data encoding processes may be implemented in a programmable computer or a special purpose digital circuit. Similarly, auxiliary data decoding may be implemented in software, firmware, hardware, or combinations of software, firmware and hardware. The methods and processes described above may be implemented in programs executed from a system's memory (a computer readable medium, such as an electronic, optical or magnetic storage device).
[0031] The particular combinations of elements and features in the above-detailed embodiments are exemplary only; the interchanging and substitution of these teachings with other teachings in this and the incorporated-by-reference patents/applications are also contemplated.
|
This disclosure describes methods and systems for encoding and decoding signals from a host signal such as audio, video or imagery. One claim recites a method comprising: receiving a host signal carrying an auxiliary signal; extracting data representing at least some features of the host signal, said extracting utilizes one or more processors; using the data representing at least some features of the host signal to determine a key; and detecting the auxiliary signal in a transform domain associated with the key, the detecting utilizes one or more processors. Other claims and combinations are provided as well.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a process for the production of ethylbenzene and styrene.
2. Description of the Related Art
Styrene is an important monomer used in the manufacture of many of todays plastics. Styrene is commonly produced by making ethylbenzene, which is then dehydrogenated to produce styrene. Ethylbenzene is typically formed by one or more aromatic conversion processes involving the alkylation of benzene.
Aromatic conversion processes, which are typically carried out utilizing a molecular sieve type catalyst, are well known in the chemical processing industry. Such aromatic conversion processes include the alkylation of aromatic compounds such as benzene with ethylene to produce alkyl aromatics such as ethylbenzene. Typically an alkylation reactor, which can produce a mixture of monoalkyl and polyalkyl benzenes, will be coupled with a transalkylation reactor for the conversion of polyalkyl benzenes to monoalkyl benzenes. The transalkylation process is operated under conditions to cause disproportionation of the polyalkylated aromatic fraction, which can produce a product having an enhanced ethylbenzene content and a reduced polyalkylated content. When both alkylation and transalkylation processes are used, two separate reactors, each with its own catalyst, can be employed. The alkylation and transalkylation conversion processes can be carried out in the liquid phase, in the vapor phase or under conditions in which both liquid and vapor phases are present.
In the formation of ethylbenzene from alkylation reactions of ethylene and benzene, other impurities and undesirable side products may be formed in addition to the desired ethylbenzene. These undesirable products can include such compounds as xylene, cumene, n-propylbenzene and butylbenzene, as well as polyethylbenzenes, and high boiling point alkyl aromatic components, sometimes referred to as “heavies,” having a boiling point at or above 185° C. As can be expected, reduction of these impurities and side products is important. This is especially true in the case of xylene, particularly the meta and para xylenes, which have boiling points that are close to that of ethylbenzene and can make product separation and purification difficult.
Ethylene is obtained predominantly from the thermal cracking of hydrocarbons, such as ethane, propane, butane or naphtha. Ethylene can also be produced and recovered from various refinery processes. Ethylene from these sources can include a variety of undesired products, including diolefins and acetylene, which can act to reduce the effectiveness of alkylation catalysts and can be costly to separate from the ethylene. Separation methods can include, for example, extractive distillation and selective hydrogenation of the acetylene back to ethylene. Thermal cracking and separation technologies for the production of relatively pure ethylene can account for a significant portion of the total ethylbenzene production costs.
Benzene is obtained predominantly from the hydrodealkylation of toluene which involves heating a mixture of toluene with excess hydrogen to elevated temperatures (500° C. to 600° C.) in the presence of a catalyst. Under these conditions, toluene can undergo dealkylation according to the chemical equation: C 6 H 5 CH 3 +H 2 →C 6 H 6 +CH 4 This reaction requires energy input and as can be seen from the above equation, produces methane as a byproduct, which is typically separated and used as fuel within the process.
In view of the above, it would be desirable to have a process of producing ethylbenzene, and styrene, which does not rely on thermal crackers and expensive separation technologies as a source of ethylene. It would also be desirable if the process was not dependent upon ethylene from refinery streams containing impurities which can lower the effectiveness and can contaminate the alkylation catalyst. It would further be desirable to avoid the process of converting toluene to benzene with its inherent expense and loss of a carbon atom to methane.
SUMMARY
One embodiment of the present invention is a process for making ethylbenzene which involves reacting toluene and methane in one or more microreactors to form a first product stream comprising ethylbenzene and/or styrene. The first product stream may also have one or more of benzene, toluene, methane, or styrene present. The process may comprise at least one separation process for at least partial separation of the components of the first product stream.
Methane may be separated from the first product stream which may be recycled back to the microreactors or may be utilized as fuel within the process. Toluene may also be separated from the first product stream and recycled to the microreactors. At least a portion of the components of the first product stream can be further processed in a styrene production process. The reactors can include a reaction zone and can be capable of dissipating heat to maintain the reaction zone within a desired temperature range for reacting toluene and methane to form ethylbenzene and/or styrene.
A further embodiment of the invention is a method of revamping an existing styrene production facility by adding one or more microreactors capable of reacting toluene with methane to produce a new product stream containing ethylbenzene. The new product stream containing ethylbenzene may then be sent to the existing styrene production facility for further processing to form styrene. The existing styrene production facility can include separation apparatus to remove at least a portion of any benzene from the new product stream, an alkylation reactor to form ethylbenzene by reacting the benzene with ethylene, and a dehydrogenation reactor to form styrene by dehydrogenating ethylbenzene.
Yet another embodiment of the present invention is a process for making ethylbenzene which includes reacting toluene and methane in one or more microreactors to form a first product stream comprising one or more of ethylbenzene, styrene, benzene, toluene and methane. The first product stream is sent to a separation zone where at least a portion of any methane and toluene are removed for recycle to the one or more microreactors. At least a portion of the benzene is removed from the first product stream and at least a portion of the benzene removed is reacted with ethylene in an alkylation reactor to form ethylbenzene. The ethylbenzene is dehydrogenated in one or more dehydrogenation reactors to form styrene.
The one or more microreactors may have one or more reaction zones and be capable of dissipating heat to maintain one or more of the reaction zones within a desired temperature range to promote reacting toluene and methane to form ethylbenzene and/or styrene. The one or more microreactors can comprise a plurality of microstructured panels creating a reaction zone comprising a plurality of microchannels. A portion of the microstructured panels can create reaction zones comprising a plurality of reaction zone microchannels and a portion of the microstructured panels can create a plurality of cooling microchannels for the flow of a cooling medium capable of dissipating heat to maintain the reaction zones within a desired temperature range for reacting toluene and methane to form ethylbenzene. The plurality of microstructured panels can be arranged in an alternating manner so the reaction zone microchannels and the cooling microchannels are capable of dissipating heat to maintain the reaction zones within a desired temperature range for reacting toluene and methane to form ethylbenzene.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram illustrating a process for making ethylbenzene and styrene.
FIG. 2 is a schematic block diagram illustrating a process for making ethylbenzene and styrene according to an embodiment of the present invention.
FIG. 3 is an illustrated example of a microstructured panel.
FIG. 4 is an illustrated example of two microstructured panels, each having microchannels, one for reactants and the other for a cooling medium.
DETAILED DESCRIPTION
Referring first to FIG. 1 , there is illustrated a schematic block diagram of a typical alkylation/transalkylation process carried out in accordance with the prior art. A feed stream of toluene is supplied via line 10 to reactive zone 100 which produces product streams of methane via line 12 and benzene via line 14 . The benzene via line 14 along with ethylene via line 16 are supplied to an alkylation reactive zone 120 which produces ethylbenzene and other products which are sent via line 18 to a separation zone 140 . The separation zone 140 can remove benzene via line 20 and send it to a transalkylation reaction zone 160 . The benzene can also be partially recycled via line 22 to the alkylation reactive zone 120 . The separation zone 140 can also remove polyethylbenzenes via line 26 which are sent to the transalkylation reaction zone 160 to produce a product with increased ethylbenzene content that can be sent via line 30 to the separation zone 140 . Other byproducts can be removed from the separation zone 140 as shown by line 32 , this can include methane and other hydrocarbons that can be recycled within the process, used as fuel gas, flared or otherwise disposed of. Ethylbenzene can be removed from the separation zone 140 via line 34 and sent to a dehydrogenation zone 180 to produce styrene product that can be removed via line 36 .
The front end of the process 300 , designated by the dashed line, includes the initial toluene to benzene reactive zone 110 and the alkylation reactive zone 120 . It can be seen that the input streams to the front end 300 include toluene via line 10 , ethylene via line 16 and optionally oxygen via line 15 . There can also be input streams of benzene from alternate sources other than from a toluene reaction, although they are not shown in this embodiment. The output streams include the methane via line 12 which is produced during the conversion of toluene to benzene in reactive zone 110 and the product stream containing ethylbenzene via line 18 that is sent to the back end of the process 400 . The back end 400 includes the separation zone 140 , the transalkylation reaction zone 160 and the dehydrogenation zone 180 .
Turning now to FIG. 2 , there is illustrated a schematic block diagram of one embodiment of the present invention. Feed streams of toluene supplied via line 210 and methane supplied via line 216 are supplied to one or more microreactors 200 which produces ethylbenzene along with other products, which can include styrene. In some embodiments an input stream of oxygen 215 may be supplied to the microreactors 200 . The output from the microreactor 200 includes a product containing ethylbenzene which is supplied via line 218 to a separation zone 240 . The separation zone 240 can separate benzene that may be present via line 220 which can be sent to an alkylation reaction zone 260 . The alkylation reaction zone 260 can include a transalkylation zone. The separation zone 240 can also remove heavy molecules that may be present via line 226 . The alkylation reaction zone 260 can produce a product with increased ethylbenzene content that can be sent via line 230 to the separation zone 240 . Other byproducts can be removed from the separation zone 240 as shown by line 232 , this can include methane and other hydrocarbons that can be recycled within the process, used as fuel gas, flared or otherwise disposed of. Ethylbenzene can be removed from the separation zone 240 via line 234 and sent to a dehydrogenation zone 280 to produce styrene product that can be removed via line 236 . Any styrene that is produced from the reactive zone 200 can be separated in the separation zone 240 and sent to the dehydrogenation zone 280 via line 234 along with the ethylbenzene product stream, or can be separated as its own product stream, (not shown), bypassing the dehydrogenation zone 280 and added to the styrene product in line 236 .
The front end of the process 500 includes the one or more microreactors 200 which can be in series or parallel arrangements. The input streams to the front end 500 are toluene via line 210 and methane via line 216 and optionally oxygen via line 215 . The output stream is the product containing ethylbenzene via line 218 that is sent to the back end of the process 600 . The back end 600 includes the separation zone 240 , the alkylation reaction zone 260 and the dehydrogenation zone 280 .
A comparison of the front end 300 of the prior art shown in FIG. 1 against the front end 500 of the embodiment of the invention shown in FIG. 2 can illustrate some of the features of the present invention. The front end 500 of the embodiment of the invention shown in FIG. 2 has a single microreactor zone 200 rather than the two reactive zones contained within the front end 300 shown in FIG. 1 , the reactive zone 100 and the alkylation reactive zone 120 . The reduction of one reactive zone can have a potential cost savings and can simplify the operational considerations of the process.
Both front ends have an input stream of toluene, shown as lines 10 and 210 . The prior art of FIG. 1 has an input stream of ethylene 16 and a byproduct stream of methane 12 . The embodiment of the invention shown in FIG. 2 has an input stream of methane 216 . The feed stream of ethylene 16 is replaced by the feed stream of methane 216 , which is typically a lower value commodity, and should result in a cost savings. Rather than generating methane as a byproduct 12 which would have to be separated, handled and disposed of, the present invention utilizes methane as a feedstock 216 to the microreactor 200 .
A comparison of the back end 400 of the prior art shown in FIG. 1 with the back end 600 of the embodiment of the invention shown in FIG. 2 can further illustrate the features of the present invention. It can be seen that the back end 400 of the prior art shown in FIG. 1 is essentially the same as the back end 600 of the embodiment of the invention shown in FIG. 2 . They each contain a separation zone, an alkylation reaction zone and a dehydrogenation zone and are interconnected in the same or essentially the same manner. This aspect of the present invention can enable the front end of a facility to be modified in a manner consistent with the invention, while the back end remains essentially unchanged. A revamp of an existing ethylbenzene or styrene production facility can be accomplished by installing a new front end or modifying an existing front end in a manner consistent with the invention and delivering the product of the altered front end to the existing back end of the facility to complete the process in essentially the same manner as before. The ability to revamp an existing facility and convert from a toluene/ethylene feedstock to a toluene/methane feedstock by the modification of the front end of the facility while retaining the existing back end can have significant economic advantages.
The microreactor 200 of the present invention can comprise one or more single or multi-stage microreactors. In one embodiment the microreactor 200 can have a plurality of microreactors connected in series (series-connected microreactors). Additionally and in the alternative, the microreactors may be arranged in a parallel fashion. The microreactor 200 can be operated at temperature and pressure conditions to enable the reaction of toluene and methane to form ethylbenzene, and at a feed rate to provide a space velocity enhancing ethylbenzene production while retarding the production of xylene or other undesirable products. The reactants, toluene and methane, can be added to the plurality of series-connected microreactors in a manner to enhance ethylbenzene production while retarding the production of undesirable products. For example toluene and/or methane can be added to any of the plurality of series-connected microreactors as needed to enhance ethylbenzene production.
The microreactor 200 can be operated in the vapor phase. One embodiment can be operated in the vapor phase within a pressure range of 4 psia to 1000 psia. Another embodiment can be operated in the vapor phase within a pressure range of atmospheric to 500 psia.
The feed streams of methane and toluene can be supplied to the microreactor 200 in ratios of from 2 to 50 moles methane to toluene. In one embodiment the ratios can range from 5 to 30 moles methane to toluene.
In one embodiment of the invention oxygen is added to the microreactor 200 in amounts that can facilitate the conversion of toluene and methane to ethylbenzene and styrene. The oxygen content can range from 1% to 50% by volume relative to the methane content. In one embodiment the oxygen content can range from 2% to 30% by volume relative to the methane content.
In one embodiment the microreactor 200 of the present invention can comprise multiple microreactors and oxygen can be added to the plurality of series-connected microreactors in a manner to enhance ethylbenzene and/or styrene production while retarding the production of undesirable products. Oxygen can be added incrementally to each of the plurality of series-connected microreactors as needed to enhance ethylbenzene and/or styrene production, to limit the exotherm from each of the microreactors, to maintain the oxygen content within a certain range throughout the plurality of microreactors or to customize the oxygen content throughout the plurality of microreactors. In one embodiment there is the ability to have an increased or reduced oxygen content as the reaction progresses and the ethylbenzene and/or styrene fraction increases while the toluene and methane fractions decrease. There can be multiple series-connected microreactors which are arranged in a parallel manner.
The oxygen can react with a portion of the methane and result in a highly exothermic reaction. The heat generated by the exothermic reaction can be regulated to some extent by the use of microreactors which can have a large surface area to reactant contact area ratio. The small contact area for the reactants can result in a short residence time for the reaction, which in some embodiments can be as short as less than a second. The shortened residence time and large surface area to reactant contact area ratio can facilitate heat dissipation from the microreactor. These factors, along with the ability for incremental oxygen addition to the plurality of series-connected microreactors, can be used to control the reaction temperatures within a range to facilitate the production of ethylbenzene and/or styrene and reduce the production of undesired components. Microreactors with integrated cooling can also be used, thus a short residence time reactor with an integrated heat exchanger can be used.
When a plurality of series-connected microreactors are utilized, counter-flow micro heat exchangers can be used to dissipate heat and provide temperature control for the reaction. In one embodiment a plurality of series-connected microreactors are utilized and one or more counter-flow micro heat exchangers are located between two or more of the microreactors used to dissipate heat and provide temperature control for the individual microreactors and the overall reaction. One temperature range to facilitate the production of ethylbenzene and/or styrene is from 550° C. to 1000° C. Another temperature range to facilitate the production of ethylbenzene and/or styrene is from 600° C. to 800° C. The heat generated by the exothermic reaction can be removed and recovered to be utilized within the process.
In one embodiment the microreactor zone 200 of the present invention can comprise one or more single or multi-stage microreactors which can contain one or more single or multi-stage catalyst sites. The catalyst that can be used in the microreactor 200 can include any catalyst that can couple toluene and methane to make ethylbenzene and/or styrene and are not limited to any particular type. It is believed that the oxidation reaction of toluene and methane can be accelerated by base catalysis. In one non-limiting example the catalyst can comprise one or more metal oxides. In one non-limiting example the catalyst can contain a metal oxide which is supported on an appropriate substrate. It is believed that with a metal oxide catalyst the oxygen/oxide sites can function as the active reaction centers which can remove hydrogen atoms from the methane to form methyl radicals and from the toluene to form benzyl radicals. The C8 hydrocarbons can be formed as a result of cross-coupling between the resulting methyl and benzyl radicals. The catalysts may contain different combinations of alkali, alkaline earth, rare earth, and/or transition metal oxides. In another non-limiting example the catalyst can comprise a modified basic zeolite. In yet another non-limiting example the catalyst can be a base zeolite, such as an X, Y, mordenite, ZSM, silicalite or AIPO4-5 that can be modified with molybdenum, sodium or other basic ions. The zeolite catalyst may or may not contain one of more metal oxides.
A catalyst can be introduced into one or more parts of the process. In one embodiment the microchannels of the microreactor can have a catalyst deposited or impregnated on or within them. The catalyst can also be affixed to an article, such as a rod, that can be contained or inserted into the microreactor in a manner which can contact the catalyst with the reactant streams. Alternatively, a process for wash coating a carrier with catalyst can be used where the carrier is capable of contacting the reactants within one or more of the microreactors. The catalyst can be contacted with the reactants at one or more points of the plurality of series-connected microreactors. The catalyst can alternately be contacted with the reactants at one or more points between the plurality of series-connected microreactors, such as for example at a location between two microreactors in conjunction with a counter-flow micro heat exchanger.
Referring now to FIG. 3 , the microreactor can comprise a number of microstructured panels 700 that can have recesses or channels of small depth that serve as flow channels or microchannels 710 . These types of microreactors can be similar to typical plate-and-frame type heat exchangers known in the art, but of much smaller size. In one embodiment the microreactor panels 700 can range from about 30 to 50 mm in length and from about 30 to 50 mm in height. The microreactor panels 700 can be constructed by micro-machining or etching a panel made of metals, silicon, glass or ceramic materials, which can be referred to as a substrate material. Microchannels 710 can be etched or otherwise formed in a pattern on the surface 712 of the substrate panel material. In one embodiment the number of microchannels formed on the surface of the panel can range from 10 to 5000. The microchannels 710 can be in fluid communication with openings through the panels which can serve as inlet 714 and outlet 716 passages between the microreactors and/or microchannels so that the reactants can enter and exit the microchannels. The panel 700 may also have pass-though holes 718 , 720 that can allow a fluid or gas to pass through the panel 700 without being in contact with the panel inlet 714 , outlet 716 or the microchannels 710 . The pass-though holes 718 , 720 in one embodiment have a diameter of from 0.5 mm to 2.0 mm. The width and depth of the microchannels 710 in one embodiment can range from 100 μm to 300 μm while the total depth of the panel 700 can range from 400 μm to 600 μm. In another embodiment the width and depth of the microchannels can range from 100 μm to 500 μm while the total depth of the panel 700 can range from 700 μm to 1 mm. In yet another embodiment the width and depth of the microchannel can range from 300 μm to 600 μm while the total depth of the panel 700 can range from 800 μm to 1.5 mm or more. The width and depth of the microchannels do not have to be consistent or have the same dimensions of the other microchannels. While in some embodiments the width may be of a larger dimension than the depth, in other embodiments the depth may be of a larger dimension than the width. If plugging is a concern, having the depth and width of the microchannels be of similar dimension to create a more uniform cross sectional flow area of the microchannel may be desired.
In yet another embodiment the microreactor panels 700 can range from about 300 mm to 900 mm in length and from about 300 mm to 900 mm in height. The width of the microchannel 710 of these larger panels can be as large as 5 mm while the depth of the microchannel 710 would still be limited to a dimension less than that of the substrate panel material. The size of the panels and dimensions of the microchannels can vary greatly while still being within the scope of the present invention.
Referring now to FIG. 4 , in one embodiment a reactant inlet stream 740 supplies an inlet stream 742 to the microchannels 710 of panel 700 . The reactants can flow through the microchannels 710 and exit panel 700 in outlet stream 744 to combine in the product stream 750 . The reactant inlet stream 740 can pass through the opening 814 of panel 800 without being in contact with the fluids flowing through the microchannels 810 of panel 800 . The product stream 750 can likewise pass through the opening 816 of panel 800 without being in contact with the fluids flowing through the microchannels 810 of panel 800 . A cooling medium stream 840 supplies an inlet stream 842 to the microchannels 810 of panel 800 . The cooling medium can flow through the microchannels 810 and exit panel 800 in outlet stream 844 to combine in the cooling medium exit stream 850 . The cooling medium inlet stream 840 can pass through the opening 718 of panel 700 without being in contact with the reactants flowing through the microchannels 710 of panel 700 . The cooling medium outlet stream 850 can pass through the opening 720 of panel 700 without being in contact with the reactants flowing through the microchannels 710 of panel 700 . The microreactor would comprise a plurality of panels that are pressed together in a manner to enable the reactants and cooling medium stream to be contained within their respective flow paths and not in communication with each other. A gasket material, a solder material, or a brazing material can be used to provide a seal between the panels.
Multiple microreactors can be utilized in a facility. In one embodiment the number of panels can range from 2 to 100. In an alternate embodiment the number of panels can range from 100 to 3000. In a commercial scale petrochemical plant the number of panels that can be used can reach hundreds or thousands, with up to a million channels or more per reactor.
As can be seen in FIG. 4 , in one embodiment the microreactor can comprise alternating panels, to provide reactant flow through the microchannels of every other panel, while a different fluid, such as a cooling medium, can be flowing through the alternate panels. The different fluid, such as a cooling medium, can be flowing through the alternate panels in a counter-flow or co-current flow in relation to the reactant flow. Dissipation of the exotherm is through the panel material that make up the microchannel walls containing the reactants and into the cooling medium that is flowing through the microchannels created by the adjacent panels. This enables a rapid heat dissipation and the ability to control the reaction temperature within the microchannel in a manner that conventional reactors can not achieve.
The substrate material used for panel construction can act as a catalyst, or the microchannels may be coated with a catalyst layer, for example by using a wash coating or thin-film deposition of a catalyst material within or adjacent to the microchannels. A catalyst material can also be placed within a recess of the panel material that is in fluid contact with the reactants flowing through the microchannels, such as just before the reactants enter the microchannels.
Other types of microreactors can be used within the scope of the present invention. The description of multiple panel microreactors is not meant to be a limiting example of the microreactor. Another microreactor that can be used is a Falling Film microreactor which utilizes a multitude of thin falling films flowing through a multi-channel reactor.
Microreactors can be provided by sources such as Atotech located in Berlin, Germany; Velocys located in Plain City, Ohio, USA; Microinnova located in Graz, Austria; and Ehrfeld Mikrotechnik BTS GmbH located in Wendelsheim, Germany. Further, other types or brands of microreactors can be used in conjunction with the present invention.
The foregoing description of certain embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or limit the invention to the precise form disclosed, and other and further embodiments of the invention may be devised without departing from the basic scope thereof. It is intended that the scope of the invention be defined by the accompanying claims and their equivalents.
|
A process for making ethylbenzene and/or styrene by reacting toluene with methane in one or more microreactors is disclosed. In one embodiment a method of revamping an existing styrene production facility by adding one or more microreactors capable of reacting toluene with methane to produce a product stream comprising ethylbenzene and/or styrene is disclosed.
| 1
|
FIELD OF THE INVENTION
The present invention relates to a shaft locking collar arrangement for bearing assemblies.
BACKGROUND OF THE INVENTION
Various arrangements are known in the art for securing the inner race of a bearing assembly to a rotatable shaft with as strong a physical locking force being exerted as is reasonably possible to insure secure locking to the shaft and with maximum accommodation for radial and thrust or axial loads or either of them on the shaft. Known arrangements include shaft engaging set screws, plural locking or tightening means on a shaft surrounding collar with multiple shaft engaging set screws, and the patented SKWEZLOC (Registered Trademark), (U.S. Pat. No. 3,276,828) arrangement which includes generally equally spaced inner ring or race finger extensions which, when locked with a single screw locking collar, serves to grip and hold the shaft and the inner race tightly in position allowing near-perfect concentricity of the inner race with the shaft so as to permit the use of the so held bearing with high speed shafts.
DESCRIPTION OF PRIOR ART
Mansfield, U.S. Pat. No. 3,276,828 is described above and reference is made to that description.
LaRou, U.S. Pat. No. 4,537,519 is a shaft locking arrangement which comprises generally the same one screw compressible locking collar as in the aforesaid Mansfield patent; however, the axially extending fingers of the inner ring or race are provided with recessed grooved areas, thus providing even greater holding power than obtainable with the arrangement in the Mansfield patent, supra.
Skeel, U.S. Pat. No. 2,547,789 relates to a wedge clamp mechanism using dual threaded screws. Various arrangements are illustrated and described, but generally a wedging member is moved to a wedging position by action of one set of threads while the other threads are screwed into a support or the like.
SUMMARY OF THE INVENTION
The present invention relates to a locking collar for use with bearing assemblies, the locking collar comprising a pair of semi-annular members, each having a pair or set of threaded openings therethrough, such that when placed together to form an annular collar, the openings of one member are concentric with the openings of the other member. Usually the openings in one member are larger than the openings in the other member. Each opening in one member is provided with threads of one size while each opening in the other member is provided with threads of a different size, such that each pair of concentric openings receives a differential screw, i.e., a screw having a large portion with one thread size and a smaller portion with a different thread size, each portion mating with the threads of the pair of concentric openings.
In another embodiment, each semi-annular member can be identical and thus interchangeable, each with one large and one smaller threaded opening. This modification reduces inventory of parts because only one configuration of collar part is required.
The annular member comprising two halves can be preassembled with the screws and placed over the axially extending fingers at one end of an inner race, the fingers being similar to those illustrated in either the Mansfield or LaRou patents, supra. After being so assembled, the screws are tightened alternately bringing the two halves of the locking collar together into clamping relationship with the axially extending fingers. The use of this arrangement results in high clamping force at lower torque and stress than when using the prior art uniform threaded screw form. For this advantage, there is a modest increase in the cost of the screws.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial sectional view of a bearing assembly in a housing or pillow block including the shaft locking collar of this invention;
FIG. 2 is an isometric view of a portion of the bearing assembly of FIG. 1 locked to the shaft by the shaft locking collar without the pillow block;
FIG. 3 is an end view of the bearing assembly of FIG. 1 showing the locking collar of this invention with parts broken away to show details of the screw arrangement; and
FIG. 4 is a plan view of one half of a two part locking collar which comprises a second embodiment of this invention in which the two parts are identical and interchangeable;
FIG. 4A is a view taken on line 4--4 of FIG. 4;
FIGS. 5 and 5A are a views of the screw adaptable for use with the collars illustrated in FIGS. 1, 2, 3 and also 4; and
FIGS. 6 to 11 show the relationship of the locking collar parts or halves during the tightening process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, and especially to FIG. 1, the bearing assembly 10 is illustrated as being connected to a shaft 12 which passes through the inner race 14 of the assembly 10. The assembly 10 comprises, in addition to the inner race 14, an outer race 16, a wear hardened grooved raceway 18 in the inner race 14, a wear hardened grooved raceway 20 in the outer raceway 16, the raceways being radially opposed to one another, and a plurality of anti-friction rolling elememts, illustrated as balls 22, in the raceways 18 and 20. The balls 22 are mounted in and spaced by pockets 23 of a cage element 24. A lubricating passage 26 is provided in the outer race and is aligned with a passageway 28 in a bearing housing or pillow block 30 in which the bearing assembly 10 is mounted. A grease fitting 32 is received in the passageway 28, and a locking or locating pin 34 in the passage 28 and in a dimple 36 in the outer race serves to limit relative rotation between the bearing assembly 10 and the pillow block 30. Sealing means 38 are provided at each end of the assembly to seal the assembly from ingress of dirt and debris and also to retain lubricant between the races. Sealing arrangements are well known in the art and need no further description.
As can be seen in FIGS. 1 and 2, the inner race 14 includes axial finger extensions 40 generally formed by providing slots 42 parallel to the axis of and in the race 14. These finger extensions permit radial compression by a surrounding locking collar 44; however, at times, the extensions 40 extend from both ends of the race 14 and a locking collar is used at both ends of the race. The fingers can be as shown in either the Mansfield or LaRou patents, supra.
The locking collar 44, more particularly illustrated in FIG. 3, is an annular assembly of two generally semi-circular or semi-annular parts or halves 46 and 48. Part 46 has openings 50, 50A of a first diameter and part 48 has openings 52, 52A of a second and different diameter. When the collar parts are assembled for use, the openings 50 and 52 are concentric with one another and the openings 50A and 52A are concentric with one another. The openings 50 and 50A are threaded as at 54 with a first sized thread while the openings 52 and 52A are threaded as at 56 with a different sized thread.
Screws 58 as illustrated in FIG. 5 comprise a first part 60 of a first diameter with a thread size 62 adaptable to mesh with threads 54 and a second part 64 of a second diameter with a thread size 66 adapted to mesh with threads 56. The head 68 of the screw 58 is provided with a recess 70 to receive a hexagonal wrench and the like. The head 68 can be slotted to receive the blade of an ordinary screwdriver or formed to receive the blade of a Phillips screwdriver without departing from the spirit of the invention.
The two part collar of this invention permits preassembly of the screws and collar halves with thread engagement drawing the two halves together until the ID just slips over the fingered end of the inner race of the bearing, as shown and described by the legends in FIGS. 6, 7 and 8.
At installation, alternate tightening of the screws draws the two halves of the collar together by virtue of the difference in thread advance at each end of the screws, see FIGS. 9, 10 and 11. The collar construction results in higher clamping force at lower screw torque and stress when compared to a split collar using one or more clamping screws with threads of one size only.
This differential lead on the screw permits a larger root diameter of the smaller end while eliminating the need for a suitable collar cross section support for a standard screw head. Thus the larger diameter of the differential screw replaces the normal screw head without projecting beyond the collar outer diameter.
The locking collar, one half of which is illustrated in FIGS. 4 and 4A comprises an annular assembly of two interchangeable and like semi-annular halves or parts 72, each having an opening 74 of one diameter threaded at 76, and an opening 78 of a different diameter threaded at 80. The threads of 76 and 80 are of different size. The two parts are assembled and connected by screws 58 in the same manner as the locking collar 44, except that tightening of the screws is accomplished from opposite sides of the collar instead of from the same side.
The appended claims are intended to cover all reasonable equivalents and be given the broadest interpretation as permitted by the prior art.
|
A two part locking collar for bearing assemblies which is received around axial fingered ends of the bearing's inner race and drawn together by differential screws, each having a part of one thread and a part of a different thread.
| 5
|
BACKGROUND OF THE INVENTION
[0001] Field of the Invention
[0002] The present invention relates to bowling lane maintenance machines and, more particularly, to the cleaning mechanism of such machines used to remove dirt, grime and old lane dressing from the surface of the lane before re-applying conditioning dressing thereto.
[0003] Description of the Prior Art
[0004] In the game of bowling a ball is rolled at an arrangement of bowling pins in order to knock them down and score points. The pins are arranged on a series of “spots” so that the pinsetting (or pinspotting) equipment can pick-up any pins left behind after the first roll of the ball and reset them for a second or spare shot. However, if a pin slides off the designated spot (referred to as an “out of range” pin), it can cause problems for the pinsetting equipment, and many times the dislocated pin(s) cannot be picked up and reset for a second attempt. This causes delays and dissatisfaction for bowlers as the pin(s) must be manually reset into place before the spare shot can occur. An out-of-range pin can also cause damage to the pinsetting equipment as it attempts to complete its cycle.
[0005] To reduce or eliminate sliding pins, different types of liquid pin deck treatments have been used, typically applied with some sort of spray bottle or pressurized sprayer with a wand (i.e. bug sprayer) to reach into the pin deck area. This method of application always results in the treatment covering more than just the area where it is needed (creating areas of contamination) and wasting product. It is also time-consuming and inconvenient to treat the pin decks in larger bowling centers. Since applying liquid treatments is very labor-intensive, the treatment does not get applied as frequently as needed, creating a problem with sliding pins.
[0006] Another method in use by bowling centers to help pins fall over rather than slide out of range has been to apply thin soft anti-skid plastic disks that adhere to each pin spot on the pin deck. A typical bowling center needs 10 disks per lane to cover the 10 spots on a triangular deck pattern—with the head pin (in front) designated as the 1-pin, the left rear pin being the 7-pin, and the right rear pin being the 10-pin. The disks covering the pin spots create an irregular surface that can make the pin deck more difficult to clean. In addition to being a more expensive method, if the disks are not properly applied and maintained they can cause the pins to fall over prematurely (i.e. when being placed on the spot by the pinsetting equipment).
[0007] Additionally, the typical composition of the pin deck surface has changed from finished hardwood (i.e. maple) to a synthetic material (i.e. phenolic laminate), creating a greater need for recurring pin deck treatments to reduce the out of ranges due to sliding pins on the slicker surface.
[0008] The present invention overcomes these problems by providing a new method and apparatus for applying liquid pin deck treatments in a consistent and automated fashion.
SUMMARY OF THE INVENTION
Brief Description of the Drawings
[0009] FIG. 1 is a left front perspective view of a maintenance machine embodying the principles of the present invention with its top cover removed to reveal internal details of construction;
[0010] FIG. 2 is a right rear perspective view of the machine;
[0011] FIG. 3 is a right front perspective illustration of the cleaning system of the machine and its relationship to certain other components;
[0012] FIG. 4 is a left rear perspective illustration of the cleaning system and related components;
[0013] FIG. 5 is a right side elevational view of the machine with the near sidewall thereof removed to reveal internal details of construction; and
[0014] FIG. 6 is an illustration of the pin deck treatment system of the machine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] The present invention is susceptible of embodiment in many different forms. While the drawings illustrate and the specification describes certain preferred embodiments of the invention, it is to be understood that such disclosure is by way of example only. There is no intent to limit the principles of the present invention to the particular disclosed embodiments.
[0016] The machine 10 illustrated in the drawings is similar in many respects to the machine disclosed in U.S. Pat. Nos. 5,729,855 and 7,060,137. Accordingly, the '855 and '137 patents are incorporated herein by reference. In view of the full disclosures in the '855 patent of the construction and operation of the lane machine, the construction and operation of the machine 10 will be described only generally herein.
[0017] The machine 10 has a cleaning system denoted broadly by the numeral 12 and located generally in the front of the machine. A dressing application system is denoted broadly by the numeral 14 and located generally in the rear portion of the machine. These two systems perform their functions as the machine travels up and down the lane through the provision of lane-engaging drive wheels 16 and 18 fixed to a transverse shaft 20 that is powered by a drive motor 22 and a chain and sprocket assembly 24 .
[0018] The dressing application system 14 includes an applicator roll 26 disposed for engaging the lane surface, a reciprocating dressing dispensing head 28 that travels back and forth across the width of the lane above roll 26 , and a brush assembly 30 between roll 26 and dispensing head 28 for receiving dressing from head 28 and delivering it to roll 26 . Details of the construction and manner of use of brush assembly 30 are disclosed in U.S. Pat. No. 7,056,384, which is incorporated herein by reference. Dressing application system 14 additionally includes a reservoir 32 and a positive displacement pump (not shown) for supplying dressing from reservoir 32 to dispensing head 28 .
[0019] Dressing dispensing head 28 is mounted for reciprocation along a transverse guide track 34 extending between the sidewalls of the machine. An endless drive belt 36 is secured to head 28 and has its opposite ends looped around a pair of pulleys 38 and 40 , the pulley 40 being operably coupled with a reversible motor 42 to provide driving power to belt 36 and thus propel dispensing head 28 along track 34 . A pair of sensors 44 and 46 adjacent opposite ends of the path of reciprocal travel of dispensing head 28 are operable to sense the presence of dispensing head 28 as it reaches one limit of its path of travel so as to signal the motor 42 to reverse directions and drive dispensing head 28 in the opposite direction along track 34 .
[0020] The pulley 38 is fixed to a long fore-and-aft extending shaft 48 disposed just outboard of the right sidewall of the machine. Near its rear end, just forward of pulley 38 , shaft 48 is provided with a notched wheel 50 whose rotation is sensed by a sensor 52 . An output from sensor 52 may be sent to the control system of the machine (not shown) for the purpose of determining the precise location of the dressing dispensing head 28 across the width of the machine and the bowling lane. Such location is coordinated with a particular lane dressing pattern that has been programmed into the control system of the machine so that dressing dispensing head 28 may be actuated to precisely dispense dressing at predetermined locations along its path of reciprocation. Distance down the lane is determined by a pair of lane-engaging wheels 53 ( FIGS. 3, 4 and 5 ) located just in front of the rear wall of the machine. Wheels 53 are fixed to a common cross shaft 54 that rotates a notched wheel 55 ( FIG. 4 ) via a chain drive 56 ( FIG. 3 ). The number of revolutions of notched wheel 55 is detected by a sensor 57 ( FIG. 4 ) that sends a signal to the control system of the machine.
[0021] The cleaning system 12 includes one or more liquid dispensing head 58 that reciprocate across the path of travel of the machine as it moves along the lane. While system 12 may also include one or more pressurized spray nozzles as in conventional machines, in a preferred embodiment no such conventional spray nozzles are utilized. In the particular embodiment disclosed herein, only one dispensing head 58 is utilized, and in this instance, head 58 is a double head, designed to accommodate two dispensing or discharge tips, described further below. Such head 58 travels essentially the full transverse width of the machine to the same extent as the dressing dispensing head 28 .
[0022] Dispensing head 58 includes two openings 59 a , 59 b . A vertically disposed, depending cleaning liquid discharge tube 60 provided with a dispensing or discharge tip 62 that is located close to the lane surface is positioned within opening 59 a . In one form of the invention, tip 62 is not in the nature of an atomizing nozzle but is instead configured and arranged to emit liquid in a fairly coherent stream so that a bead of cleaning liquid is laid down on the lane surface. One suitable tip 62 for carrying out this particular non-atomizing function is available from the Value Plastics Company of Fort Collins, Colo. as part number VPS5401001N. Other types of tips (not shown) that atomize, breakup or diffuse liquid supplied to the tip may also be utilized where broader surface area coverage by the cleaning liquid is desired. In either case, tip 62 is preferably provided with an internal check valve (not shown).
[0023] Opening 59 b includes a pin deck treatment discharge tube 61 provided with a dispensing or discharge tip 63 that is located close to the lane surface, in a similar fashion to the positioning of tube 60 and tip 62 ( FIG. 6 ). Additionally, tip 63 is similar in construction to tip 62 . In a preferred embodiment, tip 63 is bent at an angle of from about 20° to about 40°, preferably from about 25° to about 35°, and more preferably about 30°, in order to more properly direct the pin deck treatment liquid, as described in more detail below. This bend has the advantage of preventing the pin deck treatment liquid from splattering against the pin deck surface and back onto the machine front panel (since pin deck treatment is carried out while the machine is in a stopped position). Additionally, this angle allows for mechanical adjustments, which can assist with centering the stream. Furthermore, because pin deck treatment liquids will tend to dry within tip 63 , potentially causing clogging, it is preferred that tip 63 be provided with a removable cap (not shown) to seal the tip 63 (and tube 61 ) and prevent such clogging. A PLC program utilized for operating the machine can include a reminder to the operator to verify the tip is removed when the program calls for pin deck treatment liquid to be applied, as well as to remind the operator to replace the tip after application.
[0024] Cleaning system 12 further includes a guide track 64 attached to the front wall of machine 10 that slidably supports dispensing head 58 for its reciprocal movement. Track 64 extends across substantially the entire width of machine 10 to the same extent as the track 34 associated with dressing dispensing head 28 . An endless drive belt 66 is attached to dispensing head 58 for providing reciprocal drive thereto, the belt 66 at its opposite ends being looped around a pair of pulley wheels 68 and 70 respectively.
[0025] Although pulley 68 may be driven in a number of different ways, including by its own separate drive motor, in a preferred form of the invention pulley 68 is fixed to the forwardmost end of shaft 48 from pulley 38 so that both dispensing heads 28 and 58 are driven by the same reversible motor 42 . Consequently, both dressing dispensing head 28 and cleaning liquid/pin deck treatment dispensing head 58 are reciprocated simultaneously by motor 42 when the latter is actuated. However, it will be noted that dressing dispensing head 28 and cleaning liquid/pin deck treatment dispensing head 58 reciprocate in mutually opposite directions due to the fact that dressing dispensing head 28 is secured to the upper run 36 a of its drive belt 36 while cleaning liquid/pin deck treatment dispensing head 58 is secured to the lower run 66 b of its drive belt 66 .
[0026] Cleaning system 12 further includes a cleaning solution reservoir 72 at the rear of machine 10 . A supply line 74 leading from reservoir 72 is coupled in flow communication with a peristaltic pump 76 driven by a chain and sprocket assembly 78 operably coupled with the drive shaft 20 of lane drive wheels 16 and 18 . When drive wheels 16 and 18 are turning, pump 76 is operating. It will be appreciated, however, that pump 76 could be driven by its own separate drive motor. An outlet line 80 from pump 76 leads to an inlet port of a solenoid-controlled valve 82 whose operation is controlled by the control system of machine 10 . A supply line 84 leading from one outlet port of valve 82 communicates the valve 82 with discharge tube 60 of dispensing head 58 , while a return line 86 communicates another outlet port of valve 82 with reservoir 72 . Thus, depending upon the position of control valve 82 , cleaning liquid may either be pumped to dispensing head 58 from reservoir 72 or by-passed back to reservoir 72 via return line 86 . Because pump 76 is preferably a peristaltic pump, it supplies liquid to dispensing head 58 in constant volume slugs or squirts that enable the cleaning liquid to be very precisely and accurately metered onto the lane surface. Furthermore, it permits the supply of liquid to dispensing head 58 to be essentially instantaneously stopped and started, which, in conjunction with control valve 82 , affords precise, board-by-board control over the pattern of cleaning liquid applied to the lane surface by dispensing head 58 .
[0027] Cleaning system 12 further includes a pin deck treatment assembly 83 at the rear of machine 10 . Pin deck treatment assembly 83 includes a pin deck treatment product can 85 operably connected to a trigger (push-pull) solenoid 87 . Discharge tube 61 is connected to product can 85 via quick disconnect fitting 89 , preferably at a “bag-on valve” in order to avoid product contamination. Product can 85 is preferably a replaceable aerosol can (typically with 14 ounces of capacity), with the pressure in the can used to propel the treatment liquid onto a lane surface when prompted to do so by solenoid 87 . That is, solenoid 87 is controlled by a PLC program to open and close the valve. In a preferred embodiment, a drip tray 91 is included. In these embodiments, tips 62 , 63 are positioned above drip tray 91 when in their “home” or non-working position, so that drip tray 91 catches any liquid that might drip from either of the tips 62 , 63 .
[0028] The preferred volume of product dispensed per lane should be from about 3 μL to about 7 μm. The volume can be controlled several ways, such as by controlling the amount of time the PLC opens the valve, by using an adjustable needle valve or specific tubing diameter, speed of the reciprocating head, and/or by incorporating different actuators that meter the volume. Some or all of these may be used in combination to control the amount of product that is dispensed per lane.
[0029] Any commercially available pin deck treatment compositions can be used with the present inventive method and equipment. One such composition is sold under the name Snowtack 765A by Lawter, Inc. In a preferred formulation, 30% by weight of the composition is mixed with 70% by weight water, and placed into an aerosol or otherwise pressurized can.
[0030] Cleaning system 12 additionally includes a wiping assembly 88 immediately behind cleaning liquid dispensing head 58 . Assembly 88 includes a web 90 of soft material such as duster cloth looped around a lower compressible back-up member 92 in the nature of a roller that extends across the full width of the machine. Cloth 90 is stored on a roll 94 and is paid out at intervals selected by the operator and taken up by a takeup roll 96 . Wiping assembly 88 is similar in principle to the corresponding wiping assembly disclosed in U.S. Pat. No. 6,615,434, hereby incorporated by reference into the present specification.
[0031] A further component of cleaning system 12 comprises a vacuum pickup head 98 located behind wiping assembly 88 . Vacuum pickup head 98 extends essentially the full width of machine 10 and includes a pair of flexible, squeegee-type blades 100 and 102 that assist in picking up the thin film of cleaning liquid left on the lane surface after the wiping assembly 88 has acted upon the liquid. A large vacuum hose 104 leads from pickup head 98 to a holding tank 106 for storing liquid picked up by head 98 . Vacuum pressure within holding tank 106 is obtained by means of a suction fan (not shown) coupled with tank 106 .
Operation
[0032] In use, machine 10 is energized and controlled through the use of a user interface panel 108 located adjacent the right rear corner of the machine. Using interface panel 108 , any one of a number of different patterns may be selected for applying cleaning liquid to the lane surface and for the application of dressing. Details of the oil pattern application using the dressing dispensing head 28 are described in the incorporated U.S. Pat. No. 5,729,855.
[0033] With respect to cleaning operations, as machine 10 travels along the lane surface the cleaning liquid dispensing head 58 reciprocates back and forth along its track 64 across the full width of the lane. Depending upon the distance down the lane as detected by the lane distance sensor 57 and the position of the dispensing head 58 across the width of the lane as detected by the transverse position sensor 52 , control valve 82 allows cleaning liquid from constantly operating pump 76 to be squirted onto the lane surface through the outlet tube 60 and tip 62 of dispensing head 58 . Although it is contemplated that dispensing head 58 may dispense cleaning liquid to the lane across the full width of the lane, it is also within the scope of the present invention to have cleaning liquid applied on a board-by-board basis for selective stripping or cleaning of the lane surface. The check valve (not shown) within tube 60 or tip 62 instantly closes the discharge path for cleaning liquid from head 58 when control valve 82 is shifted to a non-dispensing position. The check valve thus prevents leakage from dispensing head 58 during periods of non-use and provides a sharp demarcation between the presence and absence of cleaning liquid on the lane surface.
[0034] Cleaning liquid deposited by head 58 is immediately wiped into a thin film by cloth 90 looped around the backup roll 92 of wiping mechanism 88 . While much of the liquid and oil and dirt are removed by cloth 90 , a thin film remains, and this is engaged by the squeegees 100 and 102 of vacuum pickup head 98 . Pickup head 98 thus lifts all remaining moisture, oil and grime from the lane surface and deposits it in the holding tank 106 . As the rear of the machine passes over the cleaned region, the lane dressing is applied by applicator roll 26 in the pattern selected by the operator.
[0035] When the lane machine is programmed to start conditioning the bowling lanes, the operator will have the ability to either set a 7-day planner (to pre-program the desired days of the week to apply pin deck treatment) or choose to manually to apply the pin deck treatment for that particular operation. When using the lane machine of the '137 patent, the pin deck treatment can only be applied when operating that machine in the normal “Clean & Condition” mode or in “Clean Only” mode. As the lane machine moves in a forward motion, it will reach the end of the conditioner application distance and raise the buffer brush off the lane. When the input (in this example PLC Input 0.04) for the Brush Up Switch is closed, it will energize a relay to control two PLC outputs. One of the PLC outputs will be used to turn on and off the push-pull solenoid for the aerosol can triggering mechanism and the other changes the polarity of the power being sent to the Unwind Duster Motor (used for another feature).
[0036] As the machine enters the pin deck, it will slow and come to a stop when it has reached the programmed distance to the end of lane. Next, the machine will travel in reverse for a pre-set adjustable distance and stop, then it will energize the Duster Unwind Motor for a predetermined amount of time to lower the duster cloth onto the pin deck. The PLC will actuate the solenoid to open the valve on the pin deck treatment reservoir and apply a stream of pin deck treatment with the reciprocating head.
[0037] Once applied, the machine will begin traveling forward again for a pre-set adjustable distance to wipe or smear the solution onto the pin deck and then stop again. Typically, the machine will stop with the duster cloth at, or just behind, the rear row of pin spots. The Wind-Up Duster Motor will energize to wind up and lift the used cloth from the pin deck. Finally, the machine will travel in reverse and continue back to the foul line to finish its operation.
[0038] In one preferred embodiment, the machine will “park” both tips 62 and 63 over an absorbent pad (not shown) to collect any unwanted drips that might occur when the machine is traveling on the approach for either a walking or push machine. This prevents the discharge of the sticky pin deck treatment liquid onto the approach and ensures it is only deposited within the pin deck treatment area or zone.
[0039] In a preferred embodiment, a special function allows the machine to unwind more duster/cleaning cloth when the pin deck treatment option is selected. The amount of cloth used during this operation will be adjustable to eliminate the possibility of contaminating the cushion roller wrap or other parts of the cleaning system. When an operator chooses to enable the Pin Deck Treatment option, the Squeegee Wipe feature is turned off on the '137 machine, as well as other machines with that function.
[0040] It will be appreciated that the inventive pin deck treatment method and apparatus provide a number of advantages. For example, the entire process is automated and can be set as part of a routine schedule, making pin reset issues an unlikely occurrence. Additionally, the product stream is adjustable in width (lane boards covered from side to side) and length (longitudinal distance) via programming options in the PLC. Finally, using the reciprocating head and smearing the product with a duster cloth enables the machine to precisely apply the treatment to the desired areas of the pin deck and not anywhere else.
[0041] Although the above describes some of the preferred embodiments, it will be appreciated that variations can also be made while still being within the scope of the invention. For example, an alternate method for applying the pin deck treatment could be to use a separate reservoir, pump, and/or reciprocating head controlled by a PLC program to apply the treatment. This would require more components and an increased cost over the above description, but it may be useful in situations where a larger reservoir to store more product is desired.
[0042] Furthermore, as an alternative to the reciprocating head, the pin deck treatment could be sprayed onto the lane with one or more stationary spray nozzles as the machine exits the pinsetter. This method would be possible whether using an aerosol can or the separate reservoir and pump arrangement. Furthermore, rather than applying the pin deck treatment product directly to a pin deck, the product could be sprayed directly onto the duster cloth (or other membrane, pad, etc.) and then wiped onto the pin deck by the duster system in a similar pattern to the preferred method.
|
A lane maintenance machine has a cleaning system that includes at least one liquid dispensing head that reciprocates back and forth transversely of the lane as the machine travels along the length of the lane. The dispensing head includes a dispensing tip therein that emits a pin deck treatment product and applies it to a pin deck. The system provides accurate, precise metering of the pin deck treatment liquid and affords board-by-board control of the dispensing action. A wiping assembly immediately behind the dispensing head provides a web of cloth-like material looped under a compressible backup roller to wipe or smear the applied liquid. In a preferred embodiment, the dispensing head is a double head, and it includes a second tip for dispensing a cleaning solution so that pin deck treatment can take place with the same piece of equipment, after lane cleaning has taken place, making the entire process automated.
| 0
|
BACKGROUND OF THE INVENTION
The invention is in the field of machines for processing recyclable material, and particularly concerns machines that separate paper, bulk containers, broken glass and other materials.
More specifically, the invention relates to a disc screen apparatus for classifying material in a stream of heterogeneous materials. More specifically still, the invention concerns a disc screen apparatus with discs that may be mounted to and removed from the apparatus without disassembly of the apparatus.
Material recycling has become an important industry in recent years due to decreasing landfill capacity, environmental concerns and the dwindling of natural resources. Many industries and communities have adopted voluntary and mandatory recycling programs for reusable materials. Solid waste and trash that is collected from homes, apartments or companies often combine the recyclable materials into one container, usually labeled “RECYCLABLE MATERIAL”. Recyclable materials include newspaper, magazines, aluminum cans, glass bottles and other materials that may be recycled. When brought to a processing center, the recyclable materials are frequently mixed together in a heterogenous mass of material. Ideally, the mixed materials should be separated into common recyclable materials (i.e., papers, cans, etc.).
Disc screens are increasingly used to separate heterogeneous streams of recyclable material into respective streams or collections of similar materials. This process is referred to as “classifying”, and the results are called “classification”.
A disc screen apparatus typically includes a frame in which a plurality of rotatable shafts are mounted in parallel. A plurality of discs are mounted on each shaft and means are provided to rotate the shafts commonly in the same direction. The discs on one shaft interleave with the discs on an adjacent shaft to form screen openings between the peripheral edges of the discs and structures on the adjacent shaft. The sizes of the openings determine the size (and thus the type) of material that will fall through the screen. Rotation of the discs carries the larger articles along or across the screen in a general flow direction from an input where a stream of material pours onto the disc screen to an output where those articles pour off of the disc screen.
In disc screen apparatuses that are used for classification of recyclable materials I have found that the heavy continuous flow of recyclable material tends to result in quick wear and a significant degree of damage to the discs, requiring a high level of maintenance and repair. My observation is that the discs are typically slidably engaged to their shafts, fixed in their positions by spacers, and retained in the shafts by clamping applied to the ends of the shafts. Therefore, to replace a damaged disc, the shaft on which the disc is mounted must be disassembled from the screen, the disc slid off the shaft and replaced, and the shaft reassembled to the screen. Much time is consumed in this process.
SUMMARY OF THE INVENTION
The invention is based upon the critical realization that a disc for a disc screen apparatus can be provided in two (or more) matching pieces having opposing surfaces that are clamped together around a shaft. When damaged, the matching pieces are separated, removed from the shaft and replaced by the pieces of another, undamaged disc.
One of the principal objects of this invention is therefore to provide a disc screen apparatus for use in a heavy duty processing operation in which screen repair time must be minimized.
In connection with this objective, the invention is directed toward provision of a disc that can be attached to and removed from the shaft of a disc screen apparatus without disassembling the shaft from the screen apparatus.
The present invention provides a disc screen apparatus for separating mixed materials for recycling. The disc screen apparatus includes a frame with a mixed material input area in the frame near a first end of the frame, a paper discharge area in the frame near a second end of the frame, and a container discharge area in the frame. First and second pluralities of shafts, each having a plurality of discs attached thereto, are rotatably mounted in the frame to define first and second planes that extend at first and second angles, respectively. The second plane is angled upwardly from the first end of the frame to the second end of the frame so that the second angle is greater than the first angle. A lower portion of the second plane is disposed underneath a portion of the first plane in an overlapping relationship. Separate drive mechanisms are coupled to the first and second pluralities of shafts.
Other objects and advantages of the invention will become apparent when the following detailed description is read with reference to the below-described drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side view of a disc screen machine that embodies the invention;
FIGS. 2A-2C are top views of rotatable shafts and discs showing different screen configurations;
FIG. 3A is a side elevation view of a disc, with a portion cut away, showing certain elements with hidden lines;
FIG. 3B is an elevation view of an edge of the disc of FIG. 3A;
FIG. 3C is a top plan view of an edge of the disc of FIG. 3A;
FIG. 4A is a side elevation view, with a portion cut away, of one of two pieces of the disc of FIG. 3A;
FIG. 4B is an end elevation view of the one piece of FIG. 4A;
FIG. 4C is sectional view of the one piece, taken along C—C of FIG. 4A;
FIG. 5A is a side elevation view of a rigid frame or an embedment in the one piece of FIG. 4A;
FIG. 5B is a front elevation view of the embedment of FIG. 5A;
FIG. 5C is a sectional view of the embedment of FIG. 5A, taken along C—C of FIG. 5A;
FIG. 6 is a top view taken along 6 — 6 in FIG. 1 showing the relationship of the motor, rotatable shafts, pulleys and drive mechanism;
FIGS. 7A, 7 B and 7 C are views of a shaft assembly; and
FIGS. 8A and 8B show some details of the shaft assembly in FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
My invention is a disc screen apparatus (“hereinafter “apparatus”) that separates mixed recyclable materials, of various sizes and shapes, including paper, magazines, plastic or aluminum containers and the like. The apparatus, indicated generally by 100 , includes a frame (or housing) 102 , having a first plurality of rotatable shafts 108 (“first rotatable shafts”) and a second plurality of rotatable shafts 112 (“second rotatable shafts”) rotatably supported in the frame 102 . A first motor 118 mounted on the frame 102 is coupled to a drive chain 1 19 that imparts a rotational force to the first rotatable shafts 108 , while a second motor 130 , also mounted on the frame 102 , is coupled to a drive chain 131 that imparts a rotational force to the second rotatable shafts 112 .
Preferably, the frame 102 is constructed using durable, heavy duty materials, such as steel. The precise shape of the frame 102 , and its structure and layout, are subject to the design considerations and operational constraints of any particular application. However, in this example the frame 102 is a generally closed structure with an mixed material input area 104 , container discharge area 114 and a paper discharge area 116 .
Although the frame 102 forms an enclosure, this is not absolutely necessary to the invention, but it may be required for safety reasons. The mixed material input area 104 is generally located near a first end 105 of the frame 102 , where a heterogenous material stream 106 of recyclable materials enters the apparatus. As can be seen in FIG. 1, the material stream 106 travels through the mixed material input area 104 , and falls onto the first rotatable shafts 108 . The first rotatable shafts 108 rotate in such a direction that the material stream 106 travels from the first end 105 of the apparatus toward a second end 107 of the apparatus in a general flow direction. Mounted on the first rotatable shafts 108 are a plurality of discs 110 that both agitate and propel the material stream 106 . The discs 110 may be spaced on the shafts in a variety of patterns. Depending on the patterns of the discs 110 , the material stream 106 starts to separate in one way or another. In this manner, the first rotatable shafts 108 with discs 110 act as a first disc screen. (Hereinafter, these terms are interchangeable.) In the preferred embodiment, the discs 110 are positioned in the first disc screen so that the material stream 106 is initially screened, with small materials 120 passing through the openings and larger materials continuing along the first rotatable shafts 108 , all the while being agitated by the discs 110 . At the end of the plane of first rotatable shafts 108 , the larger materials fall onto the second rotatable shafts 112 (the direction shown as arrow 124 ). Mounted on the second rotatable shafts 112 are a plurality of discs 110 . Thus, the second rotatable shafts with discs 110 act as a second disc screen, and these terms are interchangeable hereinafter. The discs 110 may be mounted on the second rotatable shaft in a variety of patterns. The second rotatable shafts 112 are generally positioned in an inclined plane 160 that has an angle 162 . This inclined arrangement of the second rotatable shafts 112 allows heavier objects 122 , such as bottles and cans, to bounce on the discs 110 and tumble backward and downward toward the container discharge area 114 , finally falling out of the container discharge area 114 into a container or plenum 150 . Lighter material such as cardboard and paper falling on the second disc screen does not bounce and is carried toward and upwardly to the paper discharge area 116 . To assist in propelling the paper 126 toward the paper discharge area 116 , one or more fans 128 may be mounted near the first end 105 of the frame to blow air 130 at the second rotatable shafts 112 .
FIGS. 2A, 2 B and 2 C show examples of the discs 110 mounted on the first and second rotatable shafts 108 and 112 , with varied spacing, creating a variety of screen patterns. FIGS. 2A and 2B show examples of two screen patterns 202 and 204 of the discs 110 mounted on the first rotatable shafts 108 . FIG. 2A shows the discs 110 mounted on the shaft in a fine screen pattern, with small spaces between the edges of the discs 110 and adjacent shafts. One such space is indicated by 204 . This fine screen pattern 202 is used in the apparatus where small materials are screened. In FIG. 2B, the discs 110 are mounted in a gross screen pattern 206 with large openings such as 208 such that larger, heavier materials are able to fall through the openings 208 between the discs 110 . In some cases, it may be desirable to have a combination of spacings between the discs (i.e., have both small openings 204 and large openings 208 ). In this way, as the material stream travels along a plurality of rotating shafts, the mixed material is separated and screened in successive stages on one disc screen. One example combination pattern formed by varying the screen patterns is shown in FIG. 2 C. In fact, this pattern describes the layout of the first disc screen. In this regard, as the material stream pours onto the disc screen apparatus in the inlet are 104 on the fine screen pattern 202 , the material stream is agitated and moved by rotation of the discs with the shafts toward and over the gross screen pattern 206 . Over the fine screen pattern 202 , relatively fine grit, glass shards, and other small materials are screened out. Over the gross screen pattern 206 , larger objects such as cans, bottles, and envelopes pour through the larger openings onto the lower end of the second rotatable shafts 112 . In the preferred embodiment, the entire second disc screen has the gross screen pattern 206 of FIG. 2 B.
In the apparatus 100 , the first and second rotatable shafts 108 and 112 extend through and are supported between sides 136 (near side shown in FIG. 1) and 138 (far side) of the frame 102 . The first rotatable shafts 108 are located in a first plane and the second rotatable shafts 112 are located below and partially underneath the first rotatable shafts 108 in an overlapping manner, with the first three shafts 112 a , 112 b , and 112 c defining a plane that is parallel to that of the first rotatable shafts 108 , and the remaining twelve defining a second plane. In the preferred embodiment, the first plane is generally disposed at a slight incline from horizontal to assist in the initial separation of the material stream 106 . The first plane angle may vary from 0 to 45 degrees, with the preferred embodiment angle being 20 degrees. The second plane is generally disposed at an inclined angle such that the larger objects 122 do not readily go up the incline. The angle may vary from 25 to 60 degrees with the preferred embodiment angle being 35 to 45 degrees. In one embodiment, the frame 102 is mounted at a fixed first point 132 and a rotatable second point 133 . The frame 102 may be rotated up or down, with the first point 132 as the pivot point, to alter an incline angle of the frame 102 using ajack 134 at the second point 133 . This rotation of the frame up or down may also be used to vary the angles of the shafts.
The number of shafts is dependent on the size of the machine 100 and on intershaft spacing. In the embodiment shown in FIG. 1, the number of shafts in the first plurality of rotatable shafts 108 is less than the number of shafts in the second plurality of rotatable shafts 112 . In the FIG. 1, there are eight first rotatable shafts 108 and fifteen second rotatable shafts 112 . The first shafts 108 and second shafts 112 are supported by bushings or bearings 140 positioned along sides 136 and 138 .
The plurality of discs 110 , made from a hard durable material with a high coefficient of friction, such as rubber, are mounted on the first rotatable shafts 108 and the second rotatable shafts 112 to form the screen patterns shown in FIGS. 2A-2C; however, the discs 110 may be mounted along the first rotatable shafts 108 and the second rotatable shafts 112 in a variety of spacing patterns. The discs 110 on adjacent shafts are offset on their respective shafts such that the discs 110 on one shaft fit between (interleave with) the discs on the other shaft without touching the other shaft. This is best seen in FIGS. 2A-2C.
Referring again to FIGS. 1 and 6, in the preferred embodiment, the first motor 118 and second motor 130 are positioned on the side 138 (far side) of the frame 102 . The motors 118 and 130 are shown with dashed lines. A drive chain 119 attaches between the motor 118 and a drive sprocket 142 mounted on the end of the first shaft 108 a that is on the side of 138 (far side). A plurality of rotation sprockets 144 are mounted at the end of each first shaft 108 , that is on the side 136 (near side). A rotation chain 146 interconnects the plurality of rotation sprockets 144 , as shown in FIG. 1. A drive chain 131 attaches between the motor 130 and a drive sprocket 142 on the end of the second shaft 112 that is on the side 138 (far side). A plurality of rotation sprockets 144 are located at the end of each second shaft 112 on side 136 (near side). A rotation chain 148 interconnects the plurality of rotation sprockets 144 . Safety covers (not shown) cover the plurality of rotation sprockets and rotation chains. There may also be access doors or panels 151 on the sides 136 and 138 to allow access or viewing of the interior of the machine.
The first motor 118 turns the drive chain 119 and drive sprocket 142 , thereby rotating the first rotatable shaft 108 a in a first direction. Since all of the first rotatable shafts 108 are interconnected by rotation sprockets 144 and rotation chain 146 , all of the first rotatable shafts 108 rotate together in the first direction at the same speed. The second motor 130 turns the drive chain 131 and drive sprocket 142 , thereby rotating the second rotatable shaft 112 in a second direction. Since all of the second rotatable shafts 112 are interconnected by rotation sprockets 140 and rotation chain 148 , all the second rotatable shafts 112 rotate together in the second direction at the same speed. The rotating second direction of the second rotatable shafts 112 is in the same direction as the rotating first direction of the first rotatable shafts 108 . Each motor may rotate its plurality of shafts at a particular speed. In the illustrative embodiment, the rotation speed of the first rotatable shafts 108 is around 60-100 revolutions per minute (rpm) and the rotation speed of the second rotatable shafts 112 is around 200-300 rpm. Although the preferred embodiment couples the motors to the shafts by sprocket/chain drives, other couplings may be used including, but not limited to, transmission couplings, geared couplings, direct couplings, and so on. Alternatively, separate individual shafts may be powered by separate individual motors. Further, the motors may be stationed at positions other than those shown, both on and off the frame 102 as design and installation considerations dictate. The sizes of the motors are dependent on a number of factors such as the number of rollers, type of drive mechanism, and so on. For example, each may have a rating of around 3HP, with a 90 degree worm drive.
The operation of the disc screen apparatus 100 is as follows. Initially, the material stream 106 pours upon the first disc screen in the material entry area 104 . In the fine screen section 202 of the first disc screen, the material stream is agitated and small matter is screened out, falling downwardly through the apparatus 100 to be collected by conventional means. The material stream 106 is propelled upwardly by the rotation of the discs toward, over, and off of the gross screen section 206 . As it passes over the gross screen section 206 , intermediate-sized objects such as cans, twelve-ounce bottles and envelopes fall through the gross mesh onto to the lower end of the second rotatable shafts 112 . Meanwhile, the larger objects including large containers, newspapers, and cardboard sections of the material stream 106 are propelled off the upper end of the first disc screen onto the midsection of the second disc screen. Thus, the material stream 106 pours onto the second disc screen for screening already in a somewhat differentiated state, with smaller objects falling onto the lower rear portion of the second disc screen, and larger objects onto its midsection. The smaller objects are screened at the lower portion of the second disc screen, either passing through the gross screen pattern into the plenum 150 or tumbling downwardly off the lower end of the second disc screen into the plenum 150 . The larger objects that pour onto the midsection of the second disc screen separate, with the larger, heavier objects such as large bottles and plastic containers being bounced off the screen and rolling downwardly toward the lower end of the second disc screen from which they fall into the plenum 150 . Meanwhile, the larger light objects such as newspapers, magazines, and cardboard sections are carried upwardly by rotation of the second rotatable shafts 112 toward, over, and off of the upper end of the second disc screen from which they fall onto a collection conveyor 152 . A distinct advantage of this operation is that the material stream 106 is classified essentially into three sections on the first disc screen. Advantageously, the second disc screen receives a material stream that has been partially classified into smaller heavier objects that pour onto the lower portion of the second disc screen and a mixture of larger heavy and light objects that pour onto the second disc screen in its midsection. This avoids the prior art problem of a single, large, very dense stream of material pouring onto a single disc stream, creating a large eddying slurry of undifferentiated material at its impact point. As is known, such a large slurry reduces the effectiveness of a disc screen, providing less sharply differentiated collections of material than are afforded by the apparatus 100 .
FIGS. 3A-3C show details of a preferred embodiment of a disc 110 . The disc 110 is designed to be replaceable on a shaft, without disassembly of the shaft and/or removal of other discs therefrom. The disc 110 is designed to separate into two portions at a separation plane 306 into disc portion 302 a and disc portion 302 b . Screws 304 clamp the disc halves 302 a and 302 b together. A central opening 308 of the disc 110 is designed to fit on the rotatable shafts 108 or 112 . The central opening 308 comprises planar sections 310 . As can be seen in the figures, the rotatable shafts 108 or 112 are eccentric (preferably square) in configuration. This provides more planar contact between the rotatable shaft and the disc. Because of the design of the disc 110 , as the disc halves 302 a and 302 b are clamped around the rotatable shaft 108 or 112 , the planar sections 3 10 make contact with the flat sides of the rotatable shafts at four clamping surfaces 312 . This allows the disc 110 to clamp or grab a shaft 108 or 112 such that it will not freely spin on the shaft. This clamping design also eliminates the need for spacers or the like to be positioned between the discs 110 to create the desired screen patterns.
The disc 110 is (preferably) square in shape with an outer peripheral edge which includes four corners 314 . In the illustrated embodiment, the corners 314 are radiused to reduce the wear on the disc 110 during use. The radiused corners may also be textured with a variety of patterns. This texturing may assist in the or movement of materials with the disc 110 . In the illustrative embodiment shown, the corners 314 are textured with a plurality of ridges 316 . The outer peripheral edge of the disc 110 defines an annular impacting surface 330 . Also shown in the figures is a cylindrical shoulder 362 or boss integrally formed on and protruding from each side of the disc. The shoulder 362 allows for room between the impacting surfaces 330 of adjacent discs 110 when they are positioned in a fine mesh pattern. Further, the shoulders 362 of adjacent discs provide a lateral space within which the peripheral edge of an interleaved disc on an adjacent shaft may be received to create a small space such as the space 204 for fine material screening. (See FIG. 2A.) For the disc 110 to function well, it must have a flexible impacting surface 330 with high abrasion resistance for impacting the materials, while at the same time having a “sticky” surface with a high coefficient of friction. There are a number of materials, such as rubber, that may be used in making the disc 110 . A coating of material may also be applied to the impacting surface 330 .
With reference to FIGS. 3A, 4 A, 4 B, 5 A and 5 B, it should appreciated that the disc 110 comprises two identical halves, placed in opposition on a shaft and clamped thereto. Each half is referred to as a “portion”. In FIG. 3A, the disc 110 includes identical opposing portions 302 a and 302 b . As best seen in FIGS. 4A-4C, a disc portion 302 (representing both of portions 302 a and 302 b ) has an internal rigid frame or embedment 318 to which a rubber material 326 is molded. (Note, for accuracy, that portion 302 corresponds to portion 302 a , with its top and bottom ends rotated 180° ). Preferably, the rubber material is a 50 - 55 durometer rubber casting compression molded around the rigid frame 318 . The rigid frame 318 imparts stiffness to the disc portion 302 and improves the clamping force 312 when two disc portions 302 a and 302 b are clamped to a shaft. As shown in FIG. 5A and 5B, the rigid frame 318 includes a first unthreaded through hole 320 and a second, threaded hole 322 . Each of the holes 320 and 322 opens through a respective exposed clamping face 325 on a respective end of the rigid frame 318 . As best seen in FIG. 4A, a through hole 327 opens through the rubber material 326 from impacting surface 330 to the through hole 320 . Referring back to FIG. 3A, it can be seen that the disc 110 may be clamped to a shaft by bringing the two disc portions 302 a and 302 b together about the shaft such that the through hole 320 in the portion 302 a faces the threaded portion 322 in the portion 302 b , and the through hole 320 in the portion 302 b faces the threaded portion 322 in the disc portion 302 a . The two portions 302 a and 302 b are clamped by threaded screws 304 that are inserted through the through holes 327 , 320 , threaded ends first, and then threaded to the respective threaded holes 322 in the opposing disc portions. This securely clamps the disc 110 to a shaft.
Secure clamping is provided, in this regard, by the exposed opposing clamping faces 325 , over which the rubber material 326 does not extend. Thus, where the clamping force is applied, the clamping faces 325 of the rigid frames 318 within the opposing disc portions 302 a and 302 b are brought together in contact to provide a stiff, nonyielding clamping interface. In addition, the planar sections 310 , which are part of the rubber material 326 , are squeezed between the metal shaft and corresponding portions 310 a of the rigid member 318 . This compresses these planar sections 310 to such an extent that the disc 110 is firmly clamped to, and cannot slide along a shaft. Now, if the disc 110 is damaged and must be repaired or replaced, it can be dissembled from the shaft by dethreading the screws 304 , removing the portions 302 a and 302 b and replacing either or both.
Two significant advantages of the disc configuration illustrated in FIG. 3A are evident. First, the clamping force exerted by the screws 304 is not parallel to any of the planar sections 310 of the inner opening of the disc 110 and therefore is not parallel to any of the surface portions of the shaft 108 or 112 . In other words, there is a component of a clamping force vector that is normal to the interface between each of the clamping planar sections 310 and the shaft 108 or 112 . This advantageously distributes the clamping force around the interface between the inner opening of the disc 110 and the shaft 108 or 112 . Second, the plane 306 where the disc portions 302 a and 302 b are brought together defines a minute seam that extends to respective opposing flat portions of the impacting surface 330 . This is best seen in FIGS. 3A and 3C. Since the impacting surface 330 tends to contact the material stream at the comers 314 , filaments, such as strings or threads are less likely to snag in the seams than if they were located at the comers of the disc 110 .
The rigid frame 318 , shown in FIG. 5A-5C, may be made of metal, such as steel or aluminum, or a rigid plastic. In the preferred embodiment, the rigid frame is made from 356 aluminum casting that has been heat treated.
FIGS. 7A-7C and 8 A- 8 B show construction of details of the rotatable shafts 108 , 112 which are represented by a shaft assembly 400 . The shaft assembly 400 consists of a central axle tube 402 and two end spindle assemblies 404 , each disposed partially in the tube 402 , near an end. In the illustrative embodiment, the axle tube 402 has a square cross-section to which the disc 110 is clamped (see FIG. 3 A). The center of the axle tube 402 is generally hollow. Each spindle assembly 404 is constructed to mount within a respective end of the axle tube 402 . The spindle assembly 404 is comprises a central spindle 406 and attachment discs 408 . One end of the central spindle 406 is dimensioned to fit inside an end of the axle tube 402 while the exposed end of the spindle 406 is dimensioned to attach to a disc screen apparatus. In the present invention, the exposed spindle ends are sized to be compatible with the rotation bearings 140 , drive sprockets 142 and rotation sprockets 144 of the apparatus 100 . The attachment discs 408 are initially dimensioned to be larger than the central opening 410 of the axle tube 402 . In the configuration shown in FIG. 7 and 8, the attachment disc 408 is circular in shape with a circular center opening that is sized to fit over the spindle 406 . One or more attachment discs 408 are welded to the spindle 406 to form the spindle assembly 404 . The spindle assembly 404 is then positioned in a fixture where the attachment discs 408 are machined to press fit into the central opening 410 . Once sized, the spindle assembly 404 is press fit into the opening 410 a set distance. The attachment discs 408 are used to center and align the spindle 406 along the axis 414 of the shaft. A plurality of holes 412 in the axle tube 402 arc used to weld the attachment discs 408 in place, thus securing the spindle assembly 404 in the axle tube 402 , forming the axle assembly 400 . The axle tubes 402 , spindles 406 and attachment discs 408 are preferably made from high strength materials, such as steel.
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. For example, the discs may have shapes other than the square one shown, and may have central openings that have eccentric shapes including curved ones such as ellipses and regular ones such as triangles, quadrilaterals, and polygons.
|
A disc screen apparatus is disclosed for separating mixed recyclable materials of varying sizes and shapes. The disc screen apparatus has an enclosure or frame with an input, a container discharge location and a paper discharge location. A first plurality of shafts and second plurality of shafts are rotatably supported by the frame. The first plurality of shafts form a first disc screen disposed in a first plane and the second plurality of shafts form a second disc screen at least a portion of which is disposed in a second plane. The second plane is disposed beneath and angled with respect to the first plane such that the planes at least partially overlap. One or more motors rotate the first and second plurality of shafts. Each shaft has a plurality of discs positioned along it. The discs are offset between adjacent shafts such that discs on each shaft interleave with discs on an adjacent shaft but do not touch the adjacent shaft. The discs are substantially square in shape with radiused corners. The radiused corners have a texture, such as ridges. The arrangement of the discs on the shafts creates a screening pattern capable of screening a portion of the mixed recyclable materials. Each disc is assembled about a shaft from two identical portions. The portions are clamped together, about the shaft to form the disc. If the disc is damaged or worn, it may be removed from the shaft for repair or replacement without disassembly of the shaft from the apparatus or removal of other discs.
| 1
|
This is a division of application Ser. No. 633,897, filed Dec. 26, 1990.
BACKGROUND OF THE INVENTION
The present invention relates to a special section of well casing that is particularly useful in offshore wells that have under-compacted formations. As hydrocarbon production has moved into deeper waters offshore, the producing formations have often been younger, under-compacted reservoirs. As these reservoirs are produced, they compact which results in axial loading and casing deformation. In many cases, the deformation of the casing has been extensive enough to cause loss of the producing wells. Since offshore production is typically from a structure having limited space, the loss of a well can seriously affect the total production from the structure. Well replacement is typically difficult, if at all possible, and always results in significant additional expense. When conditions preclude well replacement, the hydrocarbon reserves are lost forever.
One obvious solution to the problem of casing damage caused by axial load due to formation compaction would be to provide some sort of slip joint in the casing that would allow the casing to shorten without damage such as buckling or collapsing. While the slip joint would solve the problem of buckled or collapsed casing, it requires seals or other means for isolating the formation from the interior of the casing.
In addition, if slip joints are used as part of a well casing, some means must be provided for preventing the slip joint from collapsing as the casing is installed in the well. In addition to preventing the slip joint from collapsing, structure must be included for preventing it from extending beyond its limits as the casing is hung free in the well. Both of these requirements involve complicated mechanical arrangements that are, of course, subject to failure in a well. Obviously, if the slip joint compresses during installation of the casing, it will not provide protection against casing collapse when the reservoir compacts.
SUMMARY OF THE INVENTION
The present invention solves the problem of casing damage due to axial load from formation compaction by providing a special casing joint which can compress or shorten as the formation compacts. The special casing section is also provided with means to limit its elongation so that it will not be unduly extended as the casing is installed in the well. While the elongation of the special casing section is limited, it is provided with unlimited compression or shortening ability within its designed limits. The shortening of each casing section is limited but practically any desired shortening can be obtained by using multiple lengths of the special casing section. In particular, the invention provides for a finite shortening per unit length of the special casing section. Thus, when additional provision must be made for shortening of the casing section as a result of compaction of the reservoir, one may provide additional lengths of the special casing section. In particular, the invention allows axial shortening of the casing string without unacceptable radial deformation and without requiring the seals that would be necessary in the case of a slip joint.
The special casing section can be visualized as a bellows or accordian that permits shortening of its overall length in response to axial load. It can best be described as a piece of casing or thick-walled tubular product that has grooves machined on both its outside and inside diameters. The grooves are of a particular shape and are located at precise axial distances from each other. Further, the number of grooves on the outside diameter is the same as the grooves on the inner diameter. The grooves typically have a U-shaped cross section in which the depth and axial location of the U's as well as their depth in relation to the thickness of the casing wall is closely controlled. In particular, the depth of the grooves is controlled so that an overlap occurs between the grooves formed on the inner diameter and those formed on the outer diameter. These dimensions are controlled so that when the special casing section is subjected to an axial load as occurs when the formation surrounding the casing compacts, the U-shaped grooves will close. The special casing section is designed so that the ends of the grooves adjacent the inner or outer surface of the casing close and convert the U-shaped groove into a teardrop-shaped groove.
The dimensions of the grooves are also controlled in relation to the material from which the special casing section is formed to ensure that the grooves, when collapsed, will form a teardrop section. This is necessary to ensure that the special casing section does not buckle or otherwise deform because the grooves failed to close. In some cases, a protective sleeve is placed around the special casing section and is designed to provide the strength required to prevent lateral buckling of the special casing section when the axial load is applied. In addition, the outer sleeve also protects the grooves and keeps them clear of cement or formation material as the special casing section is installed in the well. Obviously, if the grooves on the outer diameter became clogged with cement or formation material, it could interfere with the functioning of the tool. The protective sleeve also limits axial extension due to high axial tension load when the casing is being installed in the well.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more easily understood from the following detailed description of a preferred embodiment when taken in conjunction with the attached drawings in which:
FIG. 1 is an elevation view of the complete special casing section.
FIG. 2 is an elevation view of the special casing section shown in FIG. 1 with the outer protective sleeves removed.
FIG. 3 is an enlarged cross section of the grooves shown in the special casing section of FIG. 2.
FIG. 4 is a cross section of the grooves shown in FIG. 3 shown in a collapsed configuration.
FIG. 5 is a cross section of one portion of the casing shown in FIG. 1 with the protective sleeve installed.
FIG. 6 is a modified form of the casing shown in FIG. 1 shown half in elevation and half in section.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 there is shown an elevation view of the special well casing assembly 10. The special casing assembly is provided with tubular connections 11 and 12 at each end that can be used to join the special casing to the conventional well casing or to additional special casing assemblies. In the unit shown in FIG. 1, two separate sections of grooves are provided with the grooves being covered by protective sleeves 13 and 14.
In FIG. 2, there is shown the details of the casing section of the assembly shown in FIG. 1. Casing section 20 is provided with a series of grooves 23 on its outer surface at two separate locations 21 and 22. These separate sections of grooves are used on the casing 20 to provide maximum amount of axial shortening in a given length of the casing 20. Obviously, the amount that the casing 20 can be shortened by compression will depend upon the number and size of grooves provided. It is necessary to provide two separate sections of grooves because only a limited number of grooves can be formed on the interior diameter of the casing 20. The number of interior grooves is limited by difficulty of machining the interior grooves at a great depth within the casing. It is obvious that if a larger diameter casing were used, the forming of the grooves on the interior diameter of the casing would be simplified and in some instances, it may be possible to combine the two sections of grooves, 21 and 22, in a single group of grooves or provide a continuous series of grooves on the interior of casing 20.
Referring to FIG. 3, there is shown an enlarged cross section of some of the exterior and interior grooves formed on the casing section 20 of FIG. 2. In particular, the exterior grooves 23 formed on the outer surface are equally spaced between the interior grooves 24 and when the uppermost groove is formed on the inner surface, then it is desirable that the lowermost groove be formed on the outer surface as shown in FIG. 3. The uppermost and lowermost grooves maybe located either on outer or inner surfaces and regardless of their positions, the uppermost and lowermost grooves will collapse only approximately one-half the distance of the remaining grooves. It should be noted that while 14 grooves are shown on the outer surface of the casing 20 of FIG. 2, only 6 are shown in FIG. 3 due to the enlarged scale of the drawing of FIG. 3.
Obviously, grooves of different dimensions and different spacings may be used with the width and number of the grooves depending upon the total desired shortening of the casing section. The geometry of the grooves and the material used in the casing control the load required to shorten the casing. In the case of 71/4" well casing having a wall thickness of 11/16ths of an inch and formed of 85,000 psi minimum specified yield strength steel, grooves having the following dimensions provide excellent results when the casing is subjected to axial load. The width A of the grooves is 0.250 inches while the groove has a depth which leaves a wall thickness B at the bottom of 0.188 inches and the spacing C between the center line of grooves on the inner surface and those on the outer surface is 0.500 inches. Using these dimensions and providing a near perfect semi-circle at the bottom of the groove as shown in FIG. 3, the grooves will have a radial overlap between the maximum depth of the inner groove and those of the outer groove of approximately 0.313 inches. While grooves having parallel sides are preferred for ease of manufacturing, V-shaped grooves having a circular bottom could also be used. Further, the uppermost and lowermost grooves can both be located on either the outer or inner diameters in place of an equal number of grooves on the inner and outer diameters as shown.
The foregoing dimensions can be varied to vary some of the characteristics of special casing section. For example, to increase the collapse strength one can increase the spacing "C" between the grooves. As an alternative, the wall thickness B could be increased to increase the collapse strength of the casing.
Referring to FIG. 4, there is shown a section of the casing of FIG. 3 in a fully collapsed or shortened condition. As shown, the uppermost groove 25 on the inner surface is provided with a spacer 27 while the lowermost groove 25 on the outer surface is provided with a similar spacer 26. The spacers 27 and 26 have a thickness equal to one-half of the groove width to limit the closure of the upper and lowermost grooves to one-half the width of the groove. While it is preferable to use spacers 27 and 26 in the end grooves, tests have shown that the spacers can be eliminated and the casing will collapse uniformly under an axial load. In contrast, the remainder of the grooves can completely close until the outer edges of the groove touch to form a teardrop-shaped closed section 30 as shown in FIG. 4 with slight bulges forming on the inner and outer surfaces as shown.
Referring to FIG. 5, there is shown a cross section of the special casing shown in FIG. 1 with the protective sleeve 13 installed. Only the upper portion of the special casing shown in FIG. 5 is shown and the lower portion containing the protective sleeve 14 in the second set of grooves is omitted in the illustration. The protective sleeve 13 is provided with a vent hole 40 near its upper edge and a vent hole 41 near its lower edge. The vent holes serve to equalize the pressure between the interior of the sleeve and the exterior as the special casing section is installed in the well. In addition, the holes can be used for filling the void between the casing and protective sleeve with oil or grease. If the void is filled, the lower vent hole 41 should be closed with a threaded plug and the upper vent hole 40 sealed with a deformable plug that will move to allow the pressure to equalize. O-ring seals 42 and 43 are provided at the upper and the lower ends of the protective sleeve to exclude borehole debris from the interior of the sleeve and to allow pumping the cavity full of oil or grease.
The protective sleeve is secured to the casing section 20 by grooved and threaded rings at its upper and lower ends respectively. The upper connection is formed by annular grooves 50 on the interior surface of the sleeve and a C-ring shaped grooved section 52 that is secured to the casing section 20. The threaded connection at the lower end is formed by threads 51 on the inner surface of the sleeve and the threaded C-ring 53. It should be noted that the grooves and threads are modified buttress-type with the inclined surfaces of the buttress facing each other as shown in FIG. 5. The lower threaded C-ring is held in position and prevented from turning by a set screw 54 which passes through a slot between the end of the ring and threads into the wall of the casing section 20 while the upper grooved C-ring 53 is free to rotate. This allows the lower ring to be threaded onto the outer sleeve and the sleeve to slide upwardly as explained below.
The sleeve is assembled on the exterior of the casing 20 by first installing the upper C-ring 52 on the exterior surface of the casing 20. The sleeve can then be slid over the bottom of the casing section 20. As the sleeve is moved upward the C-ring 52 will slide up until it is aligned with recess 57 at which point it will be forced into the recess by the sleeve and the sleeve will ratchet over the ring. The sleeve is raised further until the lower end of the sleeve clears the recess 56. The C-ring 53 can then be installed in the recess 56 and the ends of the C-ring positioned so that the set screw 54 can be installed. The sleeve can then be lowered along the casing 20 by sliding the sleeve over the C-ring 53 until both C-rings are aligned with grooves 50 and threads 51. The sleeve can then be rotated relative to the body. As the sleeve is threaded onto the C-ring 53, the C-ring 52 will contact shoulder 58 and C-ring 53 will contact shoulder 59 as shown in FIG. 5.
While the casing cannot stretch as it is installed, the compression or shortening of the casing section is limited only by the number of grooves 23 and 24 and their width. As the casing section 20 collapses or shortens by the closing of the grooves 23 and 24, the lower C-ring 53 will slide down the outer surface of the casing section 20. Once the C-ring 53 aligns with the recess section 56, the sleeve will slide over the threads on the C-ring 53 and allow the casing to be shortened until the grooves completely close as shown in FIG. 4. The similar action occurs at the top C-ring.
FIG. 6 illustrates a modified form of the special casing section that is easier to manufacture while providing a means for obtaining any desired axial shortening in a single casing section. The modified casing has two end sections 63 and 64 that are joined to a center section 65 by welds 70 and 71. Obviously, as many center sections as needed can be used to provide any desired axial shortening. The center section may be provided with annular flanges 66 having rounded corners. The flanges 66 stabilize the special casing and help ensure that the grooves will close and the casing shorten under an axial load without buckling. The flanges 66 slide on the inner surface of the modified protective sleeve 60. The modified sleeve 60 is the same as sleeve 13 except it is longer to accommodate the increased length of the special casing. The sleeve 60 is attached to the special casing using the same grooved ring 52 and threaded ring 53 as described above and illustrated in FIG. 5.
The modified casing is assembled in the same manner as described above and illustrated in FIG. 5. It should be noted that the end sections 63 and 64 are provided with larger outer diameter sections at their ends. This provides the wall thickness required for the ring and thread arrangement used to secure the protective sleeve to the casing section. The use of larger diameter sections at the ends of sections 63 and 64 allows the use of thinner walled sections where the grooves are formed. This configuration facilitates the manufacture of the sleeve by allowing the use of a constant diameter for the sleeve and still provide clearance between the sleeve and the casing section. This also produces stiff end sections and optimum grooved sections and uniform axial shortening of the casing section under axial load.
From the above description it can be readily appreciated that this invention has provided a special casing section which can shorten a designed amount thus minimizing the axial load and prevent buckling or collapsing. In addition, provisions are made for limiting the elongation of the special casing section so that the casing can be installed as a portion of the regular well casing and hung in a well without danger of the casing elongating to an extent that would cause parting of the casing. The use of the protective sleeve on the outer surface of the casing serves the dual purpose of providing strength to the casing to prevent its lateral buckling or otherwise deforming and to exclude formation debris from the grooves formed on the outer surface of the special casing. The protective sleeve also carries a portion of the axial load when the casing is being installed in a well and hanging free in the well. The grooves formed on the interior surface of the casing can be filled with a deformable plastic to exclude debris from these grooves. The deformable plastic will be extruded from the grooves when the casing is subject to a compression load.
The protective sleeve can be eliminated when the weight of the casing suspended below the special casing does not exceed its design limits and the special casing is laterally supported by the cement.
|
A method and apparatus for preventing casing damage due to high axial loading in a well as a result of compaction of the surrounding earth formations. The method consists of providing specially sized and located grooves on both the inside and outside diameters of a section of well casing. The grooves are designed and spacers may be used in some grooves to ensure symmetrical deformation of the casing when subjected to a compressive loading.
| 4
|
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/370,794 filed Apr. 8, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to the interaction of a medium with its external environment. It relates particularly to a device for automatically controlling the interaction of a medium with its external environment.
[0004] 2. Description of the Related Art
[0005] The interaction of a medium with its external environment has occupied the attention of many innovators over a considerable period of time, especially in the recent past and continuing through the present day. For example, a number of devices for modifying air quality have appeared and continue to appear on the market. These devices, which volatilize and dispense a medium, such as an air freshener, into a room or automobile interior, are often the subject of Unites States Patents. Exemplary of such United States Patents are the following: U.S. Pat. Nos. 6,361,752; 6,123,935; 6,141,496; 6,514,467; 6,416,043; 6,267,297; 6,103,201; 5,932,147; 5,253,804; and 4,754,696. Howsoever efficacious, these devices are found wanting in that they do not provide for automatic control of the interaction of the medium with the external environment, the temperature of which is often variable, not do they provide constant effectiveness of the medium in the external environment is afforded. Furthermore, presently available devices do not provide for automatic control of the interaction of a medium, and the constant effectiveness thereof with an external environment, when the desired interaction is something other than volatilizing and dispensing—that is to say, absorbing, absorbing and chemically reacting, among other interactions, are not provided for.
SUMMARY OF THE INVENTION
[0006] It is accordingly a primary object of the present invention to obviate the disadvantages of the related art. This object is achieved, and attending benefits are obtained, by the provision of the present invention, which is a device for automatically controlling the interaction of a medium with an external environment the temperature of which varies or remains constant. The device includes a medium, which is one or more of the following: a temperature-sensitive medium, a moisture-sensitive medium, a chemically-reactive medium, an evaporative medium, and an absorptive medium. The medium can be a liquid, solid, gas, fiber, gel, or an encapsulated material. The instant device also includes a mechanism for providing constant effectiveness of the medium in the external environment, as well as an automatic drive mechanism, which communicates with and drives the mechanism providing constant effectiveness of the medium in the external environment, so that a desired interaction of the medium with the external environment is afforded.
[0007] The instant drive mechanism advantageously includes a container for the medium, which is preferably a receptacle having a housing which incorporates the mechanism for providing constant effectiveness of the medium in the external environment, which is beneficially a movable vent or an expandable vent. The movable vent is preferably one or more of the following: a movable shutter, a movable louver, a movable orifice, and a movable sheath. The automatic drive mechanism, which communicates with and drives the mechanism for providing constant effectiveness of the medium in the external environment, is advantageously a temperature-responsive member or a temperature-responsive fluid movement device. The temperature-responsive member, which manifests variations in the surface area thereof as the temperature thereof is varied, is preferably a linear spring, a spiral metallic spring, a multi-metallic spring, a polymeric spring, or a pop spring.
[0008] Excellent results are obtained if the device of the present invention also includes a static vent, which is securely positioned within the housing in substantial alignment with a movable vent, and the movable vent is driven by the automatic drive mechanism to move relative to the static vent, so that constant effectiveness of the medium in the external environment is provided by varying the exposure of the medium in the external environment. The static vent is advantageously a static orifice, a static louver, or a static sheath. Especially beneficial results are achieved for some media if the movable vent and the static vent have essentially the same geometric shapes, so that constant effectiveness of the medium in the external environment is achieved by varying the exposure of the medium to the external environment in a substantially linear fashion. Especially beneficial results are also achieved for some media in the movable vent and the static vent has essentially different geometric shapes, so that constant effectiveness of the medium in the external environment is achieved by varying the exposure of the medium to the external environment in a substantially non-linear fashion.
[0009] Additional preferred embodiments of the device according to the present invention includes a device having a cooperating mechanism for presenting an on/off condition at chosen levels of exposure of the medium to the external environment, as well as a device having a cooperating mechanism for inducing a temperature change in the medium, the latter mechanism being advantageously a programmable heater such as a thermal profile generator or a time/temperature thermal profile generator. When a programmable heater is employed, beneficial results are obtained if the mechanism is provided to cooperate with the programmable heater and present a signal evincing the end of a programmed cycle.
[0010] Additional preferred embodiments of the device according to the present invention includes a mechanism for inducing air currents across the medium contained in the receptacle. Such a mechanism for inducing air currents is preferably a fan programmed for continuous operation at a substantially constant blade speed, or a fan the blade speed of which is controlled by the automatic drive mechanism.
[0011] In another preferred embodiment, the device according to the present invention has a housing which includes a front face and a back face, which are joined together to form a slot therebetween. The slot functions as the reservoir for the medium, which is configured in the form of a sheet having two major surfaces. The sheet is configured to fit within the slot and is capable of movement therein. At least one of the front face and the back face of the housing has at least one fixed vent therein. A temperature responsive member, which serves as the automatic drive mechanism, is connected to a holder for medium, which moves the medium within the slot as a result of changes in temperature, so that the medium is oriented with respect to the at least one vent for communication therethrough with the external environment. The major surfaces of the medium have at least one masked area and at least one unmasked area thereon, each masked and unmasked area having substantially the same shape and surface area as the at least one fixed vent. The at least one masked area is in substantial alignment with the at least one fixed vent when the external environment is at a first temperature, and the at least one unmasked area is in substantial alignment with the at least one fixed vent when the external environment is at a second temperature, the first temperature being higher than the second temperature.
[0012] Yet another preferred embodiment of the present invention is a device having a housing which includes a first concave face and a second concave face, which faces when joined together form an integral, hollow enclosure. The first concave face and the second concave face are connected together at one area thereof on one edge thereof by means of a hinge. The second concave face contains the medium therein. The automatic drive mechanism is a bimetallic spring, which is attached to the first concave face and the second concave face, respectively, in the vicinity of the hinge. The first and second concave faces are positioned apart to expose the medium to the external environment when the external environment is at a first temperature, and the first and second concave faces are drawn together by means of the bimetallic spring to form an integral hollow enclosure when the external environment is at a second temperature, the first temperature being lower than the second temperature.
[0013] Yet another preferred embodiment of the present invention is a device having a housing for the receptacle for the medium, and an automatic drive mechanism which is a temperature-responsive member such as a spring. For this embodiment the external environment is a liquid, and the medium is a liquid or a powder which is contained in the receptacle. In this embodiment the device additionally includes a mechanism for automatically dispensing the medium from the receptacle into the liquid external environment, which mechanism for automatically dispensing the medium is driven by the automatic drive mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For a more complete understanding of the present invention, including its primary object and attending benefits, reference should be made to the Detailed Description of the Invention, which is set forth below. This Detailed Description should be read together with the accompanying drawings, wherein:
[0015] [0015]FIGS. 1A, 1B, 1 C, 1 D, and 1 E depict a first preferred embodiment of the present invention in schematic representations, including exploded perspective, sectional, and top views thereof, respectively.
[0016] [0016]FIGS. 2A, 2B, 2 C, 2 D, and 2 E depict a second preferred embodiment of the present invention in schematic representations, including exploded perspective, sectional, and top views thereof, respectively.
[0017] [0017]FIGS. 3A, 3B, 3 C, 3 D, 3 E and 3 F depict a third preferred embodiment of the present invention in schematic representations, including exploded perspective, sectional, top views, and a section view thereof, respectively.
[0018] [0018]FIGS. 4A, 4B, 4 C, 4 D, and 4 E depict a fourth preferred embodiment of the present invention in schematic representations, including exploded perspective, sectional, and top views thereof, respectively.
[0019] [0019]FIGS. 5A, 5B, 5 C, 5 D, and 5 E depict a fifth preferred embodiment of the present invention in schematic representations, including side views and detailed views thereof, respectively.
[0020] [0020]FIGS. 6A, 6B, 6 C, 6 D, and 6 E depict a sixth preferred embodiment of the present invention in schematic representations, including a perspective and exploded perspective view thereof, respectively.
[0021] [0021]FIG. 7 schematically depicts the platform spring assembly employed in the embodiment of FIG. 6B.
[0022] [0022]FIGS. 8A and 8B schematically depict a vented and a non-vented shutter, respectively, for employment in the embodiment of FIG. 6B.
[0023] [0023]FIGS. 9A and 9B schematically depict in sectional representation a seventh preferred embodiment according to the present invention.
[0024] [0024]FIGS. 10A and 10B schematically depict in sectional representations an eighth preferred embodiment according to the present invention.
[0025] [0025]FIG. 11 schematically represents two asymmetric profiles for vents which are employed in preferred embodiments according to the present invention.
[0026] [0026]FIGS. 12A, 12B, 12 C, 12 D, 12 E and 12 F schematically depict a ninth preferred embodiment according to the present invention.
[0027] [0027]FIGS. 13A, 13B, and 13 C depict a tenth preferred embodiment of the present invention in schematic representations, including an exploded sectional view and two sectional views thereof, respectively.
[0028] [0028]FIGS. 14A, 14B, 14 C, 14 D, 14 E, and 14 F schematically depict an eleventh preferred embodiment of the present invention, which is very closely related to the embodiment depicted in FIGS. 3 A- 3 F.
[0029] [0029]FIGS. 15A, 15B, and 15 C depict a twelfth preferred embodiment of the present invention in schematic representations.
[0030] [0030]FIGS. 16A, 16B, and 16 C schematically depict a thirteenth preferred embodiment of the present invention, which is very closely related to the embodiment depicted in FIGS. 15 A- 15 F.
[0031] [0031]FIGS. 17A and 17B depict a fourteenth preferred embodiment of the present invention in schematic representations, including a perspective and exploded perspective view thereof, respectively.
[0032] [0032]FIGS. 18A and 18B depict a fifteenth preferred embodiment of the present invention in schematic representations, including an exploded view and a detailed view of some of the components thereof, respectively.
[0033] [0033]FIGS. 19A, 19B, 19 C and 19 D depict a sixteenth preferred embodiment of the present invention in schematic representations.
[0034] [0034]FIGS. 20A and 20B depict a thermal response housing assembly, which is a component of the embodiment of FIGS. 19 A- 19 D.
[0035] [0035]FIGS. 21A, 21B, 21 C, 21 D, and 21 E are schematic representations illustrating the operation of the thermal response housing assembly of FIGS. 20 A- 20 B.
[0036] [0036]FIGS. 22A, 22B, and 22 C are schematic representations of a seventeenth preferred embodiment of the present invention, which is a closely related to the sixteenth preferred embodiment represented in FIGS. 19 A- 19 D.
DETAILED DESCRIPTION OF THE INVENTION
[0037] Referring now to the drawings in detail, FIG. 1A illustrates the most basic configuration of the embodiments. The automatically controlled device comprises only three pieces: an outer housing with static vents (hereafter referred to as housing) 1 , a medium 2 , which is shaped into a movable shutter 2 (hereafter, the medium and shutter will be used interchangeably, contingent on the explanation needed) and a spring 3 .
[0038] Vent is defined as the group consisting of louvers, orifices, sheaths, and other geometrical openings that allow the medium to communicate with its external environment.
[0039] In a preferred embodiment, the spring has an unrestrained end 4 and a stationary end 5 . The shutter 2 serves two purposes: it functions as the medium and the shutter 2 . The shutter 2 comprises multiple movable vents 16 that are equally spaced circumferentially and a centrally located unrestrained spring end attachment hole 7 .
[0040] The shutter 2 for this application is comprised of a member of the group of homogeneous, non-homogeneous, multi-layered and combined materials.
[0041] An example of a homogeneous material would be naphthalene and is used as the active and medium 2 . Naphthalene is used for mothballs. This material is molded into the shape of a shutter 2 .
[0042] An example of a non-homogeneous material is an active, impregnated into a carrier material, such as cardboard, plastic, or compressed sawdust. The shutter 2 is made of a mixture of cardboard particulates, plastic and active and molded into or impregnated into the shape of a shutter 2 . The plastic acts as the binder and the cardboard is used to absorb and disperse the active. The example of an active in this case is a fragrance.
[0043] An example of a layered or laminated structure is a medium comprising progressive layers, in any permutation, of a homogeneous layer, a non-homogeneous layer and even a layer where the active is encapsulated by a plastic coating (e.g. microspheres).
[0044] The shutter medium 2 is placed onto the unrestrained end of the spring 4 via the centrally located spring attachment hole 7 . The spring and shutter assembly is inserted into the housing 1 until the assembly passes through, snaps in, and sits onto the spring and shutter assembly retainers 9 . The shutter assembly is then rotated until the stationary end of the spring 5 snaps into the spring retaining slot 10 . Once the entire assembly is complete, the device is functional.
[0045] The changes in ambient temperature control the rotation and alignment of the shutter vents 16 to the static vents 6 . The device is set so that when the ambient temperature increases or decreases, the shutter vents 16 and the static vents 6 can either be totally aligned, misaligned or any configuration in between. In this preferred embodiment, when the ambient temperature reaches its maximum designed temperature, the shutter vents 16 and the static vents 6 are in total alignment FIG. 1C at 11 and minimal medium 2 is exposed to the external environment 21 . This occurs because both the static vents 6 and the shutter vents 16 have substantially the same geometric shapes. When the device reaches its lowest designed temperature, the static vents 6 and shutter vents 16 are in total misalignment, thereby exposing the maximum amount of medium FIG. 1E at 12 through the static vent 6 and into its external environment 21 .
[0046] FIGS. 2 A- 2 E illustrate a four-piece device that comprises a housing 1 , a shutter 15 , a spring 3 , and a medium 13 .
[0047] The device functions similar to the device in FIG. 1A, with two exceptions: the shutter 15 , although identical in design to the medium FIG. 1A at 2 , does not serve the purpose as the medium 13 . The medium 13 is a separate refillable item.
[0048] The device is assembled in the same manner as the device in FIG. 1A, with the exception that the shutter assembly is now inserted into the housing 1 until it snaps into and comes to rest on the shutter assembly retainers 9 . The shutter assembly is then rotated until the stationary spring end 5 snaps into the spring retaining slot 10 .
[0049] The medium 13 has an extended pull-tab 20 to aid in insertion and removal of the medium 13 . The medium 13 is ultimately inserted into the housing 1 until it snaps into and comes to rest upon the medium retainers 14 .
[0050] A medium barrier 22 has been added to the back of the medium 13 to act as a barrier 22 so that the face of the medium 13 will only communicate with its external environment 21 through the shutter vents 16 and the static vents 6 . This forces the medium 13 to communicate with its external environment 21 solely through the automatic control system of the device.
[0051] The shutter's 15 only function in FIGS. 2 A- 2 E is to change the amount of exposure and the degree to which the medium 13 is allowed to communicate with its external environment 21 . As the temperature changes, the non-restricted spring end 4 rotates thereby causing the shutter 16 to align or misalign with the static vent 6 .
[0052] In this preferred embodiment, increasing ambient temperatures will cause the spring 3 to expand and rotate the shutter 15 counterclockwise until the shutter vents 16 are in total misalignment with the static vents 6 . This creates the situation where the static vents 6 are totally blocked off by the interference of the areas of the shutter that are non-vented 12 and results in virtually no communication of the medium 13 with its external environment 21 .
[0053] The opposite result occurs when the ambient temperature decreases. The spring 3 contracts and causes the shutter 15 to rotate clockwise. As the shutter vents 16 become increasingly more aligned with the static vents 6 , perfect alignments are ultimately achieved between the static vents 6 and the shutter vents 16 . In this configuration, the shutter 15 creates no restriction of the static vents 6 . This is depicted in FIG. 2C at 11 . This configuration allows the medium 13 to communicate fully and maximally with its external environment 21 .
[0054] This preferred embodiment and the way in which the shutter 15 rotates is ideal for a fragrance medium. Fragrances exposed to high ambient temperatures typically exhibit high vapor pressures and evaporation rates. This results in a high level of perceived fragrance strength by the consumer if left uncontrolled. The opposite is true if the fragrance medium is subject to low ambient temperatures. The consumer perceives the fragrance strength as weak or insufficient if left uncontrolled. Ideally, the perceived strength of the fragrance would be linear and independent of temperature. This device does just that; it removes the external variable of temperature variation on the medium 13 by automatically controlling the degree to which the medium is allowed to communicate with its external environment 21 throughout its useful temperature range. This is determined by the degree that the non-vented shutter areas 12 block off the static vents 6 in response to temperature change. In this preferred embodiment, the shutter 15 increases the exposure and communication of the medium 13 to its external environment 21 when the temperature decreases, by progressively minimizing the degree to which it blocks off the static vents 6 . It also progressively decreases the blockage of the static vents 6 as the temperatures rises. The result is the device increases the exposure of the medium 13 to its environment 21 when the fragrance is perceived as being weak and ineffective and decreases the exposure or communication of the medium 13 to its surroundings 21 when the fragrance is perceived as too strong or overpowering. The progression of how the shutter controls the ability of the medium 13 to communicate with its external environment 21 is depicted in FIG. 2C, FIG. 2D, and FIG. 2E. FIG. 2C shows the static vents 6 and the shutter vents 16 in total alignment 11 . FIG. 2D shows the shutter 15 beginning to close. The non-vented shutter area 12 is partially blocking off the static vent 6 . FIG. 2E shows the static vent 6 totally blocked off by the non vented shutter area 12 . The automatic rotation of the shutter 15 with changing temperature, linearizes the perceived strength of the fragrance with changing temperatures and therefore blocks out the external temperature variable the fragrance is affected by and exposed to.
[0055] It must be noted that the spring 3 can be turned over. It will then rotate in the opposite direction and move clockwise with increasing temperatures and counterclockwise with decreasing temperatures. It accomplishes the opposite results and increases the exposure of the medium 13 when hot and decreases the exposure of the medium 13 when cold. This design set up is useful for controlling and optimizing the efficacy of various insect control media; such as pheromones, insecticides, and repellants when insects are most active (hot weather) and requires the maximum amount of medium 13 exposure and helps prolong the useful life of the medium by blocking of exposure of the medium 13 to its external environment when the insects are not active. This set up is also useful for absorptive medium types.
[0056] FIGS. 3 A- 3 E illustrate a five-piece device, which includes a hosing 1 , a shutter 15 , a spring 3 , a reservoir 18 , and a medium 19 .
[0057] The device in FIGS. 3 A- 3 E is assembled in the same manner as the device in FIGS. 2 A- 2 E with the exception of adding and affixing a reservoir containing the medium 18 instead of just the medium itself FIG. 2A at 13 . The reservoir 18 is installed by inserting it into the housing 1 until the lip on the reservoir 17 snaps into and comes to rest on the reservoir retainer's 14 . The device functions, in all aspects, identically to the device in FIG. 2A.
[0058] FIGS. 4 A- 4 E illustrates a device comprising three-pieces: a housing 1 , a medium acting as a shutter (hereafter referred to as the shutter) 2 and a manually adjustable spring 3 .
[0059] The housing 1 is comprised of static vents 6 , a spring adjustment-retaining slot 24 and a shutter rotation limiter tab 25 . The spring adjustment retaining slot 24 is required to retain the spring adjuster tab 23 and allow enough lateral movement of the spring-adjuster tab 23 to move the medium 2 to the desired position in relation to the static vents 6 . The shutter rotation stop tab 25 cooperating with the shutter rotation stop slot 26 is required to insure the shutter doesn't travel beyond its intended maximum and minimum distances of travel. In essence, the spring is not allowed to over travel its design limits. If the device was designed to expose no medium to the external environment at 120 F, the shutter stop 25 inhibits the shutter from rotating beyond the desired alignment of the shutter vents 16 to the static vents 6 . In this case, perfect alignment of the vents would expose no medium to the environment and satisfy the desired effect. However, without the stops 25 , the shutter 2 will continue to rotate, as temperatures greater than the 120 F design temperature are present. This will actually begin to expose the medium to the environment again, even though it would be highly undesirable. The same is true for minimum designed temperatures. Once the lowest design temperature is present, the maximum amount of medium 2 is exposed to the environment 21 and further decreases in temperature will have no affect on the ability of the shutter to rotate; the shutter rotation stop 25 insures this.
[0060] When the consumer desires to vary the amount of medium 2 exposed to the external environment 21 , the consumer will move the manual spring-adjuster tab 23 left or right.
[0061] In a preferred embodiment, and using a fragrance medium as an example, the consumer would move the spring-adjusting tab 23 clockwise (right) to reduce the exposure of the medium to its environment 21 if the consumer perceived the fragrance strength as being too strong and counter clockwise to expose more of the medium 2 if the fragrance strength was perceived as being too weak. It must be noted, that the manual spring adjuster 23 concept may be used in many of the following devices as well, to set or vary an infinite amount activation temperatures within the useful temperature range, simply by preloading or unloading the spring. This would be done to satisfy the needs of specific applications.
[0062] Once the consumer moved the spring adjuster tab 23 to the desired setting, the automatic features of the device would take over again, at the new set point, and continue to automatically compensate for variations in ambient temperature. The manual adjustment feature is desirable to the consumer because it allows the consumer to personally tailor the device to individual needs, preferences, and specific applications.
[0063] The device is installed in the same manner as the device in FIG. 1A with the exception that the spring 3 needs to be manually compressed to give the spring adjuster tab 23 the clearance necessary to be inserted into the housing 1 and snap into and come to rest on the spring assembly retainers 9 . Once located on the spring assembly retainers 9 , the spring assembly is rotated until the manual spring adjuster tab 23 pops through the spring adjuster-retaining slot 24 . The device is now assembled and ready for use.
[0064] [0064]FIG. 5A illustrates a device that comprises an upper housing 27 , a lower housing 28 , a hinge 29 , a medium 37 , and a bimetallic spring 36 .
[0065] The upper housing 27 and the lower housing 28 are connected by a hinge 29 and will be hereafter referred to as the housing assembly. The hinge is comprised of a member of the group consisting of mechanical hinges, fasteners, or integral plastic hinges.
[0066] [0066]FIG. 5D illustrates the top spring retainer assembly. The top spring retainer 34 contains a slot 31 and a top wedge hook 39 for securing the top end of the bimetallic spring 30 . FIG. 5C illustrates the bottom spring retainer assembly. The bottom spring retainer 35 also contains a slot 33 and a bottom wedge hook 38 for securing the bottom end of the spring 32 .
[0067] The medium 37 is contained in the lower housing 28 . In this case, the lower housing 28 is acting as a medium reservoir as well.
[0068] [0068]FIG. 5A illustrates the device fully open, maximizing the exposure of the medium 37 to its external environment. Its appearance resembles an open clam shell. The device in FIG. 5A develops this configuration when the ambient temperature is the coldest and causes the bimetallic spring 30 to contract.
[0069] [0069]FIG. 5B illustrates the device fully closed, minimizing the exposure of the medium 37 to its external environment. The closure of the device is a result of high ambient temperatures expanding the spring 36 and forcing the housing assembly to close shut.
[0070] This is consistent with the previously described methods to control the perceived strength of a fragrance. When the ambient temperatures increase, the fragrance components increase in vapor pressure, evaporation rate, and perceived fragrance strength to the consumer. The opposite is true as ambient temperatures decrease. The device controls this, by opening up and allowing the medium 37 to communicate fully to its external environment when the ambient temperature is cold and the vapor pressures are at their lowest, as well as closing down, to restrict communication of the medium 37 with its external environment when the ambient temperatures get hot and the vapor pressures are at their highest.
[0071] The device in FIG. 6B comprises a rear housing 41 , a front housing 40 , a spring assembly (FIG. 7), and a manual platform adjuster 56 . The device uses two types of shutters that also function as the medium. FIG. 8A illustrates a vented shutter 61 and FIG. 8B illustrates a non-vented shutter 63 comprising masked off areas of the shutter.
[0072] The rear housing 41 comprises a shutter grip slot 59 , two shutter guide rails 45 , an axle-bearing slot 47 , a shutter slot 44 , two platform stops 46 and four front housing attachment pegs 42 .
[0073] The front housing 41 comprises a shutter grip slot 59 , a shutter slot 44 , static housing vents 55 , attachment peg receptors 43 , and an axle hole 58 .
[0074] The platform spring assembly (FIG. 7) comprises a spring 49 , a fixed spring end anchor 51 , a movable spring end pivot 52 , an axle 50 , a shutter platform connecting rod 53 , a shutter platform 48 , and a shutter platform connecting rod pivot 54 .
[0075] The vented shutter in FIG. 8A at 61 has punched out holes to define the movable vents 62 . The masked off shutter FIG. 8B at 63 illustrates a shutter that has the typical vent portions “masked off” with a barrier material as discussed in FIG. 2A at 22 and is designated as the masked area 64 . There are no holes or vents punched in this card; the card is solid with barrier material adhered to the shutter 63 in places where vents would typically be. This creates areas where the medium cannot communicate with the external environment. It also functions as a shutter.
[0076] To begin assembling the device, the platform spring assembly housing (FIG. 7) is inserted into the rear housing 41 . The front housing 40 is then appropriately assembled onto the rear housing assembly 41 via the attachment pegs 42 and the attachment peg receptors 43 . Once assembled, the manual platform adjuster 56 is secured to the axle 50 via the axle receptor 57 .
[0077] In a preferred embodiment using the vented shutter FIG. 8A at 61 , the device functions and is used in the following manner when an evaporative medium, such as a fragrance is used. The vented shutter 61 is inserted into the grip slot 59 until the vented shutter 61 comes to rest on the platform 48 . The device is designed so that the movable vents 62 and the static housing vents 55 align at the maximum design temperature. This maximally restricts the mediums communication with its external environment. When the ambient temperatures increase above the maximum design temperature, full alignment is maintained by the platform stops 46 . This is important since increasing ambient temperatures would cause the spring 49 to continue to expand, resulting in the shutter 61 to over travel. If this happened, the alignment would be lost and the non-vented areas of the shutter would begin reappearing. This would start exposing the medium to its external environment again and defeat the purpose of the invention. This would cause excessive evaporation and an extremely strong and undesirable perception of the fragrance to the consumer.
[0078] The device is also designed to function in the opposite manner when the device is exposed to its lowest designed ambient temperatures. As the temperatures drops, the spring 49 continues to contract. As the spring 49 continues to contract and reaches its lowest designed temperature, the platform 48 bottoms out on the coil of the spring 49 . At this point, the shutter vents 62 and the static housing vents 55 are in total misalignment. One could argue that the spring 49 would continue to contract and the spring would continue to decrease in diameter if the temperatures plummeted and thus allow the platform 48 to continue to drop. However, the additional movement is considered insignificant for the devices purpose. If an application warranted more stringent low temperature control, an added pair of stops 49 would be inserted.
[0079] The non-vented shutter FIG. 8B at 63 functions identically to the vented shutter FIG. 8A at 61 . The only difference in the two shutters is that holes are not punched in the non-vented shutter 63 . Barrier material is adhered or coated on the shutter and substituted for the holes or vents 62 punched in the vented shutter 61 . Both methodologies accomplish the same task.
[0080] The manual platform adjuster 56 is desirable to the consumer because it allows the consumer to adjust the exposure of the medium to its external environment. Turning the manual adjuster 56 compresses or decompresses the spring 49 which ultimately control the position of the shutter 61 or 63 via the platform 48 . If the consumer desires a stronger perceived fragrance, the shutter 61 or 63 is adjusted to be more misaligned with the static housing vents 55 . If the consumer desires weaker fragrance strength the shutter 61 or 63 is adjusted to be better aligned with the static housing vents 55 .
[0081] The device in FIGS. 9A and 9B is another automatic temperature controlled device that uses movable louvers 77 to allow the medium 73 to communicate with its external environment. The device comprises a medium 73 , a housing 71 , static housing vents 79 , a spring rod assembly 70 , and a louver assembly 72 .
[0082] The spring assembly 70 comprises a spring 75 , a spring static end 68 , a spring rod pivot 80 , and a connecting rod 74 .
[0083] The louver assembly 72 comprises a louver bar 69 , a louver bar pivot 76 , movable louvers 77 , and louver pivots 78 .
[0084] In a preferred embodiment, and using a fragrance as an example of the medium 73 , the device functions in the following manner. As the ambient temperature decreases, the spring 75 begins to contract and wind up. As the spring 75 contracts, it pulls the connecting rod 74 down. When this is occurring, it simultaneously causes the louvers 77 to move freely toward a horizontal position via the louver bar pivots 76 , and the louver housing pivots 78 . When the minimum designed ambient temperature is met, the louvers move into a horizontal position and are restricted from further travel by the louver bar stops 67 . The louver bar stops 67 restrict any potential for over travel if the ambient temperature continues to drop below the lowest designed ambient temperature for the device.
[0085] The operational sequence reverses as the ambient temperature increases and approaches the device's maximally designed temperature. The spring 75 expands and unwinds; causing the connecting rod 74 to rise and simultaneously close the louvers 77 until contacting the louver housing 71 halts their movement. The louver housing 71 provides the stopping mechanism for the louvers 77 when the maximum design temperature is met.
[0086] This operational sequence is consistent with the needs of controlling the evaporative profile of a fragrance medium 73 and blocks out the temperature variable by linearizing the evaporative profile with changing temperatures. In essence, the sequence of operations increases the mediums 73 communication with its external environment as the vapor pressure or evaporation rates of the medium 73 drop off with decreasing temperatures and restricts the mediums communication with its external environment as the vapor pressure or evaporation rates climb with increasing temperatures.
[0087] The device in FIG. 10A illustrates an automatic temperature controlled mechanism that comprises a housing 84 , static vents 87 , bimetallic spring retainers 85 , a medium reservoir 81 , a medium 83 , a wick 82 , a wick sheath 88 , and a bimetallic spring 86 with a sheath retaining hole 89 .
[0088] The device is assembled by inserting the sheath 88 into the sheath-retaining hole 89 and then inserting the bimetallic spring 86 into the spring retainers 85 . The wick 82 is inserted into the sheath 88 and the entire assembly is inserted into the reservoir opening 90 .
[0089] In a preferred embodiment, the device functions and is designed in the following manner when an evaporative medium, such as a liquid fragrance is used. Once the wick 82 is inserted into the medium 83 , the medium 83 quickly saturates the wick 82 and comes to equilibrium through capillary action. The sheaths 88 main purpose is to regulate the amount of surface area the wick 82 is exposed to in relation to its external environment. Assuming the ambient temperature is held constant, exposing more of the wick 82 to its external environment increases the evaporation rate and perceived strength of the fragrance medium 83 to its external environment and ultimately the consumer. Unfortunately, ambient temperatures vary and if the wick 82 length is held constant as temperatures change, the evaporation rates and perceived strengths of the medium 83 changes. Many devices currently operate in such a fashion and are at the mercy of varying temperatures. These devices haven't blocked out the temperature variable. This device does.
[0090] The sequence of operation is similar to what has been described previously. As the temperature increases, the bimetallic spring 86 expands and becomes increasing more convex. Since the sheath 88 is an integral part of the spring 86 , the sheath 88 rises with the spring 86 and progressively reduces the surface area or length of the wick 82 exposed to its external environment. When the ambient temperature reaches the maximum design temperature of the device, the sheath 88 significantly shields the wick 82 from its external environment and only a very little portion of the wick 82 can be seen sticking out above the face of the sheath 88 . This is illustrated in FIG. 10B.
[0091] [0091]FIG. 10A illustrates the device operating at its minimally designed temperature. The spring 86 is frilly contracted and the sheath 88 is allowing the maximum amount of wick 82 exposure to its external environment.
[0092] The two operating scenarios just described are consistent with the philosophy of minimizing exposure of an evaporative medium to its external environment when the ambient temperature is hot and maximizing the exposure of the medium to its surroundings when they are cold. This typically holds true for an evaporative medium, but as discussed before is opposite, if the desired outcome is to expose more of the medium 83 to its external environment when hot. To reverse the desired outcome and optimize this type of application, the spring 86 would control movement of the wick 82 instead. When the temperature increased, the wick 82 would be pulled out of the medium 83 , exposing more of the wick 82 and allowing maximum communication of the medium 83 to its external environment.
[0093] [0093]FIG. 11 illustrates two asymmetric vent profiles 93 and 94 . The static vent profile 93 is shown cut into a representative portion of a device housing 95 . This irregular shaped vent profile 93 would be used to compensate for complex medium that exhibited up to a third order temperature response characteristic curve. The asymmetric vent 94 is shown cut into a representative portion of a movable shutter 96 . This vent geometry 94 would be custom designed for a complex evaporative medium that required extremely tight control of the mediums exposure to its external environment. In essence, the more precisely the vent profile or profiles are designed to match the characteristics of a specific medium, the better the device will control the mediums constant effectiveness to its external environment throughout its useful temperature range.
[0094] The devices in FIGS. 12 A- 12 E illustrate the operations of two expandable vent methodologies. FIG. 12A illustrates the assembly diagram for the coiled spring actuated expandable vent device FIG. 12B. The device comprises a top cap 112 , an expandable vent housing 113 , a coil spring 115 , a spring connecting rod 116 , a connecting rod anchor 111 , a medium 117 , and a reservoir for the medium 118 .
[0095] The device is first assembled by attaching the spring 115 to the spring connecting rod 116 . The medium 117 is inserted into the medium reservoir 118 and the spring connecting rod 116 is passed through the medium 117 and attached to the connecting rod anchor 111 . The top cap 112 is attached to the expandable vent housing 113 . The spring 115 is compressed and passed through the expandable vent housing 113 until the spring bottoms out in the top cap 112 and decompresses for a tight friction fit inside of the top cap 112 and the expandable vent housing 113 is secured to the reservoir 118 .
[0096] The device functions similarly to the others previously described since the vents 114 are driven to open or close by the expansion or contraction of the spring 115 . The advantage of the expandable vent device is that it allows greater than 90% medium exposure, in comparison to only 50% medium exposure that is characteristic of the movable shutter.
[0097] In a preferred embodiment of the device and assuming the medium is a fragrance, FIG. 12D illustrates the device operating at its maximally designed temperature. As the ambient temperature rises, the spring expands and rotates the vent housing 113 clockwise until it is tightly wound and the vents 114 are totally closed.
[0098] [0098]FIG. 12C illustrates the device operating at its minimally designed temperature. As the ambient temperature decreases, the spring 115 contracts and rotates counterclockwise, causing the expandable vent housing 113 to follow and open the vents 114 to their full extent.
[0099] [0099]FIGS. 12E and 12F illustrate another expandable vent device. However, this configuration of this device uses the bimetallic spring 120 as a vehicle to compress and expand the expandable vent housing 119 and hence the expandable vents 114 .
[0100] [0100]FIG. 12E at 114 illustrates the device operating at its minimally designed temperature. The bimetallic springs 120 and 132 are contracted due to the exposure of a low ambient temperature. At the springs 19 and 132 contracted state, the expandable vent housing 119 is compressed and results in the expandable vents 114 bulging out. This configuration allows the medium to communicate with its external environment maximally.
[0101] [0101]FIG. 12F illustrates the device operating at its maximally designed temperature. The bimetallic springs 120 and 132 are fully expanded and cause the expandable vent housing 119 to elongate under tension. When the expandable vent housing 119 is fully elongated, the expandable vents 114 are in their maximally closed position and maximally restrict the medium from communicating with its external environment.
[0102] It should be noted that the utilization of a single spring located on the top or bottom will suffice, but the dual spring approach creates more expandable vent housing travel, generates higher forces and is the preferred approach. It also should be noted that the expandable vent housing could also be the medium. The housing would be a multiplayer material as previously discussed and the medium would only be exposed on the inside of the expandable vent housing.
[0103] [0103]FIGS. 13A, 13B, and 13 C illustrate a device that operates with a spring activated movable lid that allows the medium to communicate with its external environment within the useful range of its designed temperatures.
[0104] The device comprises a movable cap 122 , a bimetallic spring 124 , a spring connecting rod 123 , a connecting rod spring retainer 160 , and an upper housing 127 containing a spring retaining slot 125 , a seal-retaining slot 132 , a seal 126 , and attachment threads 137 . The device also includes a lower housing 129 containing attachment threads 138 as well as a medium 128 .
[0105] The device is first assembled by inserting the spring connecting rod 123 , through the bimetallic spring 124 and attaching the lower connecting rod attachment 158 to the connecting rod spring retainer 160 . The upper spring connecting rod attachment 131 is inserted into the cap spring connecting rod retainer 130 and secured. The seal 126 is inserted into the seal-retaining slot 132 and the bimetallic spring 124 is inserted into spring retaining slot 125 . This completes the assembly of the upper half of the housing 127 . The medium 128 is placed into the lower housing 129 . The assembly is complete and the device is ready for use when the upper housing 127 and lower housing 129 are screwed together via 137 and 138 and sealed.
[0106] In a preferred embodiment and using a complex liquid medium, FIG. 13B depicts the device operating at its minimally designed temperature. When the device is at its minimally designed temperature, the bimetallic spring 124 is fully contracted and pulling down on the cap 122 via the spring connecting rod 123 . At this juncture, no medium 128 is in communication with its external environment.
[0107] [0107]FIG. 13C depicts the device operating at its maximally designed temperature. When the device is at its maximally designed temperature, the bimetallic spring 124 is fully expanded and has pushed the cap 122 off of the seal 126 to its full extent via the spring connecting rod 123 . At this point, the medium is maximally communicating with its external environment.
[0108] FIGS. 14 A- 14 F show a device almost identical to the device illustrated in FIGS. 3 A- 3 E. The major exception is that the device in FIG. 14B uses a bimetallic spring 103 as the driving mechanism instead of a coiled spring.
[0109] The device is assembled by inserting and securing the bimetallic spring 103 into the static spring anchor 109 located on the post 108 . The movable shutter 102 , which includes vent holes 134 , is installed by inserting the movable end of the bimetallic spring 102 into the movable spring anchor 105 . The bimetallic spring 103 is installed properly when it rests against the bimetallic spring pivot 104 . The movable shutter 102 is positioned and located concentrically with the lower housing 110 by placing the movable shutter 101 via the axis hole 250 onto the movable shutter rotation bearing 107 . To complete the assembly, the upper shroud 101 , which includes static vent holes 133 , is attached to the lower housing 110 containing the medium 106 .
[0110] In a preferred embodiment the medium 106 is a fragrance gel. The sequence of operation is illustrated in FIGS. 14 D- 14 F. FIG. 14D illustrates the device at its minimally designed temperature. The movable shutter vents 134 are in total alignment with the static housing vents 133 and result in maximally exposing the medium to its external environment. The bimetallic spring 103 is contracted and appears linear.
[0111] [0111]FIG. 14E represents the device operating at increased ambient temperatures and illustrates the movable shutter vents 134 oriented to the static vents 133 in a configuration that allows the medium 106 to communicate to its external environment at only 50% of it maximal potential. At this stage, the bimetallic spring is partially expanded and bent or bowed. In essence, the static vents 133 are 50% blocked off.
[0112] [0112]FIG. 14F represents the device operating at its maximally designed temperature and illustrates the movable shutter vents 134 and the static vents 133 in total misalignment. At this stage, the bimetallic spring 103 is fully expanded and maximally bent and the medium 106 is maximally restricted from communicating with its external environment.
[0113] FIGS. 15 A- 15 C illustrate a continually variable speed fan that changes fan speed with changes in ambient temperature. The fan comprises a fan motor 145 , fan blade 144 , a thermistor-type amperage controller 148 and a power source 146 . The power source 146 is a battery, a 12-volt dc circuit or a household 120-volt circuit. An on-off switch is optional.
[0114] The device is assembled by initially inserting and securing the fan motor 145 and fan 144 into the fan retainer 151 . The fan mounting bracket assembly consists of the mounting brackets 150 ; the mounting bracket mounts 152 and the fan retainer 151 . The mounting bracket assembly and the fan are installed into the top housing via the mounting brackets 152 and secured. The medium reservoir 156 , which contains the medium 154 , is snapped into place with the top housing 140 and the device is ready for use.
[0115] In a preferred embodiment and using a fragrance as the medium 154 , the device functions in the following manner. When the device is exposed to its highest designed ambient temperature, the thermistor control 148 operates at its maximum designed voltage resistance and causes the fan motor to operate at its lowest RPM or speed. This results in the medium communicating with its external environment in the most restricted manner. As the ambient temperature begins to decrease, the thermistor controller 148 continues to decrease its voltage resistance and allows the fan to continually increase in speed. At its minimally designed temperature, the fan motor receives full design voltage and the fan speed is maximized.
[0116] The result is that the medium's 158 communication with its environment is continually controlled and is perceived by the consumer as having constant effectiveness throughout its useful temperature range.
[0117] FIGS. 16 A- 16 C represent a device identical in all aspects to the device in FIG. 15, with the exception of the control circuitry 149 . This device has an integrated circuit 149 ; a control circuit reset button 154 and an indicator light 153 that indicates when the useful life of the medium has expired. The device is assembled in the same manner as the device in FIG. 15.
[0118] In a preferred embodiment, this device is typically used in the home where the ambient temperatures are fairly stable. The medium 154 for this example is a fragrance gel. In a typical home, ambient temperatures vary very little in comparison to an automobile environment and as a result, compensating for large fluctuations in ambient temperature is not required. The devices previously described, to control the constant effectiveness of the medium in highly variable temperature environments, would not be the driving mechanisms of choice to accomplish this.
[0119] Assuming the household ambient temperatures are fairly constant, the major difficulty the device must compensate for is the decrease in vapor pressures and evaporation rates of the medium as it progresses through its useful life and ages. The lower vapor pressures and evaporation rates these mediums are characteristically known for as they age are counteracted by continually increasing the amount of airflow the medium is exposed to. This increases the evaporation rates of the medium as its vapor pressures naturally drop off in time and counteracts the effect. Many airflow movement devices can be used to programmably control the constant effectiveness of a medium to its external environment. Fans are members of the group consisting of airflow generators such as low frequency vibratory mechanisms, bellows, turbines, high frequency vibratory generators (piezoelectric), and turbines. Any of these mechanisms can be programmed accordingly and accomplish the same goal.
[0120] The device is designed and functions in the following manner. Once the chemical characteristics of the medium and its useful life have been defined, the integrated circuit is programmed for the application or product line. One or more variables can be programmed into the device and there are many parts and electric circuitry in the market one could use to accomplish the present invention which is being disclosed. However, the main goal of the present invention is to continuously control the pertinent variables of the device to maintain constant effectiveness of the medium to its external environment. These include time and temperature dependency, time versus airflow rate dependency, time versus medium exposure (evaporation or absorption) and time versus vibration profiles. High frequency vibration could also be used as a heater function. However, the following is a good straightforward description of a preferred embodiment. Two variables are programmed into the programmable circuit: time and voltage applied to the fan motor. The time variable is set using an internal programmable timer in the circuit, which would be typically designed to go through 360 degrees of counting to designate the useful life of the medium. In a straightforward programming example, 60 set points would characterize a medium that had a 60-day useful life and would represent 6 degrees of progression per day for 60 days on the clock. At this point, the timer would time out, send an electrical signal to the light 153 to turn on and then shut the control circuitry 149 off until the consumer pushed the reset button 154 to repeat the sequence of operation. This would be done when a new medium 154 was installed.
[0121] The voltage supplied 146 to the fan 145 is programmed in the same fashion and corresponds with the clock set points. When the entire programmable integrated circuit 149 is complete, a time versus fan speed profile is established.
[0122] To optimize the programmable circuit 149 , the program would be written specific to the medium and optimize the constant effectiveness of the medium 154 to its external environment. It must be noted, that a myriad of profiles could be developed and many permutations are available.
[0123] [0123]FIGS. 17A and 17B illustrate a device that identical in all aspects to FIGS. 6A and 6B with the exceptions of an added fan assembly, static vents 98 in the rear housing 41 , a movable shutter 8 , and a separate medium card 155 . The device is also assembled in the same manner as FIGS. 6A and 6B with the exception of installing the added components of the fan assembly and the movable shutter 8 .
[0124] The fan assembly is installed as follows. The fan axle 65 is inserted through the fan hole 162 and secured with the fan blade retainer 97 . The fan axle 65 is now inserted through the fan axle-receiving hole 91 and secured with the fan axle retainer 66 . The rest of the device is installed in the same manner as described in the verbiage for device in FIGS. 6A and 6B.
[0125] The movable shutter is installed by inserting it through the slot 44 until it comes to rest on the shutter platform 48 . The shutter 8 is located closest to the rear housing 41 .
[0126] The medium card 155 is also inserted into slot 44 and comes to rest on the platform stop 49 . The medium card 155 is stationary and located closest to the front housing 40 .
[0127] In a preferred embodiment, fragrance is used as the medium. The device is attached to the automobile air vent housing by the auto vent attachment 163 . The device controls the exposure of the medium to its external environment by controlling the rate of airflow delivered by the auto vent through and around the device. The volume of airflow allowed through the static vents 55 and 98 , movable shutter vents 159 , the speed of the device's fan 92 and around the periphery of the device, are all used to accomplish this. The airflow around the periphery of the device also helps control the speed of fan 92 . The fan speed is the highest when the auto vent air is cold and the vent system is unrestricted and the fan speed is the slowest when the auto vent air is hot and the vent system is restricted.
[0128] The reason why this device is so advantageous to the consumer is that it discriminates between hot air and cold air coming out of the automobile's vent system (summer versus winter). When hot air is coming out of the automobile's vent system, the spring 49 expands and moves the shutter vents 159 , via the platform 48 , to positions where the shutter vents 159 become misaligned with the static vents 98 and 55 and retard airflow through the device and fan 92 . This is consistent with what has been discussed; with an evaporative medium 155 , we decrease the exposure of the medium 155 to its external environment when the ambient temperature is hot to prevent an overpowering perception of the fragrance to the consumer and increase exposure of the medium 155 to its environment when it is cold, to increase the strength of a weak and ineffective perception of the fragrance to the consumer.
[0129] This counteracts the changes in vapor pressures and evaporation rates with changing temperatures and maintains constant effectiveness of the medium 155 as it communicates with its external environment.
[0130] [0130]FIG. 18A illustrates a breakout of a programmable heating device to control the constant effectiveness of a medium to its surrounding environment. The heating device is an electrical resistive heater and is a member of the group of heaters comprising induction heaters and high frequency vibratory heaters such as piezoelectric heaters. Any of these members can be used for the heating device and programmed accordingly.
[0131] The device is assembled in the following manner. The following components are installed in the base housing 167 ; the use up light 169 , the reset button 168 , the programmable circuitry 170 , the power source regulator 171 , the power source plug 166 , the heat shield 173 , the heater 174 and the heater/medium separator 175 . The upper housing 178 which comprises the static vents 180 and the medium slot 179 is snapped into place onto the base housing 167 and the device is assembled and ready for use once the medium 177 is inserted into the medium slot 179 and the device is plugged in.
[0132] In a preferred embodiment, this device is typically used in the home where the ambient temperatures are fairly stable. The medium 177 for this example is a fragrance gel. Assuming the household ambient temperatures are fairly constant, the major difficulty the device must compensate for is the decrease in vapor pressures and evaporation rates of the medium as it progresses through its useful life and ages. The lower vapor pressures and evaporation rates these mediums 177 are characteristically known for as they age, are counteracted by continually increasing the amount of heat the medium 177 is exposed to. This increases the evaporation rates of the medium 177 as its vapor pressures naturally drop off in time and counteracts the effect. Many heating devices can be used to programmably control the constant effectiveness of a medium to its external environment. They were discussed earlier.
[0133] The device is programmed in the same manner and using the same concepts that were described device in FIGS. 16 A- 16 C. The major exception is that we are using a heating mechanism for this application instead of a fan.
[0134] In this example, two variables are programmed into the programmable circuit 170 : time and voltage applied to the heater. The time variable is set using an internal programmable timer in the circuit, which would be typically designed to go through 360 degrees of counting to designate the useful life of the medium. In a straightforward programming example, 60 set points would characterize a medium that had a 60-day useful life and would represent 6 degrees of progression per day for 60 days on the clock. At this point, the timer would time out, send an electrical signal to the light 169 to turn on and then shut the control circuitry 170 off until the consumer pushed the reset button 168 to repeat the sequence of operation. This would be done when a new medium 177 was installed.
[0135] The voltage supplied 166 to the heater 174 is programmed in the same fashion and corresponds with the clock set points. When the entire programmable integrated circuit 170 is complete, a time versus heater temperature profile is established.
[0136] To optimize the programmable circuit 170 , the program would be written specific to the medium 177 and optimize the constant effectiveness of the medium 177 to its external environment. It must be noted, that a myriad of profiles could be developed and any permutations are available. They do not have to be linear and most often are not.
[0137] The devices in FIGS. 19 A- 19 D illustrate a novel automatic thermostatic ratchet mechanism to control the exposure of a medium 250 to its external environment. The device comprises a housing assembly, a thermal response housing assembly FIG. 20A at 205 , a latch notch assembly 210 , and a latch housing assembly 213 .
[0138] The housing assembly consists of a housing 252 , a manual id 254 , a lid hinge 258 , a latch retainer slot 260 , and a keyway slot 260 .
[0139] The thermal response housing assembly in FIG. 20A at 205 comprises a latch guide housing 206 , a latch guide slot 211 , a swing arm bracket 209 , a swing arm pivot 208 , a housing pivot 207 , and a bimetallic spring 200 . FIG. 20B illustrates the latch notch assembly 210 and comprises a latch 204 and a ratchet tooth 218 , which includes a notch 202 , an incline 214 , and a peak 203 .
[0140] FIGS. 19 A- 19 D illustrate in a simplistic way, the basic sequence of operations. FIG. 19A illustrates the device in the cold condition with the medium 250 loaded into the housing 252 . FIG. 19B illustrates the device in the hot position and FIG. 19C illustrates the device in the final stage of allowing the medium 250 to communicate with its external environment.
[0141] FIGS. 21 A- 21 E illustrates the sequence of operations. Its sole control mechanism resides in the movements of the thermal response latch assembly 213 .
[0142] In a preferred embodiment, the medium 600 will be a dishwashing detergent and the device will go through a hot, cold, and hot cycle before the medium 600 is dispensed. FIG. 21A depicts a thermal response latch assembly 213 in the first phase of the sequence. The external environment in this phase is cold and the bimetallic spring 200 is contracted, located between the two ratchets 218 and its pivot 208 is in the fully down position. As the temperature rises, the bimetallic spring 200 starts to expand, bow, and push the ratchet 218 forward. As the ratchet 218 is being pushed forward, the latch 204 is simultaneously being pushed forward because it is an integral part of the latch notch assembly 213 . When the external environment reaches its maximum temperature, the bimetallic spring 200 is fully expanded, and pushes the ratchet 218 to its farthest position forward. This is depicted in FIG. 21B.
[0143] Phase two begins when the temperature of the external environment begins to decrease. The decrease in temperature causes the bimetallic spring 200 to contract, pull back, and ride up on the incline of the ratchet 214 until the spring 200 reaches the peak of the ratchet 203 . At nearly full contraction, the spring 200 drops down into the second ratchet notch 202 . The ability of the spring 200 to ride up the ratchet incline 214 and drop back into the ratchet notch 202 is created by the bimetallic spring arm pivot 208 . At this juncture, we have completed one hot to cold cycle.
[0144] The latch housing assembly 213 goes through another hot to cold cycle as previously discussed. However, when the temperature gets hot in this cycle and the spring 200 has pushed the second ratchet tooth 218 as far as the expansion of the spring 200 will allow, it dispenses its medium 250 to the external environment. This occurs when the latch retainer slot 258 no longer retains the latch. This happens because the distance the latch 204 has traveled in the second cycle has caused the latch 204 to be pushed out so far that it loses support from the latch retainer slot 258 in the housing 252 . The ratchet arm 220 width is so much narrower than the latch 204 that is passes right through the latch retainer slot 258 via the key way 260 . This allows the latch assembly 213 to drop via the housing pivot 207 and dispense the medium 250 to its external environment.
[0145] FIGS. 21 A- 21 D work in a very similar manner to the first device with the exception that this device dispenses its medium 250 on the first cycle hot and uses a method whereby the bimetallic spring 200 pulls the latch notch assembly 210 , instead of pushing it. In addition, only one ratchet tooth 218 is used. There are no new parts in this device; the system just functions differently.
[0146] [0146]FIG. 21A illustrates the device in the start up or cold environmental condition. Please note that the spring's 200 starting position is resting on the peak of the ratchet tooth 218 . As the dishwashing temperature gets progressively hotter, the spring 200 expands and progresses down the ratchet incline 214 . As the spring 200 expands to its full extent, it falls into the ratchet notch 202 . This is illustrated in FIG. 21B. As the temperature in the wash cycle decreases, the spring 200 contracts and pulls the ratchet notch assembly 210 backwards. Once the proper design temperature is reached, the latch retainer slot 258 no longer supports the latch 204 and the medium 250 is exposed to its external environment. This is illustrated in FIG. 21D.
[0147] FIGS. 22 A- 22 C illustrate a device similar in all aspects to the embodiment presented immediately above with the exception that it may be used to either transform medium 250 from the top medium chamber to the bottom when desired, or holds two media 250 and 251 simultaneously in separate compartments until the external environments temperature is met, to allow the two to be mixed when needed. This is done by dumping the top chamber contents into the bottom chamber prior to releasing the combined ingredients to their external environment simultaneously.
|
A device is presented which automatically controls the interaction of a medium with an external environment, the temperature of which varies or remains constant. In addition to the medium, the device includes a mechanism for providing constant effectiveness of the medium in the external environment, and an automatic drive mechanism which drives the mechanism for providing constant effectiveness of the medium in the external environment. Advantageously, the device includes a receptacle for the medium, and the receptacle includes a housing incorporating the mechanism for providing constant effectiveness of the medium in the external environment, which is beneficially a movable vent or an expandable vent. The automatic drive mechanism is advantageously a temperature-responsive member or a temperature-responsive fluid movement device. The temperature-responsive member, which manifests variations in the surface area thereof as the temperature thereof is raised, is beneficially one of the following: a linear spring, a spiral metallic spring, a multi-metallic spring, a polymeric spring, or a pop spring. A preferred embodiment of the device includes at least one static vent positioned within the housing in alignment with at least one movable vent positioned therein, and the at least one movable vent is driven by the automatic drive mechanism to move in relation to the at least one static vent, thereby providing constant effectiveness of the medium in the external environment by affording varying exposure thereof as the temperature of the external environment varies.
| 5
|
BACKGROUND OF THE INVENTION
[0001] This invention relates to a cut-through transmission apparatus and a cut-through transmission method for use in a node included in a communication network.
[0002] In recent years, the internet traffic is rapidly increased. The internet traffic is carried by IP (Internet Protocol) packets which are transferred under control of a router. Following the rapid increase in internet traffic, there is a growing demand for improvement in function and performance of the router. Since most of transferred data are important data for business use, a strict demand is imposed upon the reliability, the quality, and the security. On the other hand, there arises an increasing demand for a virtual private network, such as an internet VPN service, connecting a plurality of sites or nodes.
[0003] In order to meet the above-mentioned demands, one approach is to make the router have a high performance and a full of additional functions. However, this approach has a limit. There remains a problem how to realize the above-mentioned demands in an IP packet network in association with an existing transmission network.
[0004] As the existing transmission network, there are known an SDH (Synchronous Digital Hierarchy) network, an ATM (Asynchronous Transmission Mode) network, a WDM (Wavelength Division Multiplexing) network, and a PDH (Plesiochronous Digital Hierarchy) network. By integrating the existing transmission network and the IP packet network transmitting the internet traffic and by complementing their characteristics with each other, it is expected to achieve an improved system having more efficient transmission characteristics.
[0005] Consideration will be made about conventional network structures for LAN-to-LAN connection.
[0006] Referring to FIG. 1A , four nodes A through D are connected through a plurality of SDH paths 100 in a point-to-point connection. Specifically, the SDH paths 100 as private lines are provided between the nodes A and B, between the nodes A and C, between the nodes A and D, between the nodes B and C, between the nodes B and D, and between the nodes C and D, respectively. This network structure called a mesh type is disadvantageous in that a large number of SDH paths (private lines) are required.
[0007] Referring to FIG. 1B , four nodes E, F, G, and H are connected through an IP packet network of a hop-by-hop connection. Specifically, a plurality of SDH paths 101 as private lines are provided between the nodes E and F, between the nodes F and G, between the nodes G and H, and between the nodes H and E. In addition, each of the nodes E, F, G, and H has a router function to execute a routing operation.
[0008] Referring to FIG. 2 , a router 102 performs the routing operation as a third-layer operation. Specifically, the router 102 individually identifies all packets flowing into the router 102 to judge whether each packet is to be dropped at this node or to be hopped to a next node.
[0009] In order to execute the routing operation, the router 102 is required to have a number of functions. Thus, a heavy load is imposed upon the router 102 .
[0010] Specifically, the router 102 is required to have a large routing table including routing information for all packets flowing into the router 102 and to have a high performance so as to search such a large routing table.
[0011] In addition, in order to interface the SDH paths (the private lines) in the form of DS- 1 (Digital Signal Level 1 ), the router 102 is required to have a path terminating function of terminating VT (Virtual Tributary level) 1 . 5 .
[0012] Since all of the packets are sent to a third layer after subjected to the above-mentioned operations, a processing delay is produced also for those packets which are to be hopped to the next node and need not be processed at this node. This results in significant degradation of a network performance as a whole.
[0013] Thus, packet transfer in the above-mentioned IP packet network is disadvantageous in that the third-layer operation, i.e., the routing operation inevitably gives the heavy load.
[0014] For example, Japanese Unexamined Patent Publication (JP-A) No. H10-136016 (136016/1998) discloses a packet transfer control method which is capable of shortening a time required for a router to create a private cut-through path for a particular end flow.
[0015] The operation of the above-mentioned packet transfer control method is as follows. It is assumed that, in order to transfer a packet flow defined by a relatively abstract (general) condition such as a destination network address, a first cut-through path is preliminarily established from a first router to a second router which is not adjacent to the first router. In this state, it is assumed that a second cut-through path is required to be established to transfer a packet flow defined by a more specific (detailed) condition such as a source/destination address pair and a destination port number. In this event, control messages for establishment of the second cut-through path are exchanged between the first router and the second router as an endpoint of the first cut-through path. Thus, the second cut-through path is established by the use of the first cut-through path.
[0016] In the above-mentioned packet transfer control method, cut-through connection is established by the router. As a result, an operation load imposed upon the router is not reduced.
[0017] On the other hand, Japanese Unexamined Patent Publication (JP-A) No. H10-294737 (294737/1998) proposes a packet transfer apparatus which is capable of reducing a delay which is produced upon start of transfer of a best-effort flow and required to establish a connection between the packet transfer apparatus and another packet transfer apparatus.
[0018] In the packet transfer apparatus, each router containing a switch monitors a time duration of the flow. If the flow continues for a long time, a cut-through connection is established by switching and assigned to the flow. If the flow continues for a much longer time, a short-cut connection using an ATM connection is established and assigned to the flow. Thus, a basic router is avoided.
[0019] In the above-mentioned packet transfer apparatus also, cut-through connection is established by the router, like in Japanese Unexamined Patent Publication (JP-A) No. H10-136016. As a result, the operation load imposed upon the router is not reduced.
[0020] Japanese Unexamined Patent Publication (JP-A) No. H09-172457 (172457/1997) proposes a packet transmission node apparatus, which is capable of establishing cut-through connection selectively for a traffic expected to have a relatively large amount of communication after establishment of the cut-through connection.
[0021] In the packet transmission node apparatus, a node which can be a starting point or an end point of the cut-through connection refers to, before transmission or after reception of a packet, not only information of a network layer of the packet but also at least one of source information and destination information of a transport layer. If it is judged as a result of the reference that establishment of the cut-through connection is worthwhile, initiation of connection establishment is triggered by the packet.
[0022] In the packet transmission node apparatus, the cut-through connection is established not in the router but in the node. Therefore, the load upon the router is reduced. However, since the various kinds of information must be referred to as mentioned above, packet transmission inevitably requires a complicated operation.
SUMMARY OF THE INVENTION
[0023] It is an object of this invention to provide a cut-through transmission apparatus (or a node) which is capable of remarkably saving a third-layer operation, i.e., a routing operation.
[0024] It is another object of this invention to provide a cut-through transmission method which is capable of remarkably saving a third-layer operation, i.e., a routing operation.
[0025] According to this invention, there is provided a node comprising first, second, and third layers, wherein:
a packet is mapped in the first layer; the first layer judging whether the packet is to be dropped at the node or to be hopped to a next node; the first layer transmitting the packet to the third layer through the second layer when the first layer judges that the packet is to be dropped at the node.
[0029] The first layer transmits, when the first layer judges that the packet is to be hopped to the next node, the packet to the next node by making the packet cut through the first layer.
[0030] According to this invention, there is also provided a node comprising first, second, and third layers, wherein:
the second layer judges, without terminating the first layer, whether a packet supplied from the first layer is to be dropped at the node or to be hopped to a next node; the second layer transmitting the packet to the third layer when the second layer judges that the packet is to be dropped at the node.
[0033] The second layer transmits, when the second layer judges that the packet is to be hopped to the next node, the packet to the next node by making the packet cut through the second layer.
[0034] According to this invention, there is also provided a node comprising first, second, and third layers, wherein:
the second layer transmits, when a packet supplied from the first layer is not to be dropped at the node, the packet to a next node by making the packet cut through the second layer without terminating the first layer; the second layer transmitting the packet to the third layer when the packet is to be dropped at the node.
[0037] According to this invention, there is also provided a node comprising first, second, and third layers, wherein:
if packets to be dropped and not to be dropped at the node are both contained in a transmission path, the second layer monitors all packets in the transmission path to transmit, when the packet is not to be dropped at the node, the packet to a next node by making the packet cut through the second layer and to transmit the packet to the third layer when the packet is to be dropped at the node.
[0039] According to this invention, there is also provided a transmission apparatus comprising:
a time slot extracting section for converting an input optical signal supplied through a first point into an input electric signal and for selecting among time slots in a transmission path of the input electric signal a particular time slot which includes a packet to be dropped at a second point; a drop packet extracting section for monitoring all packets in the particular time slot selected in the time slot extracting section to identify whether or not each packet is to be dropped at the second point; an add packet inserting section for packet-multiplexing the packet not to be dropped at the second point and a packet inserted at the second point to produce a packet-multiplexed packet; and a signal transmitting section for inserting into an appropriate time slot of the transmission path the packet-multiplexed packet to be sent to a third point, converting an output electric signal including the transmission path into an output optical signal, and delivering the output optical signal to the third point.
[0044] According to this invention, there is also provided a transmission method carried out in a node comprising first, second, and third layers, comprising the steps of:
judging, in the first layer where a packet is mapped, whether the packet is to be dropped at the node or to be hopped to a next node; and transmitting in the first layer the packet to the third layer through the second layer when the first layer judges that the packet is to be dropped at the node.
[0047] The transmission method may further comprise the step of:
transmitting in the first layer, when the first layer judges that the packet is to be hopped to the next node, the packet to the next node by making the packet cut through the first layer.
[0049] According to this invention, there is also provided a transmission method carried out in a node comprising first, second, and third layers, comprising the steps of:
judging in the second layer, without terminating the first layer, whether a packet supplied from the first layer is to be dropped at the node or to be hopped to a next node; and transmitting in the second layer the packet to the third layer when the second layer judges that the packet is to be dropped at the node.
[0052] The transmission method may further comprise the step of:
transmitting in the second layer, when the second layer judges that the packet is to be hopped to the next node, the packet to the next node by making the packet cut through the second layer.
[0054] According to this invention, there is also provided a transmission method carried out in a node comprising first, second, and third layers, comprising the steps of:
transmitting in the second layer, when a packet supplied from the first layer is not to be dropped at the node, the packet to a next node by making the packet cut through the second layer without terminating the first layer; and transmitting in the second layer the packet to the third layer when the packet is to be dropped at the node.
[0057] According to this invention, there is also provided a transmission method carried out in a node comprising first, second, and third layers, comprising the step of:
monitoring in the second layer, if packets to be dropped and not to be dropped at the node are both contained in a transmission path, all packets in the transmission path to transmit, when the packet is not to be dropped at the node, the packet to a next node by making the packet cut through the second layer and to transmit the packet to the third layer when the packet is to be dropped at the node.
[0059] According to this invention, there is also provided a transmission method comprising the steps of:
converting an input optical signal supplied through a first point into an input electric signal; selecting among time slots in a transmission path of the input electric signal a particular time slot which includes a packet to be dropped at a second point; monitoring all packets in the particular time slot selected in the selecting step to identify whether or not each packet is to be dropped at the second point; packet-multiplexing the packet not to be dropped at the second point and a packet inserted at the second point to produce a packet-multiplexed packet; inserting into an appropriate time slot of the transmission path the packet-multiplexed packet to be sent to a third point, converting an output electric signal including the transmission path into an output optical signal; and delivering the output optical signal to the third point.
[0067] An ATM cell may be used instead of the packet.
BRIEF DESCRIPTION OF THE DRAWING
[0068] FIGS. 1A and 1B are schematic diagrams showing existing LAN-to-LAN connections of a mesh type and a hop-by-hop type, respectively;
[0069] FIG. 2 is a schematic diagram showing an operation at a node in the existing hop-by-hop connection illustrated in FIG. 1B ;
[0070] FIG. 3 is a schematic diagram showing a specific example of a network using a cut-through transmission apparatus or a cut-through transmission method according to this invention;
[0071] FIG. 4 is a schematic diagram showing a cut-through type node using the cut-through transmission apparatus of this invention;
[0072] FIG. 5 is a schematic diagram showing a specific example of the cut-through type node illustrated in FIG. 4 ;
[0073] FIG. 6 is a block diagram showing the structure of the cut-through transmission apparatus of this invention;
[0074] FIG. 7 is a schematic diagram showing a ring to which the cut-through transmission apparatus of this invention is applied;
[0075] FIG. 8 is a schematic diagram showing the ring illustrated in FIG. 7 applied to a multi-tenant building; and
[0076] FIG. 9 is a schematic diagram showing an access network applied to the ring illustrated in FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0077] Herein, the term “cut-through” represents a connection in which the operation in the first layer is omitted by some means even if a hop-by-hop connection is normally required, i.e., a connection in which packet transfer is carried out from one logical network to another logical network only by the operation in a layer lower than the first layer.
[0078] In the cut-through transmission apparatus or the cut-through transmission method according to this invention, judgement about whether a packet is to be dropped at a current node or to be hopped to a next node and an operation following the judgement are not carried out in the third layer individually for all packets. Instead, the judgement and the execution are carried out in the first layer where the packet is mapped (“cut-through 1 ” which will later be described). Alternatively, the judgement and the operation are carried out in the second layer without terminating the first layer (“cut-through 2 ” which will later be described).
[0079] Referring to FIG. 3 , a plurality of points are labelled A, B, C, D, E, F, G, H, I, J, and K. X Corporation has four offices at the points B, D, E, and I. A private line (x) SDH path 10 passes through the points B, A, D, C, E, H, and I. Thus, the private line (x) SDH path 10 passes through all of the four offices of X Corporation at the points B, D, E, and I. On the other hand, Y Corporation has two offices at the points A and F. A private line (y) SDH path 11 passes through the points A, D, C, E, H, G, and F. Thus, the private line (y) SDH path 11 passes through the two offices of Y Corporation at the points A and F. Furthermore, Z Corporation has two offices at the points J and K. A private line (z) SDH passes through the points J, E, and K. Thus, the private line (z) SDH path 12 passes through the two offices of Z Corporation at the points J and K.
[0080] The private line (y) SDH path 11 is a private line connected in a point-to-point connection of an existing type. Therefore, the private line (y) SDH path 11 can not be accessed, for example, from the point D or E as an intermediate point.
[0081] On the other hand, the private line (x) SDH path 10 is a private line established according to this invention. The private line (x) SDH path 10 can be accessed also at the point D or E as the intermediate point.
[0082] According to this invention, packets of Y Corporation and Z Corporation can be cut through at the point E on the private line (y) SDH path 11 and the private line (z) SDH path 12 because these packets need not be dropped at the point E. Similarly, packets transferred from the point D to the point I can be cut through at the point E on the private line (x) SDH path 10 because these packets need not be dropped at the point E. Hereinafter, the private line (x) SDH path or the like will be referred to as a shared SDH path.
[0083] In this case, the private line (x) SDH path 11 , the private line (y) SDH path 11 , and the private line (z) SDH path 12 can coexist in a same network.
[0084] Thus, in the cut-through transmission apparatus or the cut-through transmission method according to this invention, packets to be hopped to a next node are cut through in the first layer or the second layer. Therefore, only those packets to be dropped at this node are sent to the third layer. Thus, it is possible to considerably save the third-layer operation, i.e, the routing operation.
[0085] In case where the packets are cut through in the second layer, the cut-through is carried out without terminating the first layer. Therefore, a large amount of operation required to terminate the first layer (for example, pointer processing upon termination of VT 1 . 5 ) becomes unnecessary. As a result, it is possible to considerably save functional operations.
[0086] The packets to be cut through are processed in the first or the second layer. In addition, the above-mentioned saving in functional operations makes it possible to minimize the delay. Thus, an end-to-end network performance is remarkably improved.
[0087] The cut-through inhibits the communication from being accessed at that point. Therefore, the security is assured.
[0088] Referring to FIG. 4 , description will be made about a cut-through node using a cut-through transmission apparatus according to a first embodiment of this invention.
[0089] The cut-through node of the first embodiment is called a “cut-through 1 ” node.
[0090] In this embodiment, each of a plurality of SDH paths 20 is taken as a single unit for which a closed user group (CUG) is preliminarily formed.
[0091] In FIG. 4 , an upper one of the SDH paths 20 does not carry any packet to be dropped at the cut-through node. In this event, the SDH path 20 is not terminated and packets on the SDH path 20 are made to pass through to a next node (cut-through 1 ).
[0092] In this method, not only the termination of the SDH path (for example, VT 1 . 5 ) but also the operation in a second layer 23 or a third layer 24 ( FIG. 5 ) become unnecessary. Therefore, it is possible to save a considerable amount of functions.
[0093] Furthermore, a packet delay at this node includes no more than a delay required for the packets on the SDH path 20 to pass through a first layer 22 . Thus, the packets can pass through this node without any substantial delay.
[0094] Turning back to FIG. 3 , the cut-through node will be described in conjunction with the specific example.
[0095] At the point E, the packets of Y Corporation and Z corporation need not be dropped. Therefore, at the point E, the private line (y) SDH path 11 or the private line (z) SDH path 12 need not be subjected to any operation at all. The cut-through is executed by the private line (x) SDH path 10 alone.
[0096] Referring to FIG. 5 , the private line (x) SDH path 10 has a throughput of n x VT 1 . 5 (n being an arbitrary natural number corresponding to a necessary band). For each unit of n x VT 1 . 5 , the private line (y) SDH path 11 or the private line (z) SDH path 12 is subjected to “cut-through (pass-through) 1 ”.
[0097] In this case, it is only necessary to terminate a section overhead (SOH), a line overhead (LOH), and a path overhead (POH) as depicted by a reference numeral 25 . Termination of VT 1 . 5 is unnecessary. Therefore, the cut-through can be realized with a very simple structure.
[0098] Turning back to FIG. 4 , description will be made about a cut-through node using a cut-through transmission apparatus according to a second embodiment of this invention.
[0099] The cut-through node of this embodiment is called a “cut-through 2 ” node.
[0100] In the cut-through 2 , if a particular SDH path 20 contains packets to be dropped and not to be dropped at this node, all packets contained in the SDH path 20 are monitored in the second layer 23 . The packets not to be dropped are cut through in the second layer 23 to the next node.
[0101] In the cut-through 2 also, the SDH path 20 is not terminated and cut through to the next node in the manner similar to the cut-through 1 , as depicted by a dotted line in FIG. 4 .
[0102] In this embodiment, the cut-through is possible without requiring the function of terminating the SDH path (for example, VT 1 . 5 ). In addition, the operation in the third layer 24 ( FIG. 5 ) is not necessary at all. Thus, a considerable amount of functions can be saved.
[0103] A packet delay at this node includes no more than a delay required for the packets to pass through the second layer 23 . Therefore, the packets can pass through this node with a relatively small delay.
[0104] Referring again to FIG. 3 , the cut-through node will be described in conjunction with the specific example.
[0105] Among a group of packets sent through the private line (x) SDH path 10 , those packets sent from the point D to the point I need not be dropped at the point E. Therefore, those packets are cut through in the second layer 23 without being sent to the third layer 24 .
[0106] In FIG. 5 , the SDH path 10 has a throughput of n x VT 1 . 5 (n being an arbitrary natural number corresponding to a necessary band). In the SDH path 10 of n x VT 1 . 5 , only those packets to be dropped at this node are subjected to “cut-through (packet through) 2 ”.
[0107] In this case also, it is only necessary to terminate the section overhead (SOH), the line overhead (LOH), and the path overhead (POH) as depicted by the reference numeral 25 , in the manner similar to the “cut-through 1 ”. The termination of the VT 1 . 5 is unnecessary. Therefore, the cut-through is realized with a very simple structure.
[0108] In the example illustrated in FIG. 5 , an input signal is decomposed into a level of VT 1 . 5 . At that level, necessary time slots are selected. Instead of VT 1 . 5 , use may be made of VT 2 , VT 3 , VT 6 , STS- 1 , STS- 3 (STM- 1 ), STS- 12 (STM- 4 ), STS- 48 (STM- 16 ), or STS- 192 (STM- 64 ).
[0109] The whole of the necessary band can includes a multiple of a single sort of band. Alternatively, use may be made of a mixture of VT 1 . 5 and STS- 1 .
[0110] Furthermore, in addition to a variety of different sorts of bands in the SDH path as mentioned above, use can be made of a complex thereof. Specifically, selection is made of an n multiple of a single sort of band, a mixture of different sorts of bands, and a combination thereof. In other words, time slots can be desiredly combined to be used as a cut-through managing unit.
[0111] Referring to FIG. 6 , a cut-through transmission apparatus according to a third embodiment of this invention will be described. In the figure, one transmission path alone is illustrated.
[0112] The cut-through transmission apparatus of this embodiment comprises a SDH path VT 1 . 5 time slot extracting section 41 for converting an input optical signal supplied through a point A into an input electric signal and for selecting among time slots in an input SDH path a particular time slot including a packet to be dropped or to be added at a point B, a drop packet extracting section 42 for monitoring all packets in the particular time slot selected by the SDH path VT 1 . 5 time slot extracting section 41 to identify whether or not each packet is to be dropped at the point B, an add packet inserting section 43 for packet-multiplexing a packet not to be dropped at the point B and a packet to be inserted at the point B to produce a packet-multiplexed packet, and an SDH signal transmitting section 44 for inserting the packet-multiplexed packet to be sent to a point C into an appropriate time slot, establishing an output SDH path, converting an output electric signal into an output optical signal, and delivering the output optical signal to the point C.
[0113] The cut-through transmission apparatus according to this embodiment is operated as follows.
[0114] The input optical signal inserted through the point A is converted by the SDH path VT 1 . 5 time slot extracting section 41 into the input electric signal. Among the time slots in the SDH frame, selection is made of the particular time slot including the packet to be dropped or to be added at the point B. In this embodiment, the time slot is extracted at a level of n x VT 1 . 5 as a single path.
[0115] Each unselected time slot includes only those packets which need not be dropped at the point B (this node) or will include those packets to be added at the point B (this node). The unselected time slot is sent from the SDH path VT 1 . 5 time slot extracting section 41 to the SDH signal transmitting section 44 and then from the SDH signal transmitting section 44 to the point C.
[0116] When the unselected time slot is sent from the SDH path VT 1 . 5 time slot extracting section 41 to the SDH signal transmitting section 44 , the above-mentioned cut-through 1 is carried out as illustrated in FIG. 6 .
[0117] On the other hand, the selected time slot includes the packets to be dropped or will include the packets to be added. The drop packet extracting section 42 monitors all of the packets in the selected time slot to identify whether or not each packet is to be dropped at the point B. If a particular packet is identified as a drop packet to be dropped at the point B, the drop packet is sent to the point B.
[0118] On the other hand, if the particular packet is identified as a non-drop packet not to be dropped at the point B, the non-drop packet is sent from the drop packet extracting section 42 to the add packet inserting section 43 . The add packet inserting section 43 packet-multiplexes the non-drop packet with an add packet to be inserted at the point B to produce a packet-multiplexed packet.
[0119] When the non-drop packet is sent from the drop packet extracting section 42 to the add packet inserting section 43 , the above-mentioned cut-through 2 is carried out as illustrated in FIG. 6 .
[0120] The packet-multiplexed packet produced by the add packet inserting section 43 is sent to the SDH signal transmitting section 44 . The SDH signal transmitting section 44 inserts the packet-multiplexed packet into an appropriate time slot. After an output SDH frame is restructured in the above-mentioned manner, the SDH signal transmitting section 44 converts an output electric signal into an output optical signal and delivers the output optical signal to the point C.
[0121] Referring to FIG. 7 , a cut-through transmission apparatus according to a fourth embodiment of this invention will be described. In this embodiment, the cut-through transmission apparatus is applied to a ring.
[0122] In this embodiment, a first shared SDH path 51 is accessible at two points A and C. A second shared SDH path 52 is accessible at two points B and D.
[0123] For example, at each of the points A and C, the cut-through 2 and the cut-through 1 are applied to the first shared SDH path 51 and the second shared SDH path 52 , respectively. On the contrary, at the points B and D, the cut-through 1 and the cut-through 2 are applied to the first shared SDH path 51 and the second shared SDH path 52 , respectively.
[0124] In the example illustrated in FIG. 7 , the number of nodes may be increased. To each of additional nodes, the cut-through transmission apparatus is applicable in the manner similar to the point A or B.
[0125] Referring to FIG. 8 , the cut-through transmission apparatus of the fourth embodiment is applied to a multi-tenant building 60 .
[0126] The multi-tenant building 60 is used by a plurality of users. Specifically, an underground node is arranged on a basement. X Corporation and Z Corporation have their offices on a first floor. On a second floor, Y Corporation has its offices for two different departments. On a third floor, Z Corporation and X Corporation have their offices. On a fourth floor, X Corporation has its office.
[0127] In this embodiment, the multi-tenant building 60 has a network which comprises a shared ring connecting the offices of the above-mentioned corporations. In this ring, the underground node extracts a communication band required by the multi-tenant building 60 as a whole. After the communication band is extracted, the underground node develops communication to the ring for distribution to the offices of the respective corporations on the respective floors. Each office extracts a part of the communication required by the corporation and cuts through the remaining part of the communication for other corporations.
[0128] Thus, it is possible to reduce the functions of the node arranged at each office and to suppress the packet delay.
[0129] For example, a part of communication for the X Corporation is cut through at the office of the Y Corporation. Therefore, the office of the Y Corporation can not access to the part of communication for the X Corporation. Thus, the security is assured by executing the cut-through.
[0130] Furthermore, the X Corporation can communicate with its another office in an adjacent building through the underground node. Communication is also possible between different offices of the X Corporation within the same building.
[0131] According to this embodiment, a network cost per corporation can be reduced and management of the network is facilitated.
[0132] Referring to FIG. 9 , an access network is applied to the above-mentioned ring.
[0133] In this embodiment, the access network is developed from an internet backbone 70 through an ADM (Add/Drop Multiplexer) 1 to a WAN 71 such as a metropolitan ring.
[0134] In the embodiment illustrated in FIG. 9 , the WAN 71 as a whole has a throughput of 150 Mbps. The WAN 71 is connected through an ADM 2 to a throughput of 50 Mbps for a first area 72 where residences and SOHOs are concentrated, through an ADM 3 to a throughput of 10 Mbps for a second area 73 where small sites are distributed, and through an ADM 4 to a throughput of 100 Mbps for a third area 74 where high-rise buildings, molls, campuses are concentrated.
[0135] For example, in the first area 72 , communication of the throughput of 50 Mbps among 150 Mbps is carried out through the ADM 2 . For the remaining 100 Mbps, no communication is performed.
[0136] Similarly, in the second area 73 , communication of 10 Mbps is carried out through the ADM 3 . In the third area 74 , communication of 100 Mbps is carried out through the ADM 4 . In other words, in the second area 73 , the remaining throughput of 140 Mbps is cut through via the ADM 3 . In the third area 74 , the remaining throughput of 50 Mbps is cut through via the ADM 4 .
[0137] Thus, it is possible to save the functions of each of ADMs 2 , 3 , and 4 , to minimize the network delay as a whole, and to assure the security.
[0138] In each of the foregoing embodiments, the packets are dealt with. The packets are, for example, multiplexed in the add packet inserting section 43 of the cut-through transmission apparatus illustrated in FIG. 6 . Alternatively, the packets may be replaced by cells which are cell-multiplexed. In this event also, the effect similar to that obtained in the foregoing embodiments can be achieved.
[0139] In the foregoing embodiments, the SDH path is used. Alternatively, the SDH path may be replaced by a PDH (plesiochronous digital hierarchy) path or a WDM (wavelength division multiplexing) path.
[0140] As described above, in the cut-through transmission apparatus or the cut-through transmission method according to this invention, the signal to be hopped to the next node is cut through in the first or the second layer while only those packets to be dropped at this node are sent to the third layer. Therefore, it is possible to considerably save the operation in the third layer, i.e., the routing operation and to reduce the load imposed upon the router forming the third layer.
[0141] In case where the cut through is carried out in the second layer, the cut through is carried out without terminating the first layer. Therefore, the operation required to terminate the first layer (for example, pointer processing upon terminating the VT 1 . 5 ) is unnecessary. This makes it possible to considerably save the functions.
|
In a node having first, second, and third layers, a packet (or a cell) is mapped in the first layer. The first layer judges whether the packet (or the cell) is to be dropped at the node or to be hopped to a next node. The first layer transmits the packet to the third layer through the second layer when the first layer judges that the packet is to be dropped at the node. The first layer transmits, when the first layer judges that the packet is to be hopped to the next node, the packet to the next node by making the packet cut through the first layer.
| 7
|
TECHNICAL FIELD
This invention concerns stabilized enzymatic liquid detergent compositions for cleaning a wide range of items including hard surfaces and soft goods such as textiles both for commercial and home use.
BACKGROUND ART
Aqueous liquid enzymatic detergents are well-known in the prior art. The enzymes incorporated in liquid detergents have mostly been Bacillus protease, but the prior art also suggests that incorporation of enzymes other than Bacillus proteases may be useful, e.g., other enzyme types (such as amylases, lipases and cellulase) as well as enzymes of non-Bacillus origin (e.g., fungal enzymes). A major problem which is encountered with such compositions is that of ensuring a sufficient storage stability of the enzymes in such compositions.
The prior art deals extensively with stabilization of enzymes in liquid detergents. It is known that a number of commonly used detergent ingredients may reduce their storage stability, e.g., aniomic surfactants and detergent builders. The prior art also suggest that various materials that are not detergent-active can be incorporated as enzyme stabilizers.
It can also be mentioned that JP-A 58-194,806 and JP-A 58-069,808 suggest the incorporation of imidazoline amphoteric surfactant in tooth paste to improve the storage stability of amylase; this teaching has apparently not been utilized in detergents.
It is now the object of the invention to provide a liquid detergent composition comprising a detergent enzyme with improved storage stability.
STATEMENT OF THE INVENTION
The object of the invention is achieved by providing a stabilized enzymatic liquid detergent composition comprising
(a) an effective amount of a microbial enzyme
(b) from about 0.1 to 10% by weight of an amphoteric compounds having the general formula (I) ##STR2## R is zero, or C 1-12 alkyl, or C 11-17 alkyl --CONH --(CH 2 ) 3 n is 1-3
In preferred compounds of formula (I) R is zero or CH 3 , n is 1, i.e., dimethylglycine, and betaine.
In the propyl amido compounds of formula (I), the alkanoyl moiety is a saturated, unbranched and unsubstituted C 12-18 Preferred examples of the group R are those derived from coco acids (mainly C 12 -C 14 ) and from tallow acids (mainly C 16 -C 18 ), e.g., lauryl, stearyl, palmityl.
Preferred proportions for the stabilizer compound are in the range of 0.25-10%, more preferably, 0.5-5% by wt of the liquid detergent composition.
DETAILED DESCRIPTION OF THE INVENTION
Microbial Enzyme
Microbial enzymes suitable for the present compositions include proteases, lipases, amylases and cellulases. The enzymes are derived from microbial sources, such as Bacillus and fungi. Some specific examples of detergent enzymes follow, each identified by enzyme type, microbial source and reference to a commercial product and/or a patent publication:
Protease of Bacillus, especially from B. licheniformis (e.g. Alcalase™) and from alkalophilic Bacillus strains according to U.S. Pat. No. 3,723,250 (e.g. Savinase™) (all available from Novo-Nordisk A/S)
Alpha-amylase of Bacillus, especially B. licheniformis. Termamyl™(Novo Industri A/S)
Protease of Fusarium, especially f. oxysporum, U.S. Pat. No. 3,652,399 (Takeda)
Protease according to DK 6376/87 (Novo)
Cellulase of Humicola, especially H. insolens. Celluzyme™ (Novo Industry A/S), U.S. Pat. No. 4,435,307 (Novo)
Lipase of Humicols, especially H. lanuginosa. Lipolase™ (Novo), EP 177,183 (Novo).
The detergent of the invention may contain two or more detergent enzymes. Examples are combinations of any two of the above enzymes, especially combinations of a Bacillus protease and any one of the above enzymes.
Amphoteric Compound of Formula (I)
Commercially available example of amphoteric compounds having the general formula (I) includes betaine. A related compound is dimethyl glycine; both are preferred compounds. The respective formulae of the two are as follows:
--(CH.sub.3).sub.3 --N.sup.+ --CH.sub.2 --COO-and -(CH.sub.3).sub.2 --N--CH.sub.2 --COO-
Surfactants
The detergent composition of the invention will usually also contain a nonionic surfactant, e.g., about 3-20% by weight. Further, the composition may optionally contain anionic surfactant and/or a second amphoteric surfactant, e.g., about 3-15% by weight.
Examples of suitable surfactants are:
Nonionics: Nonyl phenol ethoxylate, alcohol ethoxylate.
Anionics: linear alkylbenzene sulfonate, secondary alkane sulfonate, alcohol ethoxylate sulfate, alpha olefin sulfonate.
Other Ingredients
The liquid detergent of the invention may be aqueous, e.g., containing 20-70% of water and 0-20% of solvent, e.g., ethanol, propyleneglycol, or containing 1-20% of water and 5-25% of solvent. Satisfactory enzyme stability may be obtained even at water contents above 50%. Alternatively, it may be essentially free of water (e.g., water content below 1%), and will then typically contain 10-30% of solvent.
Typical solvents are mono- and dihydroxy lower alcohols and glycol ethers.
The detergent composition of the invention may be built (i.e., comprising a detergent builder) or unbuilt (i.e., essentially free of a detergent builder).
A soluble calcium salt may be included suitably in the range of about 1-20 millimole/l since calcium ion stabilizes many detergent enzymes.
pH will typically be neutral or alkaline, particularly preferred between 8-10.
The compositions may also contain, depending on the intended use, one or more of the usual known in the art detergent additives such as fabric conditioner (e.g., quaternary ammonium salts, typically 1-5%), foam boosters (e.g., 1-5%), bactericides (e.g., 1-5%), optical brighteners (e.g., 0.1-1%), dyes (e.g., 0.1-1%) and perfumes (e.g., 0.1-1%). Such additives are commonly present in detergent formulations.
In the following Examples the samples were stored at 37° C., the enzyme activity was measured before and after storage, and the results were expressed as residual activity in % of initial activity.
__________________________________________________________________________Example 1__________________________________________________________________________Detergent base I composition, w/wNonionic (Neodol 25-7) AE 25%Anionic (Neodol 25-35) AES 5%Triethanolamine 5%Ethanol 10%Stabilizer (see table below) 5% (control - no stabilizer)protease 1%amylase 0.3%water up to 100%Final pH = 9.0Stability at 37° C. with various stabilizer % Amylase Activity % Protease Activity Left After Six Weeks Left After 8 Weeks TermamylStabilizer Alcalase Esperase Savinase + Alcalase + Esperase + Savinase__________________________________________________________________________none 48 58 48 86 98 94Bentaine 65 78 70 86 86 84Dimethyl glycine 74 79 66 110 72 91Alkyl amino Propyl betaineCocoyl 67 74 61 95 77 91Isostearyl 65 76 60 62 74 118Myristoyl 68 65 59 41 (?) 97 93Palmytoyl 57 65 61 62 84 107__________________________________________________________________________
______________________________________Example II______________________________________Detergent base IINonionic (Neodol 25-7) AE 25%Anionic (Vista C-550) LAS 5%Triethanolamine 5%Ethanol 10%Stabilizer 0 (control), 0.5, 2.5, 5%protease 1%amylase 0.3%water up to 100%adjust to pH = 90Stability at 37° C. with various stabilizer % Activity left after 8 weeksStabilizer Alcalase Savinase Termamyl______________________________________none 43 38 69Bentaine, 0.5 56 52 74 2.5 59 53 74 5.0 66 53 74Dimethylglycine, 0.5 63 53 76 2.5 65 53 76 5.0 66 56 74______________________________________
|
Stabilized enzymatic liquid detergent composition, stabilized by containing therein 0,1-10%, most preferably 0.25-5% of a compound having the following formula: ##STR1## R is zero, or C 1 -12 alkyl, or C 11 -17alkyl--CONH--(CH 2 ) 3 n is 1-3.
| 2
|
STATEMENT OF RELATED APPLICATIONS
[0001] This application claims the benefit of German Patent Application No. 102015007800.3 having a filing date of 19 Jun. 2015 and German Patent Application No. 102015009530.7 having a filing date of 27 Jul. 2015.
BACKGROUND OF THE INVENTION
[0002] Technical Field
[0003] The invention relates to a road paver with a running gear, with at least one hopper for receiving road building material, with a paving screed for producing a road covering, and with a conveyor for conveying the road building material from the hopper to the paving screed. Furthermore, the invention relates to a loader with a running gear with at least one hopper for receiving road building material, with a conveyor for preferably continuously feeding the road building material from the hopper to a road paver for paving a road covering, in particular an asphalt layer or asphalt paving. The invention also relates to a homogenizing mechanism for homogenizing road building material, with a receiving space for receiving the road building material having at least one mixing element for homogenizing the road building material, and with at least one opening in order to feed the road building material to a further device.
[0004] Prior Art
[0005] Surface coverings or road structures, which can for example be walked or driven over, such as in particular carriageway coverings or road paving layers, in particular road pavings, are customarily produced from materials such as, preferably, asphalt. What are generally referred to as pavers, in particular road pavers, are used for producing the material layer that is applied on an underlying surface.
[0006] The material is usually at least substantially continuously fed to the road paver in order to ensure an even application of material that is as uninterrupted as possible. As a buffer for short interruptions in delivery, the road paver generally has a container or hopper that is also known as a material bunker. The material is usually loaded into this hopper from what is referred to as a loader with the aid of a conveyor. The road paver itself usually also has a conveyor, preferably a scraper conveyor, which serves to remove material from the hopper and feed it to a paving screed. The paving screed distributes and compacts the material evenly on the underlying surface. The road paver can be designed as a single-layer or multi-layer paver.
[0007] Surface coverings made from asphalt are processed when hot. In order to ensure optimum durability of the surface covering produced, it is necessary to avoid deviations of properties of the laid material, for example the processing temperature and/or the material composition, from predetermined values. Use is customarily made for this purpose of mixing devices which homogenize the material by mixing, in particular produce a homogeneous temperature distribution and a homogeneous distribution of the components of the material, prior to the laying of the road building material. For this purpose, the mixing device is deposited into the hopper of the road paver and serves equally as a container for receiving the road building material and as a homogenizer. The continuous mixing of the material being laid requires a very large amount of energy and results in severe wear phenomena in the mixing devices. Due to the high energy requirement, the homogenization is associated with an external energy source, in particular with the drive of the paver, and is therefore flexibly usable only to a conditioned extent. Furthermore, the increased energy requirement for the homogenization may reduce the overall power of the road paver or of the loader.
BRIEF SUMMARY OF THE INVENTION
[0008] The invention is therefore based on the object of providing a road paver and a loader and a homogenizing mechanism which permit optimum quality of the material being laid without the operation of the road paver or of the loader being impaired.
[0009] A road paver for achieving this object is a road paver with a running gear, with at least one hopper for receiving road building material, with a paving screed for producing a road covering, and with a conveyor for conveying the road building material from the hopper to the paving screed, characterized in that a mechanism for homogenizing the road building material can be positioned in the hopper, with at least one receiving space for receiving the road building material. According thereto, it is provided that a mechanism for homogenizing the road building material can be positioned in the hopper of the road paver, with at least one receiving space for receiving the road building material. The volume of the homogenizing mechanism or of the receiving space corresponds approximately to the volume of the hopper or is slightly smaller. By positioning the homogenizing mechanism in the hopper, the road building material can be homogenized directly before the road building material is fed to the paving screed or directly before the road building material is laid. As a result, directly before the laying, the road building material is blended in terms of its composition and temperature in such a manner that it can be applied uniformly on an underlying surface in a sufficiently blended and thermally homogeneous state. As a result, an optimum road covering can be produced.
[0010] The present invention preferably furthermore provides that the homogenizing mechanism is an independent unit, in particular has a dedicated energy supply, preferably a dedicated motor, and therefore the homogenizing mechanism can be operated independently of the road paver. According to the invention, it is provided for this purpose that the mechanism outside the receiving space is assigned, for example, an internal combustion engine which drives the mechanism via driving means. The operation of the mechanism is therefore independent of the operation of the road paver. The energy generated by the engine of the road paver can equally be used completely for the production of the road covering and does not additionally have to ensure the operation of the homogenizing mechanism. Furthermore, this separation of the energy supply permits the operation of the homogenizing mechanism while the road paver is in, for example, a waiting mode in which the drive of the road paver is switched off at least temporarily.
[0011] According to the invention, it is furthermore provided that the mechanism has, in the at least one receiving space, at least one mixing element which is preferably drivable in a rotating manner about a shaft parallel to a paving direction of the road paver by means of the motor of the mechanism, and in that the at least one mixing element has blades arranged radially about the shaft, wherein the shaft is preferably assigned a set of long blades and a set of short blades which are arranged in an alternating sequence along the shaft. The shaft of the mixing element is mounted in the receiving space or in the mechanism in such a manner that said shaft is rotatable and is directly connected to the engine. The blades which are attached to the shaft in a manner pointing radially outward are, for example, of wing-like design, wherein the wing can be flat, concave or convex. Furthermore, it is conceivable for the blades to have a “T” shape, wherein the base of the “T” is connected to the shaft. Various blades or various blade combinations can be connected to the shaft depending on the requirements imposed on the material to be mixed or on the road covering to be produced. According to the invention, it is provided that the “T”-shaped blades are arranged in an alternating manner with a short base and a long base along the shaft. Furthermore, the blades which are assigned to a common portion on each shaft can enclose different angles to one another. The blades are dimensioned in such a manner and the shaft is positioned in such a manner that they cover as large a volume region of the receiving space as possible and, during rotation of the mixing element, as large a portion of the road building material as possible is thoroughly mixed or ploughed through.
[0012] In particular, the present invention furthermore provides that the homogenizing mechanism has two mixing elements, the shafts of which are oriented parallel to each other and which are preferably drivable so as to rotate in opposite directions to each other, wherein the distance between the blades, which rotate in opposite directions about the shafts, of the respective mixing elements is minimized, in particular in that the blades, which rotate in opposite directions, of the respective mixing elements overlap. It is thus conceivable, for example, that a short and a long blade of each shaft always lie opposite each other in such a manner that the mixing elements, inter-engaging in a corresponding manner, thoroughly mix or homogenize the road building material. The mixing elements can be driven at different speeds governed by the situation, but are also driven in a rotating manner independently of one another at different speeds or in different directions.
[0013] A further advantageous refinement of the present invention can provide that the homogenizing mechanism has wheels with which the mechanism can be supported on an underlying surface, the wheels are preferably removable from the mechanism, and the mechanism can be fastened, in particular releasably, in the hopper. In particular in the case of a mechanism loaded with road building material, it is advantageous if the mechanism is at least partially supported by wheels. The entire weight is thus not loaded on the road paver and does not impair the driving properties thereof. In order to supply the road paver with road building material, the mechanism can be fastened in the hopper. However, it is also conceivable for the homogenizing mechanism to be positioned on the far side of the road paver and, when required, can be lowered onto the road paver or into the hopper by a lifting mechanism. During this, the road covering is preferably continuously homogenized in the receiving space of the mechanism. The wheels can be coupled to or decoupled from the mechanism, depending on the operating mode.
[0014] Furthermore, it can be provided according to the invention that the homogenizing mechanism has at least one, in particular closable, opening through which the road building material is conveyed onto the conveyor, preferably in that the at least one opening in the homogenizing mechanism at least partially corresponds to an opening in the hopper. An advantageous exemplary embodiment of the present invention provides that the mechanism has an opening on a lower side. If the homogenizing mechanism is not located in the hopper of the road paver, but rather is mounted on the other side of the road paver, this opening is closed such that the road building material does not inadvertently pass onto the underlying surface. As soon as the road building material is sufficiently homogenized, this opening is opened, and therefore said road building material is transported on the conveyor of the road paver to the paving screed.
[0015] A further possibility of refinement of the present invention makes provision that the homogenizing mechanism has a cleaning mechanism by means of which the receiving space and the at least one mixing element can be cleaned, and/or the mechanism, in particular the receiving space, can be heated by the motor, and/or the mechanism, in particular the receiving space has preferably thermal insulation. The cleaning mechanism cleans the homogenizing mechanism preferably with water or with a cleaning liquid or with an emulsion. As a result, it can be provided that the mechanism is assigned a plurality of spray nozzles which are connected to a liquid supply system. The entire interior of the homogenizing mechanism and also the shafts and the blades can be acted upon with the liquid by means of said cleaning mechanism, in particular with the spray nozzles. The interior is preferably cleaned after use of the mechanism. Road building material which has remained in the interior is thus rinsed off as long as the latter is still at a certain temperature. Furthermore, it is conceivable that the cleaning liquid additionally has an anti-stick agent which is intended to have the effect that, when the mechanism is reused, further material immediately solidifies in said mechanism. The liquid supply system comprises a tank which is directly connected to the mechanism, preferably is fastened to the mechanism.
[0016] The present invention can preferably furthermore provide that the cleaning mechanism can be operated automatically, in particular depending on the degree of soiling, filling level of the mechanism with road building material, planned refilling of the mechanism and/or external conditions, such as temperature and humidity. For this purpose, the invention can make provision for the mechanism to have at least one sensor which determines the degree of soiling of the mechanism. If a soiling threshold value that is to be specified can be determined, the cleaning can take place. The mechanism can also have sensors for ascertaining ambient conditions, such as temperature. Depending on the measured values, the cleaning mechanism can be controlled automatically via a control mechanism. In addition, the drive of the shafts can be assigned a sensor for determining the load, wherein the mechanism is cleaned depending on the load on the drive. If the load is, for example, high relative to a reference value, although there is no road building material in the mechanism, the degree of soiling can be classified as being high. Furthermore, the controller of the cleaning mechanism can be connected to an onboard computer of the road paver or to a loader, and therefore the mechanism is cleaned only between two operations to fill it with new road building material.
[0017] Furthermore, the receiving space is heated up by heating elements which are supplied with energy by the engine. So that the energy serving for heating up the road building material is not lost, the receiving space has thermal insulation. This is particularly advantageous in the event that the homogenizing mechanism is mounted away from the road paver. The mechanism can thus be deposited directly onto the road paver when required and the road building material can be laid.
[0018] Furthermore, the present invention can furthermore provide that the at least one mixing element of the homogenizing mechanism can be exchanged, preferably in that the blades of the at least one mixing element can be exchanged. In particular, the mechanical, but also the thermal loading of the blades is very high because of the homogenization. The blades may therefore become worn or defective. In order to ensure continuous operation of the homogenizing mechanism and therefore little idle time, the blades are interchangeable in groups or individually. Furthermore, the blades can be interchanged individually depending on the requirements imposed on the mixing process, and therefore optimized mixing can take place for each road building material.
[0019] A loader for achieving the object mentioned at the beginning is a loader with a running gear with at least one hopper for receiving road building material, with a conveyor for preferably continuously feeding the road building material from the hopper to a road paver for paving a road covering, in particular an asphalt layer or asphalt paving. According thereto, it is provided that the loader is assigned a mechanism for homogenizing the road building material, which mechanism can be positioned in the hopper and has a receiving space for receiving the road building material. Furthermore, it is provided according to the invention that the loader has the same features as the road paver described previously.
[0020] A homogenizing mechanism for achieving the object mentioned at the beginning is a mechanism for homogenizing road building material, with a receiving space for receiving the road building material having at least one mixing element for homogenizing the road building material, and with at least one opening in order to feed the road building material to a further device, characterized in that the at least one mixing element can be driven by an energy supply dedicated to the mechanism. According thereto, the at least one mixing element is drivable by an energy supply dedicated to the mechanism. The at least one mixing element for homogenizing the road building material is assigned here to a receiving space for receiving the road building material. Said receiving space has at least one opening in a lower region in order to feed the road building material to a further device. This further device can be, for example, the conveyor belt of a road paver or of a loader. As a result of the fact that the homogenizing mechanism is assigned a dedicated energy supply, in particular an internal combustion engine, the mechanism or the mixing elements can be operated independently of other devices, such as road pavers or loaders. The homogenizing mechanism is therefore not dependent on the fact that the device which supplies it with road building material has sufficient energy reserves for driving the mechanism and the device itself. Furthermore, the mechanism can be operated independently of the production status of the road covering. The homogenizing mechanism is therefore advantageous, in particular for short-term storage of the road building material, without the latter losing its advantageous properties.
[0021] Furthermore, it is provided in particular that the mechanism can be coupled, in particular can be releasably coupled, to a hopper of a road paver and/or of a loader. For this purpose, the mechanism and/or the road paver or loader are/is assigned coupling elements, such as hooks, eyes and the like.
[0022] The present invention can preferably furthermore provide that at least one mixing element is assigned to the mechanism, which mixing element is preferably drivable in a rotating manner about a shaft parallel to a longitudinal axis and the at least one mixing element has blades arranged radially about the shaft, wherein the shaft is preferably assigned a set of long blades and a set of short blades which are arranged in an alternating sequence along the shaft. The shaft of the mixing element is mounted in the receiving space or in the mechanism in such a manner that said shaft is rotatable and is connected directly to a motor of the mechanism. The blades which are attached to the shaft in a manner pointing radially outwards are, for example, of wing-like design, wherein the wing can be shaped flat, concavely or convexly. Furthermore, it is conceivable that the blades have a “T” shape, wherein the base of the “T” is connected to the shaft. Different blades or different blade combinations can be connected to the shaft depending on the requirements imposed on the material to be mixed or the road covering to be produced. According to the invention, it is provided that the “T”-shaped blades are arranged in an alternating manner with a short base and a long base along the shaft. Furthermore, the blades which are assigned to a common section on the shaft can enclose different angles to one another. The blades are dimensioned in such a manner and the shaft is positioned in such a manner that they cover as large a volume region of the receiving space as possible and, when the mixing element rotates, as large a portion of the road building material as possible is thoroughly mixed or ploughed through.
[0023] It can be provided in a further refinement possibility that the mechanism has two mixing elements, the shafts of which are oriented parallel to each other and which are preferably drivable so as to rotate in opposite directions to each other, wherein the distance between the blades, which rotate in opposite directions about the shaft, of the respective mixing elements is minimized, in particular in that the blades, which rotate in opposite directions to each other, of the respective mixing elements overlap without coming into contact. For example, it is conceivable that a short and a long blade of each shaft always lie opposite each other in such a manner that the mixing elements, inter-engaging in a corresponding manner, thoroughly mix or homogenize the road building material. The mixing elements can be driven at different speeds governed by the situation, but are also driven in a rotating manner independently of one another at different speeds or in different directions. For this purpose, the drive is assigned a corresponding gearing.
[0024] Furthermore, it can preferably be provided that the mechanism has wheels with which the mechanism can be supported on an underlying surface, the wheels are preferably removable from the mechanism and the mechanism can be fastened, in particular releasably, in the hopper. In particular in the case of a mechanism loaded with road building material, it is advantageous if the mechanism is at least partially supported by wheels. The entire weight is thus not loaded on the road paver and does not impair the driving properties thereof. In order to supply the road paver with road building material, the mechanism can be fastened in the hopper. However, it is also conceivable for the homogenizing mechanism to be positioned on the far side of the road paver and to be able to be lowered onto the road paver or into the hopper when required by a lifting mechanism. During this, the road covering is preferably continuously homogenized in the receiving space of the mechanism. The wheels can be coupled to and decoupled from the mechanism depending on the operating mode.
[0025] The present invention can preferably furthermore provide that the at least one opening for feeding the road building material to a further device is closable and at least partially corresponds to an opening in the hopper. In an advantageous exemplary embodiment of the present invention, the mechanism has an opening in a lower side. When the homogenizing mechanism is not located in the hopper of the road paver, but rather is mounted on the far side of the road paver, this opening is closed, and therefore the road building material does not inadvertently pass onto the underlying surface. As soon as the road building material is sufficiently homogenized, this opening is opened such that said road building material is transported on the conveyor of the road paver to the paving screed.
[0026] Furthermore, it can be provided that the mechanism has a cleaning mechanism by means of which the receiving space and the at least one mixing element can be cleaned, and/or in that the mechanism, in particular the receiving space, can be heated by means of the dedicated energy supply, and/or the mechanism, in particular the receiving space, has preferably thermal insulation. The cleaning mechanism cleans the homogenizing mechanism preferably with water or the cleaning liquid. As a result, it can be provided that the mechanism is assigned a plurality of spray nozzles which are connected to a liquid supply system. Furthermore, the receiving space is heated up by heating elements which are supplied with energy by the engine. So that the energy serving for heating the road building material is not lost, the receiving space has thermal insulation. This is advantageous in particular in the event that the homogenizing mechanism is stored away from the road paver. The mechanism can thus be deposited directly onto the road paver when required and the road building material is ready for use. The cleaning mechanism and the spray nozzles serve for acting upon the entire interior of the mechanism with the liquid or a cleaning emulsion. The interior may be cleaned after the mechanism is used. It is conceivable for the cleaning liquid to have an anti-stick agent which is intended to at least partially prevent re-solidification of road building material in the interior of the mechanism. The liquid supply system comprises a tank which is connected directly to the mechanism, preferably is fastened to the mechanism.
[0027] The present invention can preferably furthermore provide that the cleaning mechanism can be operated automatically, in particular depending on the degree of soiling, the filling level of the mechanism with road building material, planned refilling of the mechanism, and/or external conditions, such as temperature and humidity. For this purpose, the invention can make provision for the mechanism to have at least one sensor which determines the degree of soiling of the mechanism. If a soiling threshold value which is to be specified can be determined, the cleaning can take place. The mechanism can also have sensors for ascertaining ambient conditions, such as temperature. Depending on measured values, the cleaning mechanism is automatically controllable via a control mechanism. In addition, the drive of the shafts can be assigned a sensor for determining the load, wherein the mechanism is cleaned depending on the load on the drive. If the load, for example, is high relative to a reference value although there is no road building material in the mechanism, the degree of soiling can be classified as being high. Furthermore, the controller of the cleaning mechanism can be connected to an onboard computer of the loader, and therefore the mechanism is cleaned only between two operations to fill it with new road building material.
[0028] Furthermore, in a particularly advantageous exemplary embodiment of the invention, the at least one mixing element can be exchanged, preferably in that the blades of the at least one mixing element can be exchanged. In particular, the mechanical but also the thermal loading of the blades is very high because of the homogenization. The blades can therefore become worn or functionally incapable. In order to ensure continuous operation of the homogenizing mechanism and therefore little idling time, the blades are interchangeable in groups or individually. Furthermore, the blades can be interchanged individually depending on the requirements imposed on the mixing process, and therefore optimized mixing can take place for every road building material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] Preferred exemplary embodiments of the invention are described in more detail below with reference to the drawing, in which:
[0030] FIG. 1 shows a side view of a road paver with a homogenizing mechanism,
[0031] FIG. 2 shows a perspective illustration of the road paver according to FIG. 1 ,
[0032] FIG. 3 shows a top view of the road paver according to FIG. 1 ,
[0033] FIG. 4 shows a front view of the road paver and of the homogenizing mechanism according to FIG. 1 , and
[0034] FIG. 5 shows a perspective illustration of the homogenizing mechanism.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0035] The road paver 10 which is illustrated schematically in FIG. 1 is of self-propelled design. For this purpose, it has a central drive unit 11 which, for example, has an internal combustion engine which, for example, drives hydraulic pumps for supplying hydraulic engines and optionally a generator for generating energy for electric drives.
[0036] The road paver 10 has a running gear 12 which, in the exemplary embodiment shown in FIG. 1 , is designed as a crawler track, but may also be designed as a wheeled undercarriage or as a different running gear or traveling gear.
[0037] A hopper 14 of tank-like or trough-like design is arranged upstream of the drive unit 11 , as seen in the paving direction 13 . The hopper customarily holds a supply of the road building material, for example asphalt, serving to produce the road covering. A plurality of hoppers 14 may optionally also be provided. The hopper 14 has two flaps 15 which are arranged opposite each other and can be swung up parallel to the paving direction 13 . During the production of the road covering, the two flaps 15 are in a swung-up position, and therefore they enclose an angle, the apex of which coincides with a center axis of the road paver 10 , wherein said apex region is open so that the road building material can slip onto a conveyor belt guided under the flaps 15 . For the refilling of the hopper 14 , the two flaps 15 are pivoted into a horizontal position such that a receiving width of the hopper 14 is maximized.
[0038] By means of conveying members (not illustrated), the road building material from the hopper 14 under the drive unit 11 is transported through the rear end of the road paver 10 , as viewed in the paving direction 13 . The road building material is distributed over the entire working width of the road paver by a spreader screw (not illustrated) arranged behind the running gear 12 . The road building material passes here in front of a paving screed 16 which is hooked on the running gear 12 behind the spreader screw and is movable up and down.
[0039] The road paver 10 is controlled by an operator (not illustrated) from an operating stand 31 . Said operating stand 31 can be designed as a closed or open cab. The operating stand has a driver's seat (not illustrated) and an operating console. During the process of producing the road covering, the road paver 10 moves in the paving direction 13 . In the process, the road building material is conveyed from the hopper 14 to the spreader screw which spreads the material over the entire laying width, and therefore the road building material can be compacted by the following paving screed 16 to form the road covering.
[0040] In the exemplary embodiment of the present invention that is illustrated in FIG. 1 , a mechanism 17 for homogenizing road building material is assigned to the swung-open hopper 14 . Said mechanism 17 is of trough-shape design and its area corresponds approximately to the hopper 14 . The mechanism 17 illustrated in FIG. 2 has a greater height than the hopper 14 . Two mixing elements 19 , 20 are assigned to a receiving space 18 of the mechanism 17 , which receiving space serves for receiving the road building material. Said mixing elements 19 , 20 are connected rotatably to the mechanism 17 and serve for mixing or homogenizing the road building material.
[0041] A front 21 of the mechanism 17 is assigned an energy supply 22 for the mechanism 17 , in particular for the mixing elements 19 , 20 ( FIG. 4 ). Said energy supply 22 may be, for example, an internal combustion engine which drives the mixing elements 19 , 20 . Said energy supply 22 can be operated independently of the drive unit 11 of the road paver 10 . The mechanism 17 can therefore also be operated independently of the road paver 10 .
[0042] In the case of the exemplary embodiment of the energy supply 22 that is illustrated in FIG. 2 , the engine is located in a cupboard-like housing 23 which is assigned wheels 25 on a lower side 24 . During the operation of the road paver 10 , said wheels 25 are located on the underlying surface and therefore serve for additionally supporting the mechanism 17 . The wheels 25 can be attached to or removed from the housing 23 or the device 17 depending on the requirements and properties of the road paver 10 . In particular in order to relieve the device 17 of weight, it may be advantageous for the housing 23 to be supported by the additional wheels 25 .
[0043] In order to clean the receiving space 18 of the mechanism 17 , said receiving space is assigned cleaning mechanisms 26 ( FIG. 3 ). Said cleaning mechanisms 26 have, for example, nozzles through which a cleaning liquid, such as, for example, water or an emulsion with an anti-stick component, can be sprayed into the receiving space 18 or onto the mixing elements 19 , 20 . As a result, after the production of the road covering, the receiving space 18 or the mixing elements 19 , 20 can be freed from impurities, such as remaining road building material. According to the invention, the cleaning devices 26 can be operated automatically depending on various parameters. For this purpose, the mechanism 17 can be assigned at least one sensor and a control device.
[0044] The mixing elements 19 , 20 each have a shaft 27 , 28 , which shafts are oriented parallel to each other and to the paving direction 13 . The shafts 27 , 28 are assigned a multiplicity of blades 29 , in each case spaced apart radially. The blades illustrated by way of example in FIG. 3 are of “T”-shaped design. It can be provided according to the invention that the shafts 27 , 28 are assigned two sets of blades, the “Ts” of which are designed so as to differ in length. Said blades 29 which differ in length are arranged in an alternating manner, as seen in the paving direction 13 , and therefore a long blade 29 is followed by a short blade, etc. Furthermore, the individual blades 29 are arranged on the shafts 27 , 28 in a slightly rotated manner in relation to the paving direction 13 . The two shafts 27 , 28 are spaced apart from each other in such a manner that the blades 29 do not touch, but reach as large a portion of the receiving space 18 as possible.
[0045] According to the invention, the shafts 27 , 28 are driven in such a manner that they rotate in opposite directions to each other. However, it is also possible for the shafts 27 , 28 to rotate synchronously with respect to each other or at different rotational speeds.
[0046] The individual blades 29 each have a type of sleeve 30 at the transition to the shafts 27 , 28 . It is provided that the individual blades 29 are connected releasably to the shafts 27 , 28 such that, in the event of a defective blade 29 , said blade can be interchanged.
[0047] For the production of a road covering, road building material is poured into the receiving space 18 of the mechanism 17 by, for example, a lorry and is then thoroughly mixed or homogenized by the mixing elements 19 , 20 . Furthermore, the mechanism 17 has heating which is supplied in any case by the energy supply 22 . By means of the homogenization of the road building material by the mixing elements 19 , 20 , not only is the material therefore blended, but also a homogeneous distribution of temperature is also brought about.
[0048] The lower side of the mechanism 17 is assigned a preferably closable opening. The homogenized road building material passes through this opening to the conveyor of the road paver 10 , with which said road building material is transported to the paving screed 16 .
[0049] According to the invention, it is provided that the mechanism 17 can be operated independently of the road paver 10 . Accordingly, the mechanism 17 can homogenize road building material even when detached from the road paver 10 ( FIG. 5 ). The energy supply 22 which is dedicated to the mechanism 17 serves here for driving the mixing elements 19 , 20 and for the energy supply of the heating elements (not illustrated). For example, road building material can thus be prepared or homogenized while the road paver 10 is already producing a road covering. When further road building material is required, the mechanism 17 together with the road building material can then be lowered into the hopper 14 . The mechanism 17 according to the invention has proven particularly advantageous in particular because of the increased receiving volume of the mechanism 17 relative to the hopper 14 .
[0050] Even though a road paver 10 is illustrated in FIGS. 1 to 4 exclusively in combination with the mechanism 17 , the mechanism 17 is equally also usable in combination with loaders. At this juncture, it should be explicitly stressed that the present invention is not intended to be restricted to the exemplary embodiments illustrated, but rather, on the contrary, further embodiments are conceivable.
LIST OF REFERENCE NUMBERS
[0000]
10 Road paver
11 Drive unit
12 Running gear
13 Paving mechanism
14 Hopper
15 Flap
16 Paving screed
17 Mechanism
18 Receiving space
19 Mixing element
20 Mixing element
21 Front
22 Energy supply
23 Housing
24 Lower side
25 Wheel
26 Cleaning mechanism
27 Shaft
28 Shaft
29 Blade
30 Sleeve
31 Operating stand
|
A road paver ( 10 ) and a loader and a homogenizing mechanism ( 17 ) which permit optimum quality of the road building material without the operation of the road paver ( 10 ) or of the loader being impaired. Road coverings are customarily produced from materials such as asphalt by means of road pavers ( 10 ). In order to ensure optimum durability of the road covering produced, the road building material is homogenized by mixing devices prior to being laid. The continuous mixing of the road building material requires a very large amount of energy and results in severe wear phenomena in the mixing devices.
| 4
|
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of the Spanish patent application No. P201031921 filed on Dec. 22, 2010, the entire disclosures of which are incorporated herein by way of reference.
FIELD OF THE INVENTION
[0002] This invention refers to procedures for the active control of the current for the connection of very capacitive loads by using SSPCs in electrical energy distribution systems, particularly in aircraft and other vehicle's electrical. The invention also refers to the SSPCs which permit the implementation of said procedures.
BACKGROUND OF THE INVENTION
[0003] There is a strong trend in the aeronautical industry towards the More Electric Aircraft (MEA) concept as a consequence of substitutions of conventional equipments, which depend on pneumatic, mechanic and hydraulic power, by equipments that depend on electrical power. These new equipments provide an improved operational capacity thanks to an increased reliability, a lesser maintenance, an efficient energy conversion and, therefore, a greater efficiency of the aircraft in general.
[0004] To cope with this increase in electrical energy, in the new distribution architectures high voltage levels are used in order to reduce the current levels and, consequently, the cable sections and its weight. On the other hand, more important electric loads can be directly fed with direct current in place of three-phase alternate current, which also means a decrease in the number of cables used to connect the different electric loads.
[0005] This considerable growth of the number of electrical loads in these new electric distribution architectures has contributed to an increase of the quantity of the electrical and electronic components, which could conduce to instability of the whole system due to the interactions between the different equipments that compose the system. Also, raising the level of voltage, of the new electrical energy distribution systems, provokes the appearance of new problems regarding the function of some devices, such as conventional protections, and other inconveniences originated by physical effects in the wires with the new levels of voltage: corona effect, arc fault and others.
[0006] In the aeronautical industry there is an increasing demand for Electrical Power Systems managed by smart control systems for, particularly, managing the connection and disconnection of the electrical loads depending on the operational mode and available power sources.
[0007] As a consequence, solid state power controllers (SSPCs) technology have been introduced inside the electrical management centers. These components have been grouped in Electrical Power Load Management Units (EPLMUs) which offer a number of advantages over electromechanical relays and conventional circuit breakers (CBs).
[0008] Other SSPC characteristics are high reliability, low power dissipation and remote control capability by means of complex hardware. Moreover, these devices, based on power semiconductors, provide a fast response and a lower susceptibility to vibrations in comparison to electromagnetic and electromechanic components, such as CBs.
[0009] In these systems, the connection of very capacitive loads using SSPCs can cause overcurrents which, on the one hand, can irreversibly damage the SSPCs and, on the other hand, introduce perturbations which can affect the rest of the neighbouring components or the own power source.
[0010] These perturbations and overcurrents generate serious problems in onboard electrical distribution systems, and this invention is, therefore, oriented towards solving said problems.
SUMMARY OF THE INVENTION
[0011] An object of the present invention is to provide procedures for the connection of very capacitive loads to electric distribution systems using SSPCs which allow a decrease of the perturbations introduced in the system by the connection transients.
[0012] Another object of the present invention is to provide procedures for the connection of very capacitive loads to electric distribution systems using SSPCs which allow to control the overcurrents in the SSPCs.
[0013] In one aspect, these and other objects are achieved by a connection procedure of a very capacitive load to a voltage bus of an electric distribution system through an SSPC, in which the current of the SSPC is actively controlled, keeping one of its parameters constant during the whole connection time tc of said very capacitive load, or during each one of the set of stretches of said time.
[0014] In a preferred embodiment said parameter is the magnitude of the current iSSPC, which is maintained constant in a value less than or equal to the maximum value iMAX endured by the SSPC, during the whole connection time tc. This way, a reduction of the maximum current is achieved.
[0015] In another preferred embodiment, said parameter is the derivative K of the current iSSPC, which is maintained constant during the whole connection time tc, while the absolute value of the current iSSPC is maintained under or equal to the maximum value iMAX endured by the SSPC. This way, a reduction of the connection time and, particularly, a reduction of the maximum power dissipated during the first moments is achieved.
[0016] In another preferred embodiment, during a first stretch ts, said parameter is the derivative K of the current iSSPC until it reaches an objective absolute value smaller or equal to the maximum value iMAX endured by the SSPC; and during a second stretch, tm, said parameter is the magnitude of the current ISSPC, which is maintained constant at previous said value. Preferably said first stretch ts is comprised between 70% and 80% of the connection time tc, and said second stretch tm is comprised between 20% and 30% of the connection time tc. This way, a reduction of the connection time and of the maximum power dissipated during the first moments is achieved.
[0017] In another preferred embodiment, in each of the first stretches t1, . . . , tn−1 of the connection time tc, said parameter is a derivative K1, . . . , Kn−1 of the current iSSPC until it reaches an absolute value smaller or equal to the maximum value iMAX endured by the SSPC and, in the final stretch tn, said parameter is the magnitude of the current iSSPC which is maintained constant and equal to said value. Preferably, in each of said stretches, the current iSSPC is inside the safe operation curve of the semiconductor (SOA). This way, an optimization of the trajectory of the current depending on the limitations of the SSPC, the slope of the current and the maximum current through the SSPC is achieved, so that the best use of the semiconductor is achieved and its maximum dissipated power is limited.
[0018] In another aspect, the aforementioned objects are achieved by providing an SSPC which can be used in an electrical distribution system between a voltage bus and a very capacitive load, which comprises a semiconductor (preferably a MOSFET or a IGBT), a driver, a microcontroller, an internal power source, an SSPC current measuring device, a measuring device for the load voltage and also current controlling circuits connected to said microcontroller and said driver, which allow to carry out any of said procedures for the connection of very capacitive loads. These control circuits enable the optimization of the SSPC to improve its response times and decrease the power loss by the semiconductor during the connection transients.
[0019] In a preferred embodiment, said circuits include suitable components to carry out the active control of the current iSSPC by the SSPC, regulating the voltage vGS or vCE of the control entrance of the semiconductor.
[0020] Other characteristics and advantages of the present invention will be clear from the following detailed description of embodiments illustrative of its object in relation to the attached figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 shows the diagram during the connection of a capacitive load to a voltage bus through an SSPC and
[0022] FIG. 2 shows time graphs of the overcurrent and the voltage during the connection transient of a very capacitive load.
[0023] FIG. 3 shows the variation over time of the current in the SSPC during the connection of the very capacitive load in the active control with constant current procedure according to the present invention.
[0024] FIG. 4 shows the variation over time of the current in the SSPC during the connection of the very capacitive load in the active control with slope constant current procedure according to the present invention.
[0025] FIG. 5 shows the variation over time of the current in the SSPC during the connection of the very capacitive load in the generalized active control procedure according to the present invention.
[0026] FIG. 6 shows the variation over time of the current in the SSPC during the connection of the very capacitive load in the active control by optimum trajectory current procedure according to the present invention.
[0027] FIG. 7 shows the power dissipated in the semiconductor during the connection transient of a very capacitive load, for the four procedures mentioned.
[0028] FIG. 8 is a block diagram of an SSPC according to the present invention.
[0029] FIG. 9 is a block diagram which illustrates the functionality of the control circuits incorporated in the SSPC according to the present invention.
[0030] FIGS. 10 and 11 are detailed diagrams of preferred embodiments of said SSPC control circuits.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] In an aircraft electric distribution system that uses SSPCs as control devices for the connection of the loads, one of the problems which arises is the connection of very capacitive loads, which are present in a great number of the aircraft devices which require electrical energy and which, as is known, can cause overcurrents in the SSPCs, damaging them.
[0032] That way, for example, in the system illustrated in FIG. 1 , during the connection of the very capacitive load 17 using the SSPC 15 , overcurrents are produced which are directly related to the value of the capacitor of the load 17 and to the value of the bus voltage VBUS 13 in which is connected. FIG. 2 shows the variation over time of the current iSSPC(t) in the SSPC 15 and the voltages vC(t), vSSPC(t) in, respectively, the load 17 and the SSPC 15 , during the connection period which ends at time tc.
[0033] The overcurrent is caused by the initial energy demand of the capacitor, as it is initially uncharged. Therefore, if the current through the SSPC 15 is not controlled during the connection of a very capacitive load 17 , an overcurrent is produced which reaches a level high enough to charge the capacitor connected to the output of the SSPC 15 , with the voltage VBUS fixed by the main bus 13 .
[0034] These types of connections present several problems, firstly, they can irreversibly damage the semiconductor and, as a consequence, the SSPC 15 and, secondly, due to the overcurrents, perturbations are introduced which can affect the rest of the neighbouring components or the own power source.
[0035] As far as the present invention is concerned, it shall be understood that a very capacitive load 17 is a load with, preferably, a capacity of more than 150 microfarads.
[0036] The basic idea of the present invention to cope with this problem, is to provide a procedure for the connection of a very capacitive load 17 to a voltage bus 13 using an SSPC 15 , in which an active control is carried out, which maintains a parameter of the current iSSPC(t) of the SSPC 15 constant during the whole connection time tc of said very capacitive load 17 , or during each one of a set of stretches of said time.
[0037] In a first embodiment of the procedure, which we will refer to as active control with constant current procedure, illustrated in FIG. 3 , an active control is carried out which maintains a constant value for the current iSSPC(t) in the SSPC 15 , over the nominal value iNOM, but below the maximum level iMAX endured by the SSPC, during the connection time, which ends at tc. FIG. 3 also shows the variation over time of the current iR(t) in the load 17 during the connection time. This active control with constant current procedure through the SSPC 15 is better than the passive control procedures known in the prior art and allows the connection of big capacitors in small connection times. The connection times of the loads can also be configured and no hardware modifications of the device are required to implement other connection times. The connection of the load by maintaining a constant current means that the semiconductor must endure high powers during the first moments.
[0038] In a second embodiment of the procedure, which we will refer to as active control with slope constant current procedure, illustrated in FIG. 4 , an active control is carried out to connect the very capacitive load 17 by a current ramp iSSPC(t) in the SSPC 15 , whose derivative K is maintained constant during a connection time tc, which varies depending on the capacity of the load 17 , never exceeding the maximum level endured by the SSPC 15 . FIG. 4 also shows the variation over time of the current iR(t) in the load during the connection time. This active control with slope constant K current procedure through the SSPC 15 is also better than the passive control procedures and allows the connection of big capacitors in small connection times (but bigger than those achieved by the active control with constant current procedure, although the power dissipated is less). On the other hand, the connection times of the loads can be configured and no hardware modifications of the device are required to implement other connection times.
[0039] In a third embodiment of the procedure, which we will refer to as for a generalized active control procedure, illustrated in FIG. 5 , an active control is carried out to connect a very capacitive load 17 in two stretches: the first by means of a current ramp iSSPC(t) whose derivative K is maintained constant during a certain period of time ts until it reaches a value that never exceeding the maximum level iMAX endured by the SSPC 15 , and the second in which the current is maintained constant during a maintenance period of time tm, until the capacitor is completely charged. FIG. 5 also shows the variation over time of the current iR(t) in the load during the connection time. Even though the time periods ts and tm assigned to said stretches are variable time periods determined depending on the characteristics of the load 17 , in a preferred embodiment of the invention, a time period ts comprised between 70% and 80% of tc and a time period tm comprised between 30% and 20% of tc are assigned. This generalized active control procedure is more versatile than the previous ones, as it allows the connection of big capacitors in small connection times, with smaller dissipated powers when compared with the procedure by active control with a constant current, although the power dissipated is greater than in the case of the procedure by active control with constant derivative K of the current. On the other hand, the connection times of the loads can be configured and no hardware modifications of the device are required to implement other connection times, as in the case of the other two procedures mentioned.
[0040] In a fourth embodiment, which we will refer to as active control by optimum trajectory current procedure, illustrated in FIG. 6 , an active control is carried out which allows the connection of a very capacitive load 17 in several stretched of three types:
Stretch with constant derivative of the current, with an initial value of zero. Stretch with constant derivative of the current, with an initial value different to zero. Stretch at a constant current.
[0044] In any case, the first stretch of connection is a stretch with constant derivative of the current, which is the method which imposes the smallest thermal dissipation in the semiconductor during the first moments, and the final stretch is at a constant current. In the most general case with n stretches, the trajectory of the current in said n stretches with durations t1, t2, . . . tn, is determined by fixing the constant derivatives K1, . . . , Kn of each stretch, taking into account the safe operation curve of the semiconductor (SOA). This active control by optimum trajectory current procedure improves the connection of the load, compared to the three preceding procedures, as it allows the connection of big capacitors in small connection times, optimizing the dissipated powers. On the other hand, as in the preceding procedures, the connection times of the loads can be configured and no hardware modifications of the device are required to implement other connection times. The main advantage is it allows a reduction in the number of semiconductor elements needed for the commutation of a very capacitive load because, by means of this procedure, the SSPC adjusts the connection times depending on the load, regardless of its value. It also improves the connection times of the load, compared with the other active control procedures, as it uses 100% of the functioning regions of the semiconductor and adjusts itself to the SOA of the main semiconductor.
[0045] FIG. 7 shows the variation over time of the dissipated powers 3, 5, 7, 9 in, respectively, the active control with constant current procedure, the active control with slope constant current procedure, the generalized active control procedure and the active control by optimum trajectory current procedure. Considering the dissipated powers, it can be said that the maximum exploitation of the semiconductor is produced by the active control by optimum trajectory current procedure, while the minimum exploitation of the semiconductor is produced by the active control with constant current procedure.
[0046] On the other hand, Table 1 shows, as an example, the results obtained with the four procedures mentioned with regard to the use of the semiconductor. As can be observed, the relation between the average power dissipated by the semiconductor during the connection time, tc, and the maximum power that can dissipate, according to the SOA is different, depending on the connection procedure. The capacity which can be connected during the same connection time, tc, increases, as a better use of the semiconductor is achieved.
[0000]
TABLE 1
V BUS
I MAX
I NOM
t C
C
P AVG
P Max
P AVG /P Max
[V]
[A]
[A]
[ms]
[μF]
[W]
[W]
[%]
Active control with
270
4.4
1
10
143.6
568
1200
47.33%
constant current
Active control with
270
11.7
1
10
204.3
781
1200
65.08%
slope constant
current
Generalized active
270
10.95
1
10
239.5
794
1200
66.17%
control
(75% t s ; 25% t m )
Active control by
270
200
1
10
316.4
1200
1200
100%
optimum trajectory
current
[0047] FIG. 8 shows a block diagram of an SSPC 15 , in which the preceding active control procedures can be implemented, which includes a semiconductor 21 , a driver 23 , current control circuits 25 , 26 , an internal power source 27 , a measuring device for the load voltage 31 , a measuring device for the SSPC current 29 and a microcontroller 33 . The invention is applicable to any semiconductor (bipolar, SIC, etc) and preferably to a MOSFET or an IGBT.
[0048] Said current control circuits 25 , 26 are made up of components which allow the implementation of the connection procedures mentioned.
[0049] A description of a preferred embodiment of said circuits, in relation to the FIGS. 8 , 9 , 10 , 11 will now follow.
[0050] The aim of the driver 23 that controls the semiconductor 21 is to control the voltage between gate and source of the semiconductor used, from the optocoupled output signals, which will be provided by the microcontroller 33 . Taking into account that a driver 23 exists, which switches the semiconductor 21 on and off, a control circuit 26 is defined, which enables a control of the output current of the SSPC 15 by regulating the voltage vGS or vCE of the control entrance of the semiconductor 21 (see FIG. 9 ).
[0051] FIG. 10 shows the regulating circuit 26 of the voltage in the capacitor Cg, which works together with the driver 23 , which enables a regulation of the charge and discharge of the gate capacitor Cg, with different time constants. This way, the regulation is optimum and there are no sudden jumps in the Cg voltage and in the semiconductor 21 gate, and as a consequence, great changes in the current levels through the SSPC 15 are avoided. To achieve these times, a circuit made up of diode networks and resistors (RgON y RgOFF), which respectively limit the charge and discharge of the capacitor, is included.
[0052] The shoot pulses of the driver 23 are regulated by the microcontroller and are programmable according to the maximum current, connection time or safe operation area of the semiconductor (SOA) requisites. To that purpose, a feedback loop 25 based in an operational amplifier configured as a comparator (see FIG. 11 ) has been added. By means of this amplifier, the current level measured in the SSPC 15 by the current measuring device 29 is compared with the level fixed by the microcontroller, be it a ramp, a constant level, or any other control signal. This comparator generates the shoot pulses needed during the connection transients, so that it regulates the charge and discharge of the capacitor Cg voltage, and then the current through the SSPC 15 during the connection transient of the very capacitive load 17 .
[0053] Although the present invention has been described in relation to preferred embodiments, it is evident that modifications within its scope can be introduced, understanding that it isn't limited to said embodiments, but to the content of the following claims.
[0054] As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
|
Procedures for the connection of a very capacitive load to a voltage bus of an electric distribution system, by using a solid state power controller, where the current through the SSPC is controlled actively by maintaining one of its parameters (the current and/or the derivative of the current) constant during the entire connection time of said very capacitive load or during each one of a set of stretches of said connection time. The invention also refers to SSPCs structured to carry out said procedures.
| 8
|
BACKGROUND OF THE INVENTION
Acrylic acid grafted polymers are known in the art. By way of illustration, U.S. Pat. No. 4,146,488 discloses metal lubricant compositions containing poly(oxyalkylene) compounds grafted with about 3 to 15% by weight of acrylic or methacrylic acid followed by neutralization with alkanolamine. That patent discloses at column 7, lines 50 to 68 and column 8, lines 1 to 15, that such a polymer, when used in aqueous monoethanolamine borate solution is effective in providing cast iron corrosion resistance protection.
Heretofore, the effects of polymerizable-acid grafted polymers on aluminum surfaces have not been seen or explored in the literature. It has now been surprisingly found that aqueous and/or alcohol solutions of a certain class of such polymers have a particularly beneficial effect in inhibiting aluminum corrosion, most notably with respect to an aggressive form of aluminum corrosion, namely that which occurs at "heat rejecting" aluminum surfaces such as solar panels and the cylinder heads and blocks of internal combustion engines. This finding is particularly significant in view of the fact that there is increasing reliance on the use of aluminum components in the manufacture of heat transfer systems, such as those in solar and automotive systems, as part of an overall trend toward weight reduction.
OBJECT OF THE INVENTION
It is an object of the present invention to provide an aluminum corrosion inhibitor composition comprising an aqueous and/or alcohol solution of a polymerizable-acid graft copolymer, together with a method for using such composition.
This and other objects will become apparent from a reading of the following detailed specification.
SUMMARY OF THE INVENTION
In one aspect, the present invention relates to an aluminum corrosion inhibitor composition that is useful inter alia in heat transfer systems such as those found in solar and automotive systems. When used in an automobile, the composition can be added directly to the automobile coolant system via the radiator filler neck as is done with conventional antifreezes.
The composition of the present invention comprises:
(a) alcohol or mixtures of water and alcohol,
(b) a polymerizable-acid graft copolymer comprising an unsaturated grafting acid (such as an acid selected from the group consisting of acrylic, methacrylic, crotonic and maleic acids) and having a percent acid graft of between about 1% and about 60% and a base polymer consisting of a poly(oxyalkylene) compound of the formula: R"((OC n H 2n ) z OR') a wherein R' and R" are members selected from the group consisting of a hydrocarbon radical, a hydrogen atom or an acyl radical, a is an interger having a value of 1 to about 4, n has a value of 2 to 4 inclusive, z is an integer having a value of from 4 to 800 inclusive, and preferably 8 to about 500, said base polymer having a molecular weight of between about 200 and 10,000,
and wherein the amount of component (b) is between greater than about 0.05 wt. % and about 20 wt. % (preferably from about 0.1 wt. % to about 15 wt. %), based on the total amount of component (a) plus component (b) in said concentrate. The composition preferably consists essentially of component (a) plus component (b).
In another aspect, the polymerizable-acid graft copolymer can, if desired, be partially or wholly neutralized with any base to provide a desired pH for the corrosion inhibitor composition. Such neutralization can take place before or after addition of the graft copolymer to the solution.
In yet another aspect, the invention encompasses methods for making the above composition, either by direct addition of the polymerizable acid grafted copolymers to water and/or alcohol or by adding the water and/or alcohol to the acid grafted copolymers or by pre-forming a composition concentrate. The corrosion inhibitor composition can be made from the composition concentrate by dilution of the concentrate with water and/or alcohol at the use site. In the concentrate, the amount of component (b) employed is between greater than about 0.05 wt. % and about 20 wt. % based on the total amount of component (a) plus component (b) in said composition.
DETAILED DESCRIPTION OF THE INVENTION
When component (a) of the above composition consists of a mixture of alcohol and water, such mixture can have a water to alcohol weight ratio ranging from 99:1 to 0:100.
The poly(alkylene oxide) compounds used to make the graft copolymers are known in the art. These are commonly produced by reacting an alkylene oxide or a mixture of alkylene oxides, added sequentially or in combination, with an alcohol. Such alcohols can be monohydric or polyhydric and correspond to the formula R"(OH) a wherein R" and "a" are as defined above. Such alcohols include metnanol, ethanol, propanol, butanol, ethylene glycol, glycerol, the monoethylether of glycerol, the dimethyl ether of glycerol, sorbitol, 1,2,6-hexanetriol, trimethylolpropane, and the like.
Generally, the poly(oxyalkylene compounds used in this invention have molecular weights (number average) in the range of about 200 to about 10,000, preferably from 0 about 400 to about 5,000.
The grafting of the polymerizable-acid onto the poly(oxyalkylene) compounds can be carried out by free radical polymerization as is known in the art, to afford a grafted acid content of between about 1 and about 60 (preferably between about 5 and about 20).
Although useful grafting acids include, among others, acrylic, methacrylic, crotonic and maleic acids, preferred acids include acrylic and maleic acids, (more preferably acrylic acid).
The preferred poly(oxyalkylene) compounds useful in the present invention are the well-known poly(oxyethylene-oxypropylene) polymers, having a weight ratio of oxyethylene ("EO") to oxypropylene ("PO") of between 0:100 and 100:0.
As mentioned above, the acid graft copolymers useful in the present invention can, if desired, be conveniently partially or wholly neutralized to a desired pH base to provide the salt of the acid graft copolymer. Illustrative bases would include the following (although any known base can be used): ammonium hydroxide, alkali metal hydroxides, or alkaline earth metal hydroxides; or amines of the formula: ##STR1## wherein R is hydrogen or alkyl having 1 to about 6 carbon atoms, each of R 1 , R 2 , and R 3 is an alkylene radical having 2 to 4 carbon atoms, e has a value of 0, 1, 2 or 3 and b, c, and d each have a value of 0 or 1, with the proviso that when b, c and d each have a value of 1, then e is 0.
When an alkanolamine is employed, the preferred alkanolamine is a trialkanolamine but mono- and di-alkanolamines can also be used. The preferred trialkanolamine is triethanolamine although others, such as, trimethanolamine, methyldiethanolamine, tripropanolamine, diethylmonopropanol amine, tributanolamine, and the like, can also be used if desired. Exemplary monoalkanolamines include monoethanolamine, monopropanolamine, N-methyl ethanolamine, N,N-dimethyl ethanolamine, N,N-diethyl ethanolamine, and the like. Exemplary dialkanolamines include diethanolamine, dibutanolamine, N-methyl diethanolamine, N-ethyl ethanolamine, and the like.
Other useful amines include triethylamine, di-n-propylamine, tri-n-propylamine n-butylamine, n-amylamine, di-n-amylamine, n-hexylamine, ethylene diamine, propylene diamine, ethanolamine, diethanolamine, triethanolamine, cyclohexyl-amine, dicyclohexylamine, ethyl hexylamine, N-ethyl aniline, morpholine ethanol, 1-(N-methyl)-aminohexane-2,3,4,5,6-pentol, and mixtures of mono- and di-n-alkylamines. A commercial mixture of amyl amines consisting of about 60 percent mono-n-amylamine and about 40 percent di-n-amylamine can be used, although a wide variety of other commercial amines can suitably be employed.
Other optional additives may be employed in minor amounts of less than 50 wt. percent based on the weight of the aluminum corrosion inhibitor composition. Typical optional additives would include, for example, known corrosion inhibitors for aluminum or other metals in admixture with the polymerizable-acid graft copolymers of the present invention such as, for example, alkali metal, alkaline earth metal or alkanolamine salts of silicates, borates, phosphates and benzoates, hydroxy benzoates or acids thereof, silicones alkali metal nitrates, alkali metal nitrites, tolyltriazole, mercaptobenzothiazole, benzotriazole, and the like, or mixtures thereof. If one or more of the known inhibitors are employed together with the inhibitors of the present invention, the sum total of all inhibitors should be used in an "inhibitory effective amount", i.e., an amount sufficient to provide some corrosion inhibition with respect to the aluminum surfaces to be protected. Other typical optional additives would include wetting agents and surfactants such as, for example, known ionic and non-ionic surfactants such as the poly(oxyalkylene) adducts of fatty alcohols; antifoams and/or lubricants such as the well-known polysiloxanes and the poly-oxyalkylene glycols, as well as any other minor ingredients known in the art that do not adversely affect the aluminum corrosion resistance sought to be achieved.
As used herein, the term "percent acid graft" designates such graft on a weight basis.
The following example is intended to illustrate, but in no way limit the present invention.
EXAMPLE 1
A. Preparation of Acid Graft Copolymers
An acid graft copolymer within the scope of the present invention was prepared using acrylic acid and a base polymer consisting of butanol started poly(oxyethylene-oxypropylene) copolymer having a molecular weight of 770 and a viscosity of 170 Saybolt seconds at 100° F. as follows:
Into a 5-liter, 3-neck round bottom flask fitted with a water condenser, thermocouple, stirrer, and means of introducing acrylic acid and catalyst, was placed 2700 gms of the polymer. By means of a heating mantle, the flask was heated to a temperature of 150° C., followed by the addition of 35 grams of tertiary-butyl perbenzoate and 312 grams of acrylic acid. The peroxide feed was begun 10 minutes prior to starting the acid feed and both ingredients were fed over a period of 90 minutes after which the product (herein called "Grafted Copolymer A") was allowed to cool to room temperature.
Several other acid grafted copolymers were prepared in accordance with the above procedure to provide Grafted Copolymers B, C, D, and E as listed in Table I below. The "% Graft" for the grafted copolymers of Table I was calculated on the basis of the total amount of grafting acid fed into the reaction mixture.
TABLE I______________________________________ Properties of Base Polymer ViscosityGrafted Graft- % (SayboltCo- ing % EO/ Molec- sec. atpolymer Acid Graft Starter PO ular Wt. 100° F.)______________________________________A acrylic 10% butanol 50/50 770 170B acrylic 60% butanol 0/100 710 165C acrylic 5% butanol 0/100 2051 1145D acrylic 10% butanol 50/50 4000 5100E acrylic 15% ethyl- 100/0 8000 solid ene glycol______________________________________
The above acid grafted copolymers were individually tested in solutions employing the following formulation:
______________________________________FORMULATIONComponent Wt. %______________________________________Ethylene glycol 90.9273Boric acid 0.404875% H.sub.3 PO.sub.4 1.687745% KOH 3.8802Total wt. % 96.00______________________________________
To the above formulation was added the individual acid grafted copolymer in an amount as specified in Table II below. Additional ethylene glycol was then added to the formulation as required to provide 100 wt. percent of a concentrate.
The concentrates were diluted to make working solutions by mixing 33 wt. % of concentrate with 67 wt. % of "corrosive water" (deionized water containing 300 ppm. each of SO 4 -- , HCO 3 - and CL - , all added as the Na salts).
B. Laboratory Disc Heat Flux Test: Method, Apparatus and Results
A test method used in the industry was employed to determine the inhibitory effect of the formulated composition of the present invention with respect to heat rejecting aluminum surfaces. This test method is described in Corrosion, 15 257t at 258t (1959) "Laboratory Methods for Determining Corrosion Rates Under Heat Flux Conditions" and also in an ASTM textbook entitled, "Engine Coolant Testing: State of the Art", A Symposium Sponsored by ASTM Committee D-15, at pages 17-19 (Printed, May 1980), both incorporated herein by reference. A summary of the test equipment and procedure follows:
The apparatus consists of a 1 liter flask, fitted with a condenser, a thermometer, a temperature controller a 11/2 inch diameter×1/4 inch thick No. 319 aluminum casting alloy (herein "the aluminum disc"), and a soldering iron heat source.
The apparatus was charged with 750 ml. of test solution and heated to effect boiling at the aluminum disc surface and to maintain a solution temperature of 85° C. The test duration was 168 hours. The weight loss of aluminum from the aluminum disc was determined and used as a measure of corrosion inhibitor effectiveness.
The results are given in Table II which follows:
TABLE II______________________________________Working Solution Wt. % Grafted Wt. % Grafted Al wt.Containing Grafted Copolymer in Copolymer in lossCopolymer Concentrate Working Solution (mg.)______________________________________A 0.15 0.05 255A 0.33 0.11 117A 0.75 0.25 128B 0.75 0.25 108C 0.75 0.25 122D 0.75 0.25 79E 0.75 0.25 169-- (Comparison I).sup.1 No graft.sup.1 No graft.sup.1 320-- (Control).sup.2 None.sup.2 None.sup.2 231______________________________________ .sup.1 Comparison I contained no graft copolymer, but instead contained i the concentrate 0.675 wt. % of the base polymer used to prepare Grafted Copolymer D together with 0.075 wt. % of polyacrylic acid having a MW of 5000 in the above specified "Formulation". .sup.2 Base Formulation containing no graft or other polymer.
|
Composition providing aluminum corrosion resistance comprising aqueous and/or alcohol solution of a polymerizable-acid graft copolymer consisting of a poly(oxyalkylene) compound grafted with an unsaturated acid, said graft copolymer having a percent graft of between about 1 and about 60 percent. Typical acids would be those selected from the group consisting of acrylic, methacrylic, crotonic and maleic acids.
| 8
|
RELATED APPLICATIONS
The current application claims priority to U.S. Provisional Application No. 61/422,092, filed Dec. 10, 2010, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
The current invention is directed toward a method for producing a semiconducting graphene oxide material in which the oxidation is confined to the graphene layer.
BACKGROUND OF THE INVENTION
Graphene, a material comprising a lattice of carbon atoms positioned in a ‘honeycomb-type’ arrangement and tightly joined by in-plane sp 2 bonds, has garnered much attention from research communities because its unique electrical and mechanical properties make it potentially ideally suited for various engineering applications, such as nanoelectronics and integrated circuits. Compared to other conductive and semiconductive materials, graphene has a superior carrier mobility and low resistivity, making it a promising candidate for integrated circuits. (Castro Neto A H, et al., Rev Mod Phys. 2009, 81, 109-62; Geim A and Novoselov K., Nature Materials. 2007, 6, 183-91; Novoselov K S, et al., Science. 2004, 306, 666-9; Novoselov K S, et al., Nature. 2005, 438, 197-200; Novoselov K S; McCann E, et al. Nat Phys. 2006, 2, 177-80; and Zhang Y, et al., Nature. 2005, 438, 201-4, the disclosures of which are incorporated herein by reference.)
However, graphene is inherently a semimetallic material—as opposed to a semiconductor material—and this limits its usability. (See, e.g., Oostinga J B, et al., Nature Materials. 2007, 7, 151-7; Ni Z H, et al., ACS nano. 2008, 2, 2301-5; Pereira V M, et al., Physical Review B. 2009, 80, 045401; Han M Y, et al., Phys Rev Lett. 2007, 98, 206805-8; Nakada K, et al., Phys Rev B. 1996, 54, 17954-61; and Ponomarenko L A, et al., Science 2008, 320, 356-8, the disclosures of which are incorporated herein by reference.) As a result, researchers have employed a number of methods to introduce a finite band gap within graphene, and thereby convert it into a semiconductor. One approach to introduce an energy gap opening in graphene is to break its lattice symmetry using foreign atoms such as hydrogen, gold, nitrogen, oxygen, and organic molecular dopants. (See, e.g., Bostwick A, et al., Physical Review Letters. 2009, 103, 056404; Balog R, et al., Nat Mater. 2010, 9, 315-9; Sessi P, et al., Nano letters. 2009, 9, 4343-7; Geirz I, et al., Nano Lett. 2008, 8, 4603-7; Wehling T, et al., Nano letters. 2008, 8, 173-7; Luo Z, et al., Appl Phys Lett. 2009, 94, 111909-11; Leconte N, et al., ACS nano. 2010, 4, 4033-8; Nourbakhsh A, et al., Nanotechnology. 2010, 21, 435203-11; Kim D C, et al., Nanotechnology. 2009, 20, 375703, Alzina F, et al., Physical Review B. 2010, 82, 075422 Gokus T, et al., ACS nano. 2009, 3, 3963-8; Childres I, et al., New Journal of Physics. 2011, 13, 025008; Dong X, et al., Small. 2009, 5, 1422-6; and Lu Y H, et al., The Journal of Physical Chemistry B. 2008, 113, 2-5, the disclosures of which are incorporated herein by reference.)
For example, researchers have used wet oxidation methods to insert foreign atoms into the graphene structure. These impurities alter the sp 2 carbon hybridization in graphene to an sp 3 carbon hybridization, and eliminate the π-bonds that facilitate charge transport across the graphene plane. Consequently, with diminished charge transport the desired band gap is obtained. (See, e.g., Elias D C, et al., Science. 2009, 323, 610-3; Sofo J O, et al., Physical Review B. 2007, 75, 153401; and Boukhvalov D W, et al., Physical Review B. 2008, 77, 035427, the disclosures of which are incorporated herein by reference.) However, the wet oxidation process is less than ideal: it typically uses harsh chemicals, such as strong acids and oxidizing agents; it takes a significantly long time to complete; and it does not allow for the creation of site specific oxidation, which substantially limits the usability of this modified graphene. (See, e.g., Hummers W S and Offeman R E, J Am Chem Soc. 1958, 80, 1339; Park S and Ruoff R, Nature nanotechnology. 2009, 4, 217-24; Li D, et al., Nat Nanotechnol. 2008, 3, 101-5; Sun X, et al., Nano Res. 2008, 1, 203-12; Becerril H A, et al., Nano Lett. 2008, 2, 463-70, the disclosures of which are incorporated herein by reference.)
Researchers have also experimented with using plasma oxidation, a dry oxidation method, to create a graphene oxide semiconductor material. This method is advantageous in a number of respects: it does not use any harmful chemicals; it is a more rapid process; and it allows for site specific oxidation. For example, Nourbakhsh et al. have fabricated and characterized such a graphene oxide layer. (See Bandgap Opening in Oxygen Plasma-Treated Graphene, Nourbakhsh et al. Nanotechnology 2010, 21, 435203-11, the disclosure of which is incorporated herein by reference.)
Previous studies also show that the p-doping level, electron-electron scattering rate, and the total density of states of an UV/ozone treated graphene are dictated by the defect density associated with surface concentration of oxygenated functional groups and oxygen molecule. At a very low defect density, the p-doping level and electron-electron scattering rate increase in proportion to the increase in defect density. At a higher defect density, a continuous decay and smoothing of the van Hove singularities becomes apparent, and a further increase in the defect density results in a significant drop in the conductance. This indicates a strong Anderson metal—insulator transition, with an overall change in the carrier concentration in the order of 10 12 cm −2 . These studies also show that an increase in defect density becomes increasingly difficult as the oxygen adsorption reaches a constant value after a certain UV/ozone exposure time. (See, e.g., Leconte N, et al., ACS nano. 2010, 4, 4033-8; Nourbakhsh A, et al., Nanotechnology. 2010, 21, 435203-11; Kim D C, et al., Nanotechnology. 2009, 20, 375703, Alzina F, et al., Physical Review B. 2010, disclosed above.)
Similar electronic transport behaviors are also observed in oxygen plasma treated graphene, where the p-doping level increases with the increase of oxygen plasma exposure, rendering the oxidized graphene unipolar. As the oxygen plasma exposure increases further, the level of disorder in the structural symmetry of graphene becomes more pronounced, which leads to a decrease in conductance and mobility, as well as a transition from semimetallic to semiconducting behavior. However, the prior art has yet to develop a process for the production of a semiconductor graphene oxide material suitable for practical applications. For example, although Nourbakhsh et al. discuss characterizing a graphene oxide layer created by a plasma oxidation process, the authors do not provide any guidance on how to avoid the creation of oxides on the substrate surface. For example, the authors incorrectly suggest that the band gap that can be created using this dry oxidation process can be as high as 3.6 eV (they reached this figure via calculation). It has now been discovered that such high band-gaps are impossible absent the destruction of the graphene oxide band gap. Accordingly a need exists for improved fabrication processes capable of forming graphene oxide materials in which the oxidation is confined within the graphene layer such that they can be used in practical applications.
SUMMARY OF THE INVENTION
The present invention is directed to a novel fabrication method that allows for a versatile but precise manipulation of graphene so as to develop graphene oxide material that possesses an appreciable, and determinable, band gap, and in which the oxidation is confined to the graphene layer. This novel fabrication method can thus develop graphene oxides that are optimized for practical use. The process includes subjecting a graphene sample to a dry oxidation process for a pre-determined period of time, wherein the length of oxidation exposure determines the magnitude of the band gap.
In one embodiment of the invention, masks are used in conjunction with the oxidation process, and the masking and oxidation steps are optionally iterated in order to achieve a desired configuration.
In yet another embodiment of the invention, a UV/Ozone oxidation process, which can allow for a greater control in achieving a desired band gap, is used as the oxidation process.
In still another embodiment, a remote indirect plasma oxidation treatment, which allows for more expedient oxidation while providing a safer oxidation treatment as compared to a direct plasma oxidation treatment, is used as the oxidation process.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will be more fully understood when considered with respect to the following detailed description, appended claims, and accompanying drawings, wherein:
FIG. 1 provides a flow chart of an exemplary embodiment of a process for forming a graphene oxide material in accordance with the current invention.
FIG. 2 provides a data plot showing exemplary experimental results demonstrating how the band gap in a graphene oxide grows over time after exposure to oxidation.
FIG. 3 provides data plots showing exemplary experimental results demonstrating the band gap in a graphene oxide after exposure to (1) a UV/Ozone oxidation treatment, and (2) a plasma oxidation treatment.
FIG. 4 provides a data plot showing exemplary experimental results correlating the size of the band gap with the oxygen concentration.
FIG. 5 provides a flow chart of an exemplary embodiment of a process for using a masking technique in conjunction with the process for forming graphene oxide material in accordance with the current invention.
FIG. 6 provides an optical microscopy image of partially oxidized graphene layer after 10 seconds oxidation at RF power of 20 watt, the covered region exhibits energy gap opening of ˜0.1 eV (top left), while the uncovered region exhibits energy gap of ˜0.4 eV (bottom right), a physical mask is used to partially cover a graphene layer from being exposed to oxygen plasma or UV/ozone treatment (top right).
FIG. 7 provides data plots illustrating: (a) UV/ozone and oxygen plasma treatments are employed to create an energy gap opening in graphene layer, (b) Current-image of a pristine graphene layer obtained by scanning tunneling microscope (STM) showing a highly-symmetric hexagonal lattice structure, (c) Raman spectrum of a pristine graphene layer where the peak intensity ratios of ID/IG and IG/IG′ are measured to be 0.09 and 0.20 respectively (A single Lorentzian profile of the G′ band shows the signature of a monolayer graphene).
FIG. 8 provides data plots illustrating: (a) typical averaged differential conductance curves dI/dV of oxygen plasma and UV/ozone treated graphene as probed using STS at more than five random locations of the sample with stabilization voltage and current of 100 mV and 650 pA respectively, (b) Energy gap opening in graphene as a function of exposure time of oxygen plasma and UV/ozone treatments, (c) Low resolution x-ray photoelectron spectroscopy (XPS) of graphene samples at different degrees of oxidation, and (d) Energy gap opening in graphene as a function of the oxygen concentration (oxygen-to-carbon atomic ratio) of the samples (The oxygen-to-carbon atomic ratio (O/C ratio) is obtained from (c)).
FIG. 9 provides data plots illustrating: (a) typical high resolution C 1s XPS spectra of (a) pristine, (b) UVO5m, (c) OP10s, (d) UVO120m, (e) OP60s samples, where deconvolution of these spectra using Gaussian-Lorentzian lineshape and Shirley baseline correction show the presence of C—O, C═O, and O—C═O functional groups, and (f) surface concentration of C—O, C═O, and O—C═O functional groups as a function of the energy gap in the LDOS of graphene samples.
FIG. 10 provides data plots illustrating typical high resolution O 1s XPS spectra of: (a) pristine, (b) OP10s, (c) UVO120m, (d) O2P60s, (e) UVO240m, and (f) OP150s samples, where deconvolution of these spectra using Gaussian-Lorentzian lineshape and Shirley baseline correction show the presence of C—O, C═O, and O—C═O functional groups, and where the presence of a strong additional O 1s peak in (c) and (d) may be associated with physisorption of oxygen.
FIG. 11 provides data plots illustrating typical high resolution Ni 2p XPS spectra of: (a) pristine, (b) UVO120m, (c) O2P60s, and (d) OP150s samples, where deconvolution of these spectra using a combination of Lorentzian asymmetric and Gaussian-Lorentzian lineshape, as well as Shirley baseline correction show the presence of a metallic Ni in all graphene samples, and where the presence of a multiplet associated with Ni(OH) 2 can be seen in the heavily oxidized graphene samples (b) and (c).
FIG. 12 shows atomically resolved STM images of (a) UVO5m, (b) O2P10s, (c) UVO120m, and (d) O2P60s for samples obtained at a scan rate of 20.3 Hz and a stabilization voltage and current of 100 mV and 650 pA respectively, where the insets show Fourier transformed unit cells
DETAILED DESCRIPTION OF THE INVENTION
The current invention is directed to a precise, versatile, and novel dry oxidation method of fabricating a semiconducting graphene material that can be used in a number of practical applications, such as: nanoelectronics, high frequency low noise field effect transistors which can be used for amplifiers, full wave rectifiers, RF resonators and switches, and integrated circuits. In particular, the current invention recognizes that absent very rigorous process parameters, graphene oxide layers are prone to the development of substrate oxides that can negatively impact the electronic characteristics and usability of the materials for practical applications, and has further discovered that by confining the oxidation to the graphene layer it is possible to prevent these substrate oxides.
FIG. 1 provides a flowchart of a fabrication process in accordance with some exemplary embodiments of the invention. As shown, in some embodiments, the fabrication process includes: 1) obtaining a suitable substrate; 2) depositing a graphene layer onto said substrate; and 3) subjecting the graphene layer to a dry oxidation treatment, wherein the dry oxidation treatment is confined to the graphene layer to prevent the development of oxide interaction with the substrate. In particular, as will be described in greater detail below, the current invention provides methods of controlling the flux of oxidation and overall concentration of oxide in the graphene surface to ensure that oxidation is confined within the graphene layer, and more particularly, such that oxygen ions do not penetrate through the graphene to form oxides on the underlying substrate thereby resulting in the creation of unwanted substrate oxides.
The following sections will elaborate on these basic fabrication steps, and will also provide descriptions of alternative embodiments that may be used in accordance with the above fabrication steps:
Substrate Layer
A variety of substrates may typically be used in the fabrication of electronic devices. As described above, the current invention is directed to graphene oxide materials that may be used in practical electronic applications. Accordingly, any substrate suitable for use as a structural foundation for a practical electronic device may be used with the current invention. For example, some commonly used substrate materials include: silicon, silicon dioxide, aluminum oxide, sapphire, germanium, gallium arsenide, an alloy of silicon and germanium, and indium phosphide, and it should be understood that any of these substrate materials may be used with the fabrication process of the current invention. In making a selection of an appropriate substrate material in accordance with the current invention, it will be understood that it is preferable that the influence of the processing applications on the substrate be minimized. In some cases this can be difficult, because the substrate is typically bonded to the electrical device prior to various processing applications, and so they too are subjected to those processing applications. In particular, as discussed above and in following sections, it is important to the creation of high quality graphene oxide materials that the dry oxidation treatment be confined to the graphene layer. Accordingly, in some embodiments the substrate material can be chosen such that the material is resistant to the production of surface oxides from exposure to oxygen ions.
Graphene Layer
As described above, once a substrate material has been chosen, a graphene layer must be deposited thereon. With regard to this step of the fabrication process, it will be understood that the deposition of graphene can be achieved in any manner suitable for the formation of a continuous graphene layer on the chosen substrate.
For example, in one embodiment of the invention, graphene samples can be grown by chemical vapor deposition techniques on nickel coated SiO 2 /Si substrates at 900° C. under a flow of 25 sccm methane and 1500 sccm hydrogen precursor gases. The sample can then be exposed to vacuum-pyrolysis treatment at an elevated temperature of 250° C. and a mild vacuum at 2.5 torr for 24 hours to remove the residual oxygen adsorbed during the growth process. Alternatively, in another embodiment of the invention, the graphene substrate configuration can be achieved by depositing single-layer graphene (SLG) flakes by micromechanical exfoliation on n-doped Si substrates covered with a 90 nm thermally grown SiO 2 film.
It should be understood that the above processes are merely provided as examples and simply represent possible embodiments of the invention that illustrate how the desired substrate-graphene configuration can be achieved. The enumeration of these embodiments is not meant to imply that they represent the only ways a substrate-graphene configuration can be achieved in accordance with this invention—any method of obtaining this graphene substrate configuration can be used consistent with the invention.
Dry Oxidation and Variability of the Band Gap
As previously described with regard to the flow chart in FIG. 1 , in some embodiments of the invention the graphene is exposed to a dry oxidation treatment. Dry oxidation techniques (as opposed to wet oxidation techniques) oxidize via a gas phase process and confer the following benefits: they typically do not require the use of any harsh chemicals; they are relatively quick procedures; and they are compatible with the use of masks. FIG. 2 provides a data plot showing how the band gap in a graphene oxide grows over time after exposure to both plasma and UV/ozone dry oxidation processes. In this respect, any dry oxidation technique suitable for the controlled deposition of oxygen ions on a surface may be used with the current invention, including, for example, direct plasma oxidation treatment, indirect remote plasma oxidation treatment, and UV/Ozone treatment.
Importantly, any of the above mentioned dry oxidation techniques would allow for the creation of specific desired band gaps within the graphene material to be achieved by controlling the oxidation process. Generally speaking, a longer exposure to the oxidation process will result in a larger band gap. The longer exposure time is understood to allow the dry oxidation treatment to induce oxygen adsorbates onto the graphene layer. These oxygen adsorbates introduce defects in the graphene's inherent sp 2 structure, and thereby disrupt the graphene's inherent π-bond network (the π-bond network is what facilitates the electron mobility and charge transport across the graphene plane). FIG. 3 correlates the band gap with the concentration of oxygen. Unaltered graphene has an oxygen concentration of roughly 9%, whereas graphene with a band gap of roughly 2.5 eV has an oxygen concentration of roughly 21%. Thus, measuring the oxygen concentration can help verify the presence of a band gap, and by controlling the concentration of oxygen it is possible to engineer the band gap of the graphene oxide to be between 0 and 2.5 eV.
Moreover, the specific type of dry oxidation treatment used also impacts the variability of the band gap—the use of a plasma oxidation treatment increases the band gap much more rapidly than does the use of a UV/Ozone oxidation treatment. This difference in rapidity is thought to be a function of the different concentrations of reactive oxygen species per unit time present in both treatments. FIG. 4 illustrates the difference, and shows that a 60 second plasma oxidation treatment yields a 2.5 eV band gap, while a 2 hour UV/Ozone treatment yields just a 2 eV band gap. Therefore, using the UV/Ozone oxidation treatment allows the band gap to be controlled with greater resolution. Conversely, using either of the plasma oxidation techniques allows a desired band gap to be achieved much more rapidly.
Although a number of different dry oxidation processes may be used with the current invention to produce graphene oxides, and to engineer the band gap characteristics of these materials, with regard to the current invention it is of critical importance that the oxidation treatment should be confined to the graphene layer, and that, in turn, the substrate should not be exposed to the oxidation process. Exposure of the substrate to oxidation, and or leaching of the oxide from the graphene layer to the substrate can lead to the formation of oxides on the substrate, which can negatively impact the graphene oxide material. Accordingly, by controlling the process parameters to ensure that the oxidation is confined within the graphene layer it is possible to improve surface quality and produce substantially defect-free graphene oxide semiconductor material suitable for practical use.
In view of this, the inventive oxidation process is tailored to avoid the formation of substrate oxides and ensure confinement of the oxide within the graphene layer.
First, in some such embodiments, the concentration of the oxide is carefully monitored and controlled to ensure that it does not exceed a maximum concentration of 21%. It has been determined that oxygen concentrations of greater than 21% result in the creation of substrate oxides, and the subsequent formation of oxides with the substrate surface. Second, in some embodiments an indirect remote plasma oxidation treatment is used. Such an indirect remote plasma treatment is less vigorous, and therefore reduces the possibility of damage to the graphene surface, and/or the likelihood that oxygen ions reach the substrate surface.
With the above process restrictions in mind, the following embodiments of the invention are provided as examples and illustrate how dry oxidation treatments can be applied to a graphene sample in accordance with the invention:
(1) In one embodiment of the invention, a UV/Ozone treatment is applied at standard room temperature and pressure for a selected period of time such that the concentration of the oxygen within the graphene oxide layer does not exceed 21%.
(2) In another embodiment of the invention, a remote oxygen plasma machine (for example, the Tepla M4L) is used under 20 Watts of RF power at a constant oxygen flow rate of 20 sccm and chamber pressure of 500 mTorr for an appropriate amount of time. Note that in no case should more than 50 Watts of RF power be used when using the plasma oxidation treatment method. Again, the oxygen content within the graphene layer must be confined to 21% or less.
It should be understood that these are simply embodiments of the invention that illustrate how dry oxidation treatments may be applied, and are not meant to limit the scope of the invention—any suitable dry oxidation treatment method may be used in conjunction with the invention.
Masking
Although the above discussion has described basic embodiments of the invention, in some alternative embodiments the fabrication process is used in conjunction with masking techniques to allow for the creation of graphene/graphene oxide materials with multi-function surfaces and/or variable band gap regions. Masking is a technique used in circuit manufacture that allows for the creation of multiple regions with distinct electrical properties within a single layer. Essentially, masks are employed prior to the material's treatment, thereby protecting the covered region from the treatment's influence.
Some such embodiments, a summary of which is shown in the flow chart provided in FIG. 5 , include 1) obtaining a suitable substrate; 2) depositing a graphene layer onto said substrate; 3) masking portions of the graphene layer; 4) subjecting the graphene layer to a dry oxidation treatment, wherein the dry oxidation treatment is confined to the graphene layer; and 5) optionally reiterating steps 3 and 4 if a more intricate electronic configuration is desired.
Thus, in one embodiment of this invention, masking can be employed prior to the dry oxidation treatment. Any region protected by the mask during an initial dry oxidation treatment will retain graphene's inherent semimetallic properties. Using this technique, a graphene oxide material with multiple regions can be developed. Accordingly, it is possible to incorporate masking techniques with the current fabrication technique allows for the creation of more intricate graphene samples.
As shown in FIG. 6 , in order to achieve site specific oxidation, a physical mask is used to partially cover the graphene layer, preventing the covered region from being exposed to oxygen plasma or UV/ozone treatment. The unexposed region retains its gapless electronic properties, while the energy gap of the exposed region starts to open up depending on the exposure time and power. For instance, in FIG. 6 , after 10 seconds of oxidation using oxygen plasma treatment at RF power of 20 watt, the uncovered region exhibits an energy gap of ˜0.4 eV, while the covered region can still be considered gapless.
Moreover, the masking and oxidation processes can be iterated to achieve even further intricate semiconductor patterns. For example, a masking layer can be employed during an initial oxidation process, and then removed during a second oxidation cycle. The resulting material would have two regions with different band gaps: the region that was subject to the initial mask could have some appreciable band gap, whereas the region that was not exposed to the masking but still subjected to both oxidation treatments would have and even greater band gap. Moreover, different masking patterns can be used between the multiple oxidation steps to achieve even further intricate patterns. Thus, in yet another embodiment of this invention, multiple masking and oxidation cycles are used to obtain multiple regions of varying band gaps.
Many applications will be made possible by having the ability to oxidize graphene layer at a particular location or with a specific pattern. These applications include graphene based 2D LEDs, high frequency transistors and solar cells. These devices will certainly take advantage of graphene's ballistic electron mobility behavior as well as its intrinsic strong and light weight properties.
EXEMPLARY EMBODIMENTS
The following embodiments are only exemplary and illustrative in nature, and are not meant to limit the scope of the invention.
Materials and Methods
Graphene samples used in the following studies were grown by chemical vapor deposition technique on nickel coated SiO 2 /Si substrates at 900° C. under a flow of 25 sccm methane and 1500 sccm hydrogen precursor gases. (See, Reina A, et al., Nano Lett. 2009, 9, 30-5; Brien M O and Nichols B, Sensors Peterborough NH. 2010, TR, 5047; and Reina A, et al., Nano Research. 2009, 2, 509-16, the disclosures of which are incorporated herein by reference.) These as-grown samples were then exposed to vacuum-pyrolysis treatment at an elevated temperature of 250° C. and a mild vacuum at 2.5 torr for 24 hours to remove the residual oxygen adsorbed during the growth process. In the following discussion, these vacuum-pyrolysis treated graphene samples are referred as pristine samples. The presence of monolayer graphene on the pristine samples was confirmed by Raman spectroscopy (Renishaw M1000) obtained with excitation energy of 2.41 eV.
Two different oxidation processes were applied to the pristine graphene samples. The first set of graphene samples were oxidized by UV/ozone treatment (Bioforce Nanosciences) at standard room temperature and pressure for 5 minutes, 30 minutes and 120 minutes. Another set of graphene samples were oxidized by remote oxygen plasma (Tepla M4L) under 20 Watts of RF power at a constant oxygen flow rate of 20 SCCM and chamber pressure of 500 mTorr for 5 seconds, 10 second, 30 seconds and 60 seconds. For brevity, in the discussion that follows, oxygen plasma treated samples are referred as O2P samples followed by the exposure time in seconds, and UV/ozone treated samples are referred as UVO samples followed by the exposure time in minutes.
Atomic-resolution images of treated graphene samples were obtained using a scanning tunneling microscope (Digital Instrument Nanoscope IIIa ECSTM) equipped with Pt/Ir scanning tip (Veeco, Inc) at constant height mode. During the imaging process, a graphene sample was placed on a flat sample stage and clamped from the top with a metal electrode that creates a direct contact with the graphene film. Tunneling I-V and differential conductance characteristics were obtained using the tunneling spectroscopy capability of the same scanning tunneling microscope. All scanning tunneling microscopy/spectroscopy (STM/STS) imaging and measurements were conducted at room pressure and temperature at a scan rate of 20.3 Hz and a stabilization voltage and current of 100 mV and 650 pA respectively. Differential conductance characteristic, dI/dV, of each sample was obtained by averaging dI/dV curves from mat least five randomly selected locations on the sample. At higher degrees of oxidation, these curves were obtained from regions that still exhibit reasonable atomic periodicity and can be imaged without excessive noise using STM. Surface chemistry characterizations were assessed using x-ray photoelectron spectroscopy (Surface Science M-Probe XPS). The XPS spectral analysis was performed using a Gaussian-Lorentzian curve-fit with Shirley baseline correction.
Example 1
Band Gap Studies
The atomically resolved image of pristine graphene samples obtained by scanning tunneling microscope (STM) exhibits a highly-symmetric hexagonal lattice structures, which is a typical signature of a pristine graphene layer. In agreement with previously reported study, these hexagonal lattice structures show an atomic spacing of ˜0.23 nm ( FIG. 7 b ). (See, e.g., Mizes H A, et al., Physical Review B. 1987, 36, 4491, the disclosure of which is incorporated herein by reference.) Three distinct peaks of D band (˜1350 cm−1), G band (˜1580 cm−1) and G′ band (˜2700) can be seen in the Raman spectrum of the pristine graphene samples ( FIG. 7 c ). (See, e.g., Dresselhaus M S, et al., Nano Lett. 2010, 10, 751-8; Reina A, et al., Nano Lett 2009, 9, 30-5; and Dresselhaus M S, et al., Annual Review of Condensed Matter Physics. 2010, 1, 89-108, the disclosure of which is incorporated herein by reference.) The peak intensity ratio between the disorder-induced D band and sp2 symmetry G band, ID/IG, was measured to be 0.09. The presence of monolayer graphene can be deduced from the existence of a strong single Lorentzian profile of G′ band with an intensity ratio IG/IG′ of 0.20. (See, Dresselhaus M, et al., Philosophical transactions—Royal Society Mathematical, Physical and engineering sciences. 2008, 366, 231-6, the disclosure of which is incorporated herein by reference.)
As revealed by scanning tunneling spectroscopy (STS), the tunneling I-V characteristics of the oxidized graphene samples exhibit a deviation from that of the pristine graphene samples around the zero-bias region, where a sign of tunneling current flattening start to occur once the graphene is oxidized. As graphene undergoes longer duration of oxidation, this flat region becomes wider and more apparent. For example, the lightly oxidized UVO5m and O2P5s graphene show a vague flat region of 0.2 eV and 0.3 eV, while the heavily oxidized UVO120m and O2P60s graphene show a flat region as large as 1.8 eV and 2.4 eV. This large deviation of I-V characteristics of the oxidized graphene to the as-grown one suggests a strong correlation between the oxidation process and the electronic characteristics of oxidized graphene.
The evolution of electronic characteristics of oxygenated graphene can be understood by investigating the tunneling differential conductance, which is proportional to the local density of states (LDOS), at various durations and types of oxidation process. The tunneling differential conductance presented herein was calculated numerically by taking the first derivative of the tunneling current with respect to the bias voltage ( FIG. 8 a ). As expected, the tunneling differential conductance of the pristine graphene samples shows that their LDOS is zero at zero-energy, which confirms that their Fermi level is zero at the Dirac point. Another feature that is noticeable in the tunneling differential conductance curve is the presence of two peaks surrounding the zero-energy, which may be attributed to the constructive interference in phonon-mediated inelastic scattering. (See, Brar V W, et al., Physical Review Letters. 2010, 104, 036805; and Rutter G M, et al., Science. 2007, 317, 219-22, the disclosure of which is incorporated herein by reference.)
In contrast to that of the pristine graphene samples, the tunneling differential conduction spectra of the oxidized graphene samples shows a sign of flattening around the zero-energy region, suggesting a considerable suppression in the LDOS around the zero-energy. The mildly oxidized UVO5m graphene show a narrow flat region of about 0.2 eV around the zero-energy region. The suppression in the LDOS becomes much more pronounced as the graphene samples undergo a prolonged oxidation time. In fact, the heavily oxidized UVO120m and O2P60s graphene show extended suppression in the LDOS up to 1.8 eV and 2.4 eV ( FIG. 8 a ). The occurrence of such energy gap in the LDOS suggests that the electronic characteristic of oxidized graphene has been transformed from zero energy gap semimetallic, into semiconducting or even insulator. (See, e.g., Leconte & Nourbakhsh, disclosed above.)
In agreement to the previous studies, the extent of the energy gap of oxidized graphene seems to depend heavily on the oxidation time, where longer exposure time to UV/ozone and oxygen plasma treatments results in larger energy gap opening. (See, Alzina, Gokus & Childres, cited above.) It is important to note that the increase of energy gap opening in oxygen plasma treated graphene is significantly faster than that in UV/ozone treated graphene. For instance, after only 60 seconds of oxygen plasma treatment, the O2P60s graphene has an energy gap of 2.44 eV. In contrast, 120 minutes of UV/ozone treatment gives the UVO120m graphene an energy gap of 1.93 eV. Such difference may be caused by different concentrations of reactive oxygen species per unit time present in both treatments. Note that in both treatments the energy gap opening does not increase linearly with the increase of oxidation time ( FIG. 8 b ). In fact, a further opening of energy gap becomes increasingly difficult as the oxygen adsorption reaches saturation very rapidly, and defects are created on the surface that may render the graphene oxide unsuitable for use in electronic application. (Leconte, cited above.)
It can be expected that the opening of energy gap in the LDOS of oxidized graphene is induced by the introduction of disordered defects in the sp 2 structure of graphene due to the presence of oxygen adsorbates. These defects produce a strong disruption to the π-bond network that facilitates the electron mobility and charge transport across the graphene plane. (Elias, cited above.) Since the magnitude of such disruption depends heavily on the spatial distribution of defects sites and the degree of induced localization, an increase of defect density will certainly reduce the electron mobility. (See, Bostwick & Luo, cited above.) In addition, any alteration to the π-bond network near the defect sites further distorts the electron-phonon couplings and electron-electron interactions. (See, Luo, cited above; and Manes J L, Physical Review B. 2007, 76, 045430, the disclosure of which are incorporated herein by reference.) Therefore, the energy gap in the LDOS observed in this study can be associated with the electron mobility gap introduced by disordered defects in the π-bond network. (See, Childres, cited above.)
A more meaningful relation can be obtained by correlating the energy gap of the oxidized graphene to its oxygen-to-carbon atomic ratio (O/C ratio). Basically, the O/C ratio represents the surface concentration of oxygen adsorbates. In this study, the O/C ratio of graphene samples was obtained from the x-ray photoelectron spectroscopy (XPS) survey scans. Multiple peaks related to C 1s, O 1s, Si 2s and Ni 2p can be seen on the XPS spectra of all graphene samples ( FIG. 8 c ). Because the intensity of photoelectron is directly proportional to the atomic density of the sample, the fractional atomic concentration of oxygen and carbon atoms can be inferred from the intensity of the O 1s and C 1s peaks. (See, Hesse R, et al, Surface and Interface Analysis. 2005, 37, 589-607; and Peng Y and Liu H, Industrial & Engineering Chemistry Research. 2006, 45, 6483-8, the disclosures of which are incorporated herein by reference. Notice that the intensity of the O 1s peak increases as the graphene samples undergo a prolonged oxidation process. Also note that the intensity of O 1s peak of pristine graphene is not zero, which suggests that a small amount of oxygen is readily adsorbed at the graphene boundaries during the growth or storage phase and may not be easily removed.
As expected, the correlation between energy gap of an oxidized graphene and its O/C ratio is monotonic, where a higher O/C ratio yields a larger energy gap, regardless of the oxidation method used. This finding implies that the observed energy gap opening is indeed introduced by defects created by oxygen adsorbates, which create disruption in the π-bond network. These defects also induce a localization effect, where each of the oxidized site acts as a strongly repulsive hard wall barrier, and the degree of such localization is dictated by the spatial distribution and the density of the oxidized sites. (See, Luo, cited above.) In addition, the correlation confirms the existence of an O/C ratio threshold around 15%, above which the energy gap opening increases exponentially ( FIG. 8 d ). Such threshold might be explained as a crossing from weak to strong localization regimes in graphene as localization quickly spreads over all energy spectrum at the very strong disorder regime.
In contrast to the previous studies, a slight increase in O/C ratio below this threshold does not increase the opening of energy gap dramatically. (See, Leconte & Kim, cited above.) At such regime, however, the experimental data seem to agree with the prediction done by electronic band structure calculation, where an O/C ratio of ˜12% yields an energy gap opening of ˜0.2 eV. (See, Nourbakhsh, cited above.) On the other hand, a slight increase in O/C ratio above this threshold results in drastic increase of energy gap opening, which is not quite in agreement with the prediction done by electronic band structure calculation. Experimental data show that an energy gap opening of ˜1.5 eV can be obtained by an O/C ratio of just ˜18%. Clearly, such prediction underestimates the energy gap opening because the electronic gap calculation is only valid for graphene that retains its structural integrity. At a high O/C ratio (greater than 21%), the defect density becomes extremely high such that it is unlikely that the band structure has survived. This implies that the observed opening of energy gap beyond this limit may not be a band gap, and therefore is not suitable for use in electronics applications.
Example 2
XPS Studies
The presence of oxygen adsorbates in the oxidized graphene samples was further investigated using high-resolution XPS scans. Curve-fitting and deconvolution of the high-resolution XPS spectra of C 1s was performed using a Gaussian-Lorentzian peak shape with Shirley baseline correction. Deconvolution of the C 1s XPS spectra of both oxygen plasma and UV/ozone treated samples shows four distinct peaks associated with sp2 C—C (284.7±0.1 eV, FWHM 0.9 eV), C—O (285.2±0.1 eV, FWHM 1.45 eV), C═O (286.7±0.1 eV, FWHM 1.45 eV), and O—C═O (288.6±0.1 eV, FWHM 4 eV). (See, Yang D, et al., Carbon. 2009, 47, 145-52, the disclosure of which is incorporated herein by reference.) The C 1s XPS spectra of the pristine graphene samples show a very strong C—O peak which may be caused by a significant presence of hydroxyl or epoxide groups at the edge. These spectra also show a relatively weak C═O peak and the absence of a peak associated with O—C═O group ( FIG. 9 a ). The O—C═O peak can be barely seen in the C 1s XPS spectra of lightly oxidized samples, i.e. O2P5s, UVO5m, O2P10s, and O2P10s samples ( FIG. 9 b and FIG. 9 c ). A more pronounced O—C═O peak can be seen in the C 1s XPS spectra of the heavily oxidized samples, i.e. UVO120m, O2P30s, and O2P60s samples ( FIG. 9 d and FIG. 9 e ), suggesting a significant presence of carboxyl groups.
As mentioned earlier, the energy gap opening of graphene samples can be correlated to their oxygen adsorbates concentration. The pristine graphene samples are expected to have a very low surface concentration of oxygenated functional groups. On the other hand, higher surface concentration of these groups is expected to be found in graphene samples that have larger energy gap. Although the correlation is not exactly linear, the surface concentration of these groups does increase as the increase of energy gap opening of the graphene samples ( FIG. 9 f ). The surface concentration of C—O group increases significantly from ˜10% to ˜35% as the energy gap increases from 0 eV to 2.4 eV. Notice that a large increase in the concentration of the C—O group is needed to initiate the energy gap opening of the graphene. Similarly, the surface concentration of C═O and O—C═O groups increases from ˜3% to ˜8% and ˜0% to ˜12% respectively for the same increase of energy gap. This finding implies that majority of oxygen adsorbates introduced by oxygen plasma or UV/ozone treatment is in the form of hydroxyl and carboxyl groups.
An oxygen uptake by the graphene layer during the oxidation process can also be observed in the O 1s and Ni2p XPS spectra of both oxygen plasma and UV/ozone treated samples. The O 1s spectra show three distinct components associated with O—C═O (531.5±0.3 eV, FWHM 1.4 eV), C═O (532.6±0.3 eV, FWHM 1.3 eV), and C—O (533.5±0.3 eV, FWHM 1.4 eV). (See, Yang, cited above.) The area percentage of each O 1s spectral component agrees with the corresponding component in the C 1s spectra. A major O 1s peak, which can be seen obviously in UVO120m and O2P60s samples, may be associated with absorbed hydroxide species or water (535.2±0.7 eV, FWHM 1.9 eV). (See, Biesinger M, et al., Surface and Interface Analysis. 2009, 41, 324-32, the disclosure of which is incorporated herein by reference.) An additional weak O 1s peak (536.2±0.8 eV, FWHM 2.1 eV) may be associated with physisorption of oxygen. (See, Biesinger, cited above.) The main Ni metal 2p 3/2 spectral component can be found at 532.5±0.5 eV with FWHM of 1 eV, while the second and third ones can be found at binding energy shifts of +3.65 eV and +6.05 eV respectively, with FWHM of 2.6 eV and 2.8 eV respectively.
Example 3
Substrate Oxide Studies
It is important to note that the energy gap opening reported herein is not induced by the production of nickel oxide or hydroxide during the oxidation process. High-resolution O 1s XPS spectra show the non existence of peaks associated with Ni—O for all samples, even after 60 seconds of oxygen plasma and 120 minutes of UV/ozone treatments ( FIG. 10 a - d in the ESM). A distinct Ni—O peak can only be seen in the O 1s spectra of samples that have been oxidized even further, e.g. after being oxidized for 150 seconds in oxygen plasma or 240 minutes in UV/ozone treatments, ( FIG. 10 e - f in the ESM). Additional evidence provided by the Ni 2p 3/2 spectra shows that the nickel catalyst layer is not oxidized, and remains in metal form in most of the samples. However, a weak presence of Ni(OH) 2 can be observed from the Ni 2p 3/2 spectral component of the heavily oxidized samples, i.e. UVO120m, O2P30s, and O2P60s samples ( FIG. 11 a - c in the ESM). A significant footprint of Ni(OH)2 can only be observed in the Ni 2p 3/2 spectra of samples that have been oxidized even further, e.g. after being oxidized for 150 seconds in oxygen plasma treatment ( FIG. 11 d in the ESM).
It will be understood from the findings mentioned above that the oxygen uptake is indeed caused by the oxidation of graphene, as long as the samples are not over oxidized. For the heavily oxidized samples, i.e. UVO120m, O2P30s, and O2P60s samples, a small fraction of oxygen uptake is caused by the production of Ni(OH) 2 . Such an uptake may also induce an energy gap in the LDOS, rendering the data invalid for energy gap larger than ˜1.9 eV. If the energy gap data from these heavily oxidized samples are omitted, one can find an almost linear relation between the energy gap opening and the overall surface concentration of the oxygenated functional groups.
Example 3
STM Studies
The effect of both oxygen plasma and UV/ozone treatments to the electronic structure of graphene can be literally seen from the evolution of the atomically resolved images obtained by scanning tunneling microscope (STM). As graphene is oxidized, defects on the hexagonal lattice structure due to the presence of oxygen adsorbates in the form of oxygenated functional groups start to occur. For samples with low concentration of oxygen adsorbates, i.e. O2P5s and UVO5m samples, the degree of disorder is quite low such that the hexagonal lattice structures still can be recognized from the raw STM images without using any further image processing technique ( FIG. 12 a ). At higher concentration of oxygen adsorbates, the distortion to the lattice structure is amplified such that the hexagonal patterns become much less apparent and more difficult to be recognized from the raw STM images. Fourier transformation of the raw STM images of O2P10s and UVO30m samples reveals a superposition of a hexagonal lattice structure and a rectangular lattice structure with a size of ˜0.41 nm by ˜0.25 nm. Previous study suggests that this rectangular unit cell, which is independent of scan speed and azimuthal scanning direction, represents the abundance of oxygenated functional groups, in particular the hydroxyl and carboxyl groups, on the oxidized graphene. (See, e.g., Pandey D, et al., Surface Science. 2008, 602, 1607-13; and Buchsteiner A, et al., J Phys Chem B. 2006, 110, 22328-38, the disclosures of which are incorporated herein by reference.)
At even higher concentration of oxygen adsorbates, i.e. UVO120m and O2P60s samples, the defect density becomes very high, such that the hexagonal patterns cannot be recognized anymore from the raw STM images ( FIG. 12 c and FIG. 12 d ). Fourier transformation of the raw STM images of O2P60s samples shows a very faint hexagonal lattice structure superposed on a more intense rectangular lattice structure, suggesting a strong manifestation of oxygenated functional groups, in particular the hydroxyl and carboxyl groups, on its surface. (See, Pandey, cited above.) Such high surface concentration may induce extra strain to the already perturbed lattice structure which initiates lattice structure breaking. This might explain why the STM images of the highly oxidized graphene samples appear more disordered and chaotic; the concentration of carboxyl groups has increased from 0% in the pristine graphene to ˜12.2% in the O2P60s samples. Judging from the existence of these functional groups, one may expect that the highly oxidized graphene samples exhibit different electronic characteristics to their pristine counterparts.
CONCLUSION
Applicant has disclosed a novel fabrication method that allows for a versatile but precise manipulation of graphene so as to develop within it an appreciable band gap while at the same time ensuring that oxidation is confined within the graphene layer. Such a graphene material can be very well-suited for a host of practical electronic applications.
The experimental findings presented herein show the effect of dry oxidation processes, in particular oxygen plasma and UV/ozone treatments, to introduce an energy gap opening in graphene. The opening of the gap itself can be correlated to the surface concentration of oxygen adsorbates, where the energy gap increases strongly as the increase of oxygen adsorbates concentration. In fact, an increase of oxygen-to-carbon atomic ratio from ˜9% to ˜21% is enough to increase the energy gap opening from 0 eV to ˜2.4 eV. Note that a significantly observable energy gap opening occurs when the oxygen adsorbates concentration is higher than the oxygen-to-carbon atomic ratio threshold of ˜15%. At high oxygen adsorbates concentration (˜21%), the defect density becomes extremely high such that it is unlikely that the band structure has survived. This implies that the observed opening of energy gap may be associated with a mobility gap, not a band gap. The presence of oxygenated functional groups, e.g. C—O, C═O and O—C═O groups, induces distortion to the π-bond network of the graphene such that the hexagonal patterns become much less apparent and the rectangular unit cells become much more pronounced. In general, the oxygen plasma treatment gives a much faster rate of oxidation than the UV/ozone treatment. On the other hand, the slower oxidation rate of UV/ozone treatment may provide a better control over the degree energy gap opening.
DOCTRINE OF EQUIVALENTS
Those skilled in the art will appreciate that the foregoing examples and descriptions of various preferred embodiments of the present invention are merely illustrative of the invention as a whole, and that variations in the fabrication methodologies of the present invention, may be made within the spirit and scope of the invention. Accordingly, the present invention is not limited to the specific embodiments described herein but, rather, is defined by the scope of the appended claims. Unless otherwise specified, all of the references disclosed herein are incorporated by reference into the specification.
|
A method of fabricating a graphene oxide material in which oxidation is confined within the graphene layer and that possesses a desired band gap is provided. The method allows specific band gap values to be developed. Additionally, the use of masks is consistent with the method, so intricate configurations can be achieved. The resulting graphene oxide material is thus completely customizable and can be adapted to a plethora of useful engineering applications.
| 2
|
This application is a continuation of Ser. No. 07/338,010, filed Apr. 14, 1989 and now abandoned, which is a continuation-in-part of Ser. No. 07/059,745, filed Jun. 8, 1987 and now U.S. Pat. No. 4,843,742.
BACKGROUND OF THE INVENTION
This invention relates to a trenching or trench excavating apparatus wherein a deep trench is dug and corners are formed, the trench to receive poured concrete as in the formation of an inground retaining wall. It is contemplated that the trench dug by the apparatus will have a depth of up to or exceeding 25 feet.
Propulsion apparatus which is engageable with the side or base walls of a trench is disclosed in co-pending application Ser. No. 059,745, and may be utilized to provide propulsive force within the trench, enabling a relatively light machine to be used for a particular trenching operation. Such propulsion apparatus may have difficulty adapting to varying ground types and may jam due to the ingress of dirt dislodged during the excavation process, or wet concrete, which is often poured immediately behind the trenching arm to minimize the probability of trench collapse in soft ground conditions.
DESCRIPTION OF THE PRIOR ART
The prior art discloses endless chain excavators together with mobile concrete forms mounted behind the excavator. It is intended that the excavator continuously dig a trench and while the trench is being dug, concrete is poured behind the excavator into the form carried by the excavator. The upper end of the excavator is mounted on a tractor that moves along the ground carrying the excavator with it.
In digging trenches and pouring concrete for retaining walls, it is important for the excavator to maintain a vertical attitude and for the assembly to dig itself into the ground to the proper depth in a vertical attitude. In this way proper corners can be formed.
When excavating a trench that is of considerable depth, for example 25 feet deep, it is extremely difficult to move the lower end of the excavator at the same pace as the tractor which carries the upper end. Hence, it is difficult, if not impossible, to maintain the required vertical attitude of the excavator without adding costly and heavy bracing structure between the tractor and excavator.
U.S. Pat. No. 4,681,483 discloses a foot which may be utilized for excavating material when excavating an initial slot from which a trench may be formed. There is no provision, however, in that patent for utilizing the foot for effective propulsion of the trencher. As described in that patent, that foot is employed for digging only.
SUMMARY OF THE PRESENT INVENTION
It is an object of the present invention to alleviate the above and other disadvantages and to provide improved trenching apparatus and methods of forming inground retaining walls which will be reliable and efficient in operation. Another object of the present invention is to provide for the propulsion of a vertically-oriented excavator at the lower end of the excavator.
A further object of the present invention is to combine a digger with the propulsion system so as to enable the excavator and accompanying structure, such as a concrete form, to dig itself into the ground in a substantially vertical attitude. Other objects and advantages of this invention will hereinafter become apparent.
The objects of the invention are attained, in part, by mounting a combined digger and propulsion element at the lower end of the excavator. A drive system for the combined element is provided to impart digging motion to the element during the digging operation (i.e., "digging" constitutes the action of the digger in digging the trenching arm into the ground) and to provide propulsive motion to the element during the excavating operation (i.e., the "excavating operation" constitutes excavation of the trench itself which occurs after the digging operation by forward movement of the trenching arm against the advancing face of the trench).
A mechanism is provided for thrusting that combined element downwardly into the ground to support a portion of the weight of the excavator and to obtain a good grip upon the base wall of the trench.
In a preferred form of the invention, a foot of the type shown in U.S. Pat. No.4,681,483 is mounted at the end of the excavator. In accordance with one aspect of the present invention, a linkage and a propulsion ram have been added to impart a propulsion motion to the foot. Still further, a vertical loading ram has been provided to lift the foot as it steps forward and to press the foot down so that it takes part of the weight of the excavator.
The advantages of the present invention are that it becomes possible to dig straight down with the excavator and accessory equipment, such as a concrete form, and when the desired depth has been obtained to proceed forward, digging a trench, with the excavator maintained in a vertical attitude. At a corner, the excavator is raised, shifted to the proper angle to form the corner and driven straight down to begin the excavation of the adjacent wall.
In the preferred embodiment, one element becomes a digger, a propulsion element, and a loading device to accept part of the weight of the excavator in order to obtain the necessary grip on the trench so that a forward force can be imparted to the lower end of the excavator.
In one aspect, this invention resides broadly in a trenching arm propulsion apparatus for urging a trenching arm forward to engage with the advancing excavation face of a trench, said propulsion apparatus including:
a propulsion member engageable with the base wall of the trench;
preload apparatus adapted for urging said propulsion member against the base wall;
drive apparatus for driving the trenching arm forward along the trench relative to said propulsion member from a starting position adjacent said propulsion member;
retraction apparatus for withdrawing said propulsion member into a stowed position free of operative contact with the base wall; and
reverse drive apparatus for drawing said propulsion member forward to said starting position.
The propulsion member may include a flat or curved plate engageable frictionally with the base wall, or there may be provided propulsion plate inclination means whereby the propulsion plate may be moved between an engagement-drive attitude substantially normal to the base wall and a frictional-drive attitude substantially parallel to the base wall.
The preload apparatus may include an actuator of any type such as a rotary or linear electric actuator. It is preferred, however, that the preload apparatus include a linear hydraulic preload actuator, and that the preload actuator be of a reversible type, such that it may also operate the retraction apparatus, although the latter may be operated by an independent hydraulic retraction actuator if desired. The propulsion apparatus may be attached to the trenching arm by slides along which the propulsion member may be driven by the preload actuator. The latter may be controlled to provide any desired preload function, but it is preferred that the preload actuator be controlled to maintain a substantially constant level of preload during operative movement of the propulsion member such that a substantially constant tractive effort may be obtainable therefrom.
Preferably, the drive apparatus includes a double-acting propulsion actuator such that it may also function as the reverse drive apparatus, although separate actuators may be used if desired. A positioning actuator may also be provided and may be adapted to interact with the propulsion actuator such that the displacement of the propulsion member relative to the trenching arm along and normal to the wall may be controlled to any desired configuration by actuator control means. For instance, the actuator control means may control the propulsion and positioning actuators to hold the propulsion member at a desired attitude relative to the wall while it is extended relative to the trenching arm, and may then control the preload actuator to withdraw the propulsion member from the wall before returning it to a position adjacent the trenching arm.
The drive apparatus and the reverse drive apparatus may include separate actuators, but it is preferred for simplicity that a double-acting propulsion actuator be provided for operating both the drive apparatus and the reverse drive apparatus. The propulsion apparatus may further include a positioning actuator adapted to interact with the propulsion actuator such that the displacement of the propulsion member relative to the trenching arm along and normal to the wall may be controlled to a desired configuration by actuator control means.
The actuator control means may control the propulsion and positioning actuators to hold the propulsion member at a desired attitude relative to the base wall while it is extended relative to the trenching arm, and may control the preload actuator to withdraw the propulsion member from the base wall before returning it to a position adjacent the trenching arm. The actuator control means may be set to control the preload, propulsion and positioning actuators for operation of the propulsion member in an excavating mode for cooperating with the trenching arm to excavate a starting slot for a trench, and in a propulsion mode for urging the trenching arm forward within a trench. Actuator travel sensing means may be provided for feedback of propulsion member position and attitudo, whereby the control means may be provided with feedback signals.
The propulsion apparatus may be fitted to a stand alone trenching arm adapted for excavating a trench while being supported and propelled by the propulsion apparatus and/or an upper drive apparatus. In a preferred embodiment, however, the trenching arm is supported at its upper end on a tractor which provides the drive for urging its upper end forward, as well as supporting chain drive apparatus for driving the trenching chain.
In a further aspect, this invention resides in continuously-operable propulsion apparatus for a trenching arm including:
a propulsion element frame;
a continuous propulsion element movable about said propulsion element frame and having an endless propulsion surface engageable between said propulsion element frame and the base wall of a trench;
preload apparatus connected between the trenching arm and said propulsion support frame for urging said propulsion element into engagement with the base wall; and
drive apparatus for moving said continuous propulsion element about said propulsion element frame.
The continuously-operable propulsion means may be divided transversely into a plurality of propulsion segments between which support means for the propulsion element frame may pass. The propulsion segments may be provided with extendible cutter apparatus moveable between an extended position in which material may be cut from outside or between the propulsion segments and a stowed position in which the cutter apparatus is confined within the axial boundaries of the propulsion segments such that material may be excavated adjacent the support means.
The drive means may be formed to drive the propulsion means in a reverse drive mode to function as a supplementary excavation device for cooperating with the trenching arm to excavate a starting slot from which the trench may be cut. The propulsion means may include a rotary wheel or an endless belt. The endless belt may be segmented transversely into belt segments whose travel paths away from the base wall diverge to form a transverse aperture through which support means for said propulsion element frame may pass.
In another aspect of this invention, chain apparatus for application in the presence of dirt or mud is disclosed, said chain apparatus including a plurality of chain links pivoted together along transverse pivot axes, each said chain link including a front link face and a rear link face adapted for operative sealing engagement with respective rear and front link faces on adjacent ones of said links over a range of angles of articulation between adjacent ones of said links about said pivot axes such that operative sealing is maintained between adjacent links during passage of the chain apparatus about a sprocket.
Suitably, the front and rear link faces are formed of part-cylindrical portions having their cylinder axes substantially coincident with respective pivot axes, whereby they may pivot cooperatively such that operative sealing is maintained therebetween.
In yet another aspect, this invention resides in a method of propelling a trenching arm forward within a trench to engage with the advancing excavation face of the trench, including:
providing a propulsion apparatus having a propulsion element engageable with the base wall of the trench and operable to move the trenching arm forward relative to the base wall; and
operating said propulsion apparatus to urge the trenching arm against the advancing excavation face of the trench.
In yet another aspect, this invention resides in excavation apparatus including:
a tractor;
a vertical endless chain excavator mounted on said tractor;
a form for concrete extending vertically behind said excavator;
an elongated foot mounted at the lower end of said form;
foot rotation means for swinging said foot back and forth in a vertical attitude for digging vertically;
foot displacement means for moving said foot back and forth in a horizontal attitude to propel the lower end of said excavator forward; and
preloading means for applying at least a portion of the weight of said excavator onto said foot.
In one further aspect of this invention, excavation apparatus is disclosed including:
a tractor;
a vertical endless chain excavator mounted on said tractor;
a form for concrete extending vertically behind said excavator; and
a combined vertical digger and forward propulsion unit mounted on the lower end of said form.
The combined vertical digger and forward propulsion unit may include an endless element carrying teeth and drive means for driving the endless element in one direction to dig and in an opposite direction for propulsion.
In one more aspect, this invention resides in excavating apparatus including:
a tractor operable at ground level;
an endless bucket excavator projecting in excess of 20 feet below ground level; and
a propulsion mechanism mounted on the lower portion of said excavator to move the lower end of said excavator against an unexcavated face of a trench as the upper end of the excavator is advanced by said tractor.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that this invention may be more readily understood and put into practical effect, reference will now be made to the accompanying drawings, wherein:
FIG. 1 is a sectional side view of a propulsion apparatus according to the invention;
FIGS. 2, 3, 4 and 5 are partial side views of the propulsion apparatus of FIG. 1, showing the propulsion foot in the four extremes of its movement during a slot excavation cycle;
FIGS. 6, 7, 8 and 9 are partial side views of the propulsion apparatus of FIG. 1, showing the propulsion foot in the four extremes of its movement during an arm propulsion cycle;
FIG. 10 is a pictorial view of a wheel-type propulsion apparatus according to the invention;
FIG. 11 is a sectional side view of a chain-type propulsion apparatus according to the invention;
FIG. 12 is a sectional top view of the propulsion apparatus of FIG. 11;
FIGS. 13 and 14 show details of the propulsion chain links used in the propulsion apparatus of FIGS. 11 and 12, and
FIG. 15 illustrates an excavator according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The propulsion apparatus 10 shown in FIGS. 1 to 9 is enclosed in a housing 11 slidably attached to the rear face of a trenching arm 12 along slides 13. The housing 11 is moveable along the trenching arm 12 by a preloading actuator 14 attached to the trenching arm 13 by a pair of interlocking racks 15 which may be adjusted to obtain the desired range of movement for the housing 11 relative to the base of the trenching arm 12.
Within the housing 11 is a hydraulic positioning actuator 16, the operating rod 17 of which extends through a slide 20 and rod seals 21 attached to the base of the housing 11. The propulsion foot 22 is pivoted to the base of a foot carrier 23 by a foot pivot 24, and the foot carrier 23 in turn has an upper front pivot 25 connected direct to the housing 11 and an upper rear pivot 26, which is connected to the housing 11 through a propulsion actuator 27. A crank arm 30 formed on the rear of the propulsion foot 22 is connected to the operating rod 17 through a link 31. A flexible boot 28 surrounds the lower end of the propulsion actuator 27 to prevent the ingress of dirt or wet concrete into the housing 11.
An endless digging chain 33 passes around the trenching arm 12 and may be utilised for excavating a slot beneath itself when excavating a vertical starting slot for a trench or for excavating a trench in front of itself when forming the trench.
As shown in FIGS. 2 to 5, the trenching arm 12 is operable to excavate a vertical starting slot beneath itself to position itself for the excavation of a trench. During this phase of the trenching operation, the propulsion foot 22 is operated in a slot excavation cycle to scrape material 32 from beneath the propulsion apparatus 10 and deposit it adjacent the trenching arm 12 where it may be picked up by the trenching chain and drawn to the surface for disposal. Firstly, the foot 22 is moved into a raised horizontal position by retraction of the positioning actuator 16 and the preloading actuator 14, as shown in FIG. 2. The foot 22 is then forced downward into the material 32 by extension of the preloading actuator 14, as shown in FIG. 3. While engaged within the material 32, the foot 22 is then swung in an arc of approximately ninety degrees about the foot pivot 24, as shown in FIG. 4, shearing material 32 from beneath the propulsion apparatus 10 and depositing it adjacent the trenching arm 12, from where the digging chain 33 conveys it around the front of the trenching arm 12 to the surface of the ground. The preloading actuator 14 is then retracted to raise the foot 22 clear of the material 32, as shown in FIG. 5, after which the foot 22 is swung back into the horizontal position in which it began the cycle.
Referring now to FIGS. 6 to 9, it will be seen that, when the trenching arm 12 has reached the desired depth for the excavation, the propulsion foot 22 may be operated in a propulsion cycle to force the trenching arm 12 forward into the advancing face of the trench. At the beginning of a propulsion cycle, as shown in FIG. 6, the foot 22 is held in a raised horizontal position with the preloading actuator 14 and the positioning actuator 16 in their retracted positions. Referring now to FIG. 7, the preloading actuator is then extended until the foot 22 is engaged with the base wall 34 of the trench with the desired level of preload applied to it. This preload may be controlled to any desired value, but it is preferred that it attain a significant portion of the weight of the trenching arm 12 and the trenching machine supporting it, whereby significant longitudinal drive force may be generated by the propulsion apparatus 10. The propulsion actuator 27 is then retracted, rotating the foot carrier 23 about the upper front pivot 25 such that the foot 22 is forced rearward relative to the housing 11, as shown in FIG. 8, urging the trenching arm 12 forward. The foot carrier 23 and the link 31 form a linkage which maintains the foot 22 in a substantially horizontal attitude during this phase of the cycle. When the foot 22 has reached the limit of its rearward travel relative to the trenching arm 12, the preloading actuator 14 is retracted, as shown in FIG. 9, raising the foot 22 away from the base wall 34, after which extension of the propulsion actuator 27 drives the foot carrier 23 and the attached foot 22 forward into its starting position.
If the ground conditions are deemed to be unsuitable for force transfer by frictional contact between the foot 22 and the base wall 34, such as in the case of wet clay, the positioning actuator 16 may be extended sufficiently to rotate the foot 22 into a substantially vertical position such that it may embed itself into the base wall 34 to provide the necessary force transfer.
The wheel-type propulsion apparatus 40 shown in FIG. 10 has a support arm 41 pivoted to a support frame 42 attached to a trenching arm 43. A radial-piston hydraulic motor 44 of the rotating-casing type has its shaft bolted to the outer end of the support arm 41, and a wheel rim 45 with cleats 46 is attached around the motor casing 47. A preload actuator 50 extends between the support arm 41 and the support frame 42 to permit the wheel rim 45 to be forced against the base of the trench 51.
The propulsion apparatus 40 may be operated to propel the trenching arm 43 along the trench (unnumbered) by rotating the wheel rim 45 forward (i.e., clockwise as viewed in FIG. 10) at a slow rate comparable to the advance rate of the trenching arm 43. Where it is necessary to excavate a slot at the start of a trench 51, the wheel rim 45 may be rotated backwards (i.e., counterclockwise as viewed in FIG. 10) at higher speed such that the cleats 46 may scrape material from beneath the wheel rim 45 and deliver it to the trenching arm 43 for transport to the surface.
The chain-type propulsion apparatus 60 shown in FIGS. 11 to 14 has a housing 61 which is attached through slides 62 to a trenching arm 63. A chain assembly 64 is attached to the lower end of the housing 61 and comprises a chain frame 65 about which a central chain 66 and outer chains 67 pass. The central chain 66 passes over front sprocket assembly 70 and rear sprocket 71, while the outer chains 67 also pass over upper sprocket assembly 72. The chain frame 65 is connected to the housing 61 via a bifurcated support (unnumbered) which passes between the upper portions of the central and outer chains 66 and 67. Roller chains 74 and 75 provide drive from hydraulic motors 76 and 77 to the upper sprocket assembly 72. The roller chain 74 from the upper hydraulic motor 76 passes around idlers 80 to clear the lower hydraulic motor 77.
The chains 66 and 67 comprise links 81 formed with complementary front and rear faces 82 and 83 respectively which slide relative to one another as the links 81 pass around a sprocket such that no significant passages open up for the ingress of dirt or wet concrete. Face seals 85 attached to the chain frame 65 engage with recessed side faces 86 on the links 81 to minimize ingress of dirt or wet concrete through these gaps.
The propulsion apparatus 60 may be operated to propel the trenching arm 63 along a trench by driving the chains 66 and 67 forward (i.e., in a counterclockwise direction of rotation, such that the apparatus of 60 moves to the left as viewed in FIG. 11) at the top at a slow rate comparable to the advance rate of the trenching arm 63. Where it is necessary to excavate a slot at the start of a trench, the chains 66 and 67 may be driven backwards (i.e., counterclockwise as viewed in FIG. 11) at higher speed such that the cleats 87 may scrape material from beneath the chains 66 and 67 and deliver it to the trenching arm 63 for transport to the surface.
The excavator apparatus 90 shown in FIG. 15 comprises a tractor 91 which may move along the ground 92 on crawler tracks 93. An endless chain excavator assembly 94 is mounted to the tractor 91 for vertical movement relative to the tractor 91, and carries an endless digging chain 95 which may excavate the advancing face 96 of a trench 97. A U-section concrete form 100 extends vertically along the rear face of the excavator assembly 94, and a combined vertical digger and forward propulsion unit 101 is mounted on the lower end of the concrete form 100. Hydraulic power for the operation of the vertical digger and forward propulsion unit 101 is supplied by a hydraulic power pack 102 mounted on the tractor 91, and operation of the vertical digger and forward propulsion unit 101 is controlled by a solenoid assembly (unnumbered) under the control of a control computer 104. The hydraulic power pack 102 also provides power to drive the crawler tracks 93 and the digging chain 95.
To form an inground wall, the excavator apparatus 90 is positioned above the starting point for the wall with the excavator assembly 94 in a raised position fully above the ground 92. The digging chain 95 is energised, and the vertical digger and forward propulsion unit 101 is operated by the control computer 104 in its vertical digging mode. The excavator assembly is then lowered into the ground, and the digging chain 95 and the vertical digger and forward propulsion unit 101 combine to excavate a starting slot for the trench 97. When the starting slot has reached the desired depth, the crawler tracks 93 are energised for forward motion, and the control computer 104 is switched to control the vertical digger and forward propulsion unit 101 in a forward propulsion mode, urging the digging chain 95 forward against the advancing face 96 of the trench 97.
Concrete is poured into the trench 97 behind the concrete form 100 to form an inground wall 105.
It will of course be realised that while the above has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is defined in the appended claims.
Attached hereto and incorporated by reference is a Computer Program Appendix listing a computer program for operating the prototype propulsion apparatus of the present invention.
|
Propulsion apparatus is disclosed for urging a trenching arm forward against the advancing face of an elongate trench being dug by the trenching arm. The propulsion apparatus includes a propulsion member which is engageable with the base wall of the trench such that the trenching arm may be urged forward relative to the engaged propulsion member. The propulsion member may then be withdrawn from engagement with the base wall and retracted towards the trenching arm before commencing a further propulsion cycle. The propulsion member is also operable to cooperate with the trenching arm in excavating a starting slot at the beginning of a new trench.
| 4
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a thermosetting resin composition providing rapid curing and being distinguished in low shrinkage when used according to the resin transfer molding method (which will be referred to as RTM or R-RIM hereafter) which is one of the molding methods for fiber reinforced thermosetting plastics (which will be referred to as FRP hereafter).
2. Description of Related Art
RTM is characteristic in that it permits low pressure, low temperature molding so that the equipment investment such as mold and press costs can be reduced. However, the method has various problems in that its finished product output (productivity) and the mechanical characteristics of the manufactured material (moldability) are poor as compared with those of other conventional methods and also that it provides molded articles whose surface has poor smoothness and therefore it is unsuitable for producing outside plate or shell plate moldings which require mirror surface-like, beautiful appearance.
In order to remedy these shortcomings, there is a need for a resin composition having improved curing performance and more rapid curing at low and moderate temperatures as well as low shrinkage.
Generally, thermosetting resins containing a vinyl monomer as a crosslinking agent have a high volume reduction ratio upon curing, e.g., as high as 5 to 12%. This not only causes decrease in strength, occurrence of cracks, bend or warp, and the like but also deteriorates the surface smoothness of molded articles due to raising of glass fiber contained in the reinforced resin composition used as a starting material on the surface of the molded articles.
In order to overcome the above-described problems, there has been generally used a method in which a thermosetting resin is blended with a thermoplastic resin such as polystyrene or polyvinyl acetate. In order for the thermoplastic resin to effectively act as a low shrinkage agent, the molding temperature upon molding by curing must be high enough. In fact, there has been obtained no sufficient shrinkage lowering effect by methods other than heat-molding at temperatures not lower than 100° C.
That is, the R-RIM methods which involve molding at low or moderate temperatures of lower than 100° C. exhibit only insufficient shrinkage lowering effect. Conventional approaches for the problems have been concentrated on the improvement of the low shrinkage agent. For example, in the method disclosed in Japanese Patent Publication (Kokai) No. 60-141753, excellent shrinkage lowering effect is obtained at 20° C. However, this improvement is achieved at the sacrifice of curing time, i.e., 6 to 8 hours are necessary to cure the resin. Therefore, rapid curing and low shrinkage have not been achieved at the same time by conventional approach.
SUMMARY OF THE INVENTION
As the results of intensive research with a view to obtaining a thermosetting resin composition which will satisfy both the requirements of rapid curing and low shrinkage simultaneously at low and moderate temperatures, the present inventors have developed a thermosetting resin composition distinguished in having rapid curing characteristics and low shrinkage during molding by dissolving, in a monomer mixture composed of styrene and methyl (meth)acrylate, a mixture of (a) an unsaturated polyester, (b) a polymer having a (meth)acrylate group only at one or both terminals of its main chain and (c) a poly(meth)acrylate oligomer having an isocyanurate ring in its basic skeleton, and mixing the resulting mixture with a low shrinkage agent.
Accordingly, the present invention provides a thermosetting resin composition comprising
(a) an unsaturated polyester,
(b) a polymer having a (meth)acrylate group only at one or both terminals of its main chain,
(c) a poly(meth)acrylate oligomer,
(d) a styrene monomer, and
(e) a methyl methacrylate monomer.
In another aspect, the present invention provides a method of molding a thermosetting resin composition comprising
(a) an unsaturated polyester,
(b) a polymer having a (meth)acrylate group only at one or both terminals of its main chain,
(c) a poly(meth)acrylate oligomer,
(d) a styrene monomer, and
(e) a methyl methacrylate monomer,
wherein said method comprises dividing said thermosetting resin composition into two parts, adding a curing agent to one of said two parts and a curing accelerator to another to form two partial compositions, introducing said two partial compositions into a mold, and allowing said two partial compositions to mix with each other and cure.
DETAILED DESCRIPTION OF THE INVENTION
The unsaturated polyester (a) which can be used in the present invention refers to an unsaturated polyester which contains 20 to 70% by weight of an unsaturated dibasic acid and is obtainable through reaction between an acid component containing a saturated polybasic acid, if desired, and a polyhydric alcohol component in an equivalent proportion of 1:1. If the unsaturated dibasic acid is less than 20% by weight, the curing performance degrades, and if it is greater than 70% by weight, the resistance to cracking deteriorates.
Examples of such an unsaturated dibasic acid component constituting the unsaturated polyester (a) include well known and widely used α,β-unsaturated dibasic acids such as maleic acid, fumaric acid, itaconic acid, citraconic acid, metaconic acid and chlorinated maleic acid or anhydrides thereof. Among these unsaturated dibasic acids, maleic anhydride is preferred.
Examples of the saturated polybasic acid component which can be used concurrently in the present invention together with the unsaturated dibasic acids, if desired, include widely known and conventionally employed saturated acids, or anhydrides or esters thereof such as phthalic acid, phthalic anhydride, tetrahydrophthalic anhydride, cis-3-methyl-4-cyclohexene-cis-1,2-dicarboxylic anhydride, isophthalic acid, terephthalic acid, dimethylterephthalic acid, monochlorophthalic acid, dichlorophthalic acid, trichlorophthalic acid, chlorendic acid (Het acid), tetrabromophthalic acid, sebacic acid, succinic acid, adipic acid, glutaric acid, pimelic acid, trimellitic acid and pyromellitic acid.
Examples of the alcohol component of the unsaturated polyester (a) include widely known and conventionally employed polyhydric alcohols such as, for example, ethylene glycol, diethylene glycol, triethylene glycol, polyethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, polypropylene glycol, 1,3-butylene glycol, 2,3-butylene glycol, 1,4-butylene glycol, neopentyl glycol, hexylene glycol, octyl glycol, trimethylolpropane, glycerine, pentaerythritol, ethylene oxide or the propylene oxide addition product of hydroquinone, ethylene oxide, or the propylene oxide adduct of bisphenol A, hydrogenated bisphenol A and tricyclodecane dimethylol. Of these, propylene glycol is particularly preferred.
The polymer (b) having a (meth)acrylate group only at one or both terminals in its main chain which can be used in the present invention is a polymer, which is preferably in the form of a straight chain and has hydroxyl groups as side chains, the polymer having (meth)acrylic acid, hydroxy(meth)acrylate or glycidyl (meth)acrylate introduced into the molecular chain as a terminal group of the main chain and containing 10% by weight or more, preferably, 20 to 40% by weight, based on the molecular weight of the polymer, of (meth)acryloyl group of the formula: ##STR1##
The polymer (b) used in the present invention specifically refers to epoxy acrylates, polyester acrylates and urethane acrylates, preferably polyester acrylates and epoxy acrylates.
Such epoxy acrylate is an epoxy acrylate obtainable by reaction of a polyepoxide (epoxy resin) with an α,β-unsaturated monobasic acid in an equivalent proportion of 1:2. That is, it refers to an epoxy acrylate having a main chain of polyepoxide and both terminals of a (meth)acrylate group.
Representative examples of the polyepoxide (epoxy resin) include condensation products of polyphenols and (methyl)-epichlorohydrin. For the polyphenols, bisphenol A, 2,2,-bis(4-hydroxyphenyl)methane (bisphenol F), halogenated bisphenol A, resorcinol, tetrahydroxyphenylethane, phenol novolak, cresol novolak, bisphenol A novolak and bisphenol F novolak may be employed. Also usable are epoxy compounds of the alcohol ether type obtainable from polyols such as ethylene glycol, butane diol, glycerine, polyethylene glycol, polypropylene glycol and alkylene oxide-adduct of bisphenols, and (methyl)epi-chlorohydrin; glycidyl amines obtainable from anilines such as diaminodiphenylmethane, diaminophenylsulfone and p-aminophenol, and (methyl)epichlorohydrin; glycidyl esters based on acid anhydrides such as phthalic anhydride and tetrahydro- or hexahydrophthalic anhydride, and alicyclic epoxides such as 3,4-epoxy-6-methylcyclohexylmethyl and 3,4-epoxy-6-methylcyclohexyl carbonate. Compounds having a bisphenolic skeleton are preferred.
For the α,β-unsaturated monobasic acids, acrylic acid and methacrylic acid are representative.
The unsaturated polyester acrylate having (meth)acrylate groups at its terminals which can be used in the present invention refers to an unsaturated polyester acrylate having an unsaturated glycidyl compound added to an unsaturated polyester obtainable through reaction of an acid component containing a saturated polybasic acid or its anhydride, and if desired, an unsaturated polybasic acid or its anhydride with an alcohol component in an equivalent proportion of 2:1. Also usable is an unsaturated polyester acrylate having an unsaturated glycidyl compound added to an unsaturated polyester containing a carboxyl group at each terminal.
Examples of the unsaturated glycidyl compound constituting a component of the polyester include those that are generally known and conventionally used such as glycidyl esters of unsaturated monobasic acids of acrylic acid and methacrylic acid such as, for example, glycidyl acrylate and glycidyl methacrylate. For the unsaturated glycidyl compound, glycidyl methacrylate is preferred.
Examples of the dibasic acid component include any generally known and conventionally used saturated acids or their anhydrides or esters such as, for example, phthalic acid, phthalic anhydride, tetrahydrophthalic anhydride, cis-3-methyl-4-cyclohexene-cis-1,2-dicarboxylic anhydride, isophthalic acid, terephthalic acid, dimethylterephthalic acid, monochlorophthalic acid, dichlorophthalic acid, trichlorophthalic acid, chlorendic acid (Het acid), tetrabromophthalic acid, sebacic acid, succinic acid, adipic acid, glutaric acid, pimelic acid, trimellitic acid and pyromellitic acid. Isophthalic acid is preferred.
As the unsaturated polybasic acid or anhydride thereof to be used jointly, generally known and conventionally used α,β-unsaturated polybasic acids such as maleic acid, fumaric acid, itaconic acid, citraconic, metaconic acid and chlorinated maleic acid, or anhydrides thereof may be employed as desired.
Examples of the alcohol component of the polyester acrylate include polyhydric alcohols which are generally known and conventionally used such as ethylene glycol, diethylene glycol, triethylene glycol, polyethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, polypropylene glycol, 1,3-butylene glycol, 2,3-butylene glycol, 1,4-butylene glycol, neopentyl glycol, hexylene glycol, octyl glycol, trimethylolpropane, glycerine, pentaerythritol, ethylene oxide or propylene oxide adduct of hydroquinone, hydrogenated bisphenol A and tricyclodecane dimethylol. Glycols of rigid structure having a bisphenol skeleton are particularly preferred.
The number average molecular weight for the polymer (b) used in the present invention is preferably 900 to 3,000, and more preferably 1,000 to 2,800. If the number average molecular weight is less than 900, the molded product tends to have deteriorated crack resistance although its curing property is somewhat improved. If the number average molecular weight is greater than 3,000, the molding process requires a great deal of time because of degradation of the rapid curing performance which thus results in a decrease in productivity.
The poly(meth)acrylate oligomer (c) used in the present invention is a polyester poly(meth)acrylate having at least one isocyanurate ring in its molecule and represented by the formula ##STR2## wherein A represents (meth)acrylic acid, Y represents a polybasic acid, X represents a polyhydric alcohol residue comprising a tris(hydroxyalkyl) isocyanurate group as essential component, and n is an integer of 0 to 3.
The oligomer (c) can be obtained by esterification reaction between a polyhydric alcohol comprising a tris(hydroxyalkyl) isocyanurate as essential component and (meth)acrylic acid. Suitable example of the tris(hydroxyalkyl) isocyanurate include tris(2-hydroxyethyl) isocyanurate, tris(2-hydroxypropyl) isocyanurate, tris(hydroxycyclohexyl) isocyanurate, etc. as described in Japanese Patent Publication (Kokai) No. 62-20522.
According to the present invention, the weight based mixing proportion of the unsaturated polyester (a) and the polymer (b) having a (meth)acrylate group at one or both terminals in its main chain is (a):(b) =90:10 to 20:80, and preferably 80:20 to 30:70. When the unsaturated polyester is more than 90 parts by weight, cracks tend to occur and complete curing is difficult, and when it is less than 20 parts by weight, the shrinkage lowering effect is not obtained sufficiently.
The weight based mixing proportion of the poly(meth)acrylate oligomer (c) to sum of the unsaturated polyester (a) and the polymer (b) having a (meth)acrylate group only at one or both terminals in its main chain is (c):(a)+(b)=2:98 to 40:60, and preferably 5:95 to 50:50. When the amount of the poly(meth)acrylate oligomer is less than 5 parts by weight, the heat resistance of the resulting resin composition is insufficient as well as the reaction temperature due to generation of heat upon curing decreases, with the result that no shrinkage lowering effect can be obtained. On the other hand, When its is more than 50 parts by weight, the crosslink density of the resin becomes undesirably high, which not only causes cracks but also is economically disadvantageous.
In the present invention, the components (a), (b) and (c) may be replaced by a molecule in which the unsaturated polyester residue, (meth)acrylate residue and poly(meth)acrylate oligomer residue in the components (a), (b) and (c), respectively, are contained in the same molecule as attached thereto via chemical bonds.
The styrene monomer (d) and methyl methacrylate monomer (e) used in the present invention are important for efficiently crosslinking the components (a), (b) and (c) comprised by the thermosetting resin composition to obtain a resin composition having rapid curing and shrinkage lowering properties. For example, use of styrene monomer alone fails to give rapid curing property. On the other hand, shrinkage lowering property is not obtained by using methyl methacrylate alone although rapid curing property is enough. More particularly, the styrene monomer (d) reacts with the unsaturated polyester (a) to generate heat and raises the temperature of the reaction mixture, which contributes to improve shrinkage lowering effect. The methyl methacrylate monomer (e) is particularly important since it reacts with the polymer (b) which has a (meth)acrylate group only at one or both terminals in its main chain to exhibit rapid curing property. However, a small amount of one or more other vinyl monomers may be added to the components (d) or (e) so far as they will not deteriorate the effects of the present invention. The poly(meth)acrylate oligomer, component (c), is particularly important for improving the heat resistance of the resulting resin composition which would otherwise decrease when a thermoplastic polymer is used as a low shrinkage agent.
The styrene monomer, component (d) is used in an amount of 30 to 150 parts by weight, preferably 40 to 140 parts by weight, per 100 parts by weight of the unsaturated polyester, component (a). When the styrene monomer is contained in an amount of less than 30 parts by weight, the viscosity of the composition increases to deteriorate the efficiency of working, or the elevation of temperature due to heat generation upon curing is low, resulting in insufficient shrinkage lowering effect. On the other hand, the crosslink density decreases to thereby deteriorate heat resistance and mechanical strength of the resulting resin composition when the amount of the styrene monomer is more than 150 parts by weight.
The weight based mixing proportion of the methyl methacrylate monomer, component (e), is 30 to 150 parts by weight, and preferably 40 to 140 parts by weight, per 100 parts by weight of sum of the polymer which has a (meth)acrylate group only at one or both terminals in its main chain components, component (b), and the poly(meth)acrylate oligomer, component (c). The viscosity of the resin composition increases to deteriorate the efficiency of working or rapid curing property of the resin composition when the amount of the methyl methacrylate monomer is less than 30 parts by weight. On the other hand, when the resin composition contains more than 150 parts by weight of the methyl methacrylate monomer, the crosslink density of the resin decreases and problems occur that the heat resistance and mechanical strength of molded articles made therefrom decrease as well as the surface of the molded articles becomes sticky.
The thermoplastic resin composition of the present invention may contain a thermoplastic organic polymer in an amount of 5 to 40 parts by weight, and preferably 10 to 30 parts by weight, per 100 parts by weight of sum of the components (a), (b) and (c). When the amount of the thermoplastic resin is less than 5 parts by weight, there is obtained insufficient shrinkage lowering effect, and on the other hand rapid curing property is not obtained when it is contained in an amount more than 40 parts by weight.
For the low shrinkage agent, three can be cited, for example, such thermoplastic resins as homopolymers or copolymers of lower alkyl esters of acrylic or methacrylic acid such as methyl methacrylate, ethyl methacrylate, butyl methacrylate, methyl acrylate and ethyl acrylate, and monomers of styrene, vinyl chloride and vinyl acetate, copolymers of at least one of said vinyl monomers and at least one of monomers comprising lauryl methacrylate, isovinyl methacrylate, acrylamide, methacrylamide, hydroxyalkyl acrylate or methacrylate, acrylonitrile, methacrylonitrile, acrylic acid, methacrylic acid and cetylstearyl methacrylate; and further cellulose acetate butyrate and cellulose acetate propionate, polyethylene, polypropylene and saturated polyesters and the like. These may be added, if desired, for particular use, so long as the effect of the invention is not impaired.
The resin composition of the present invention may contain one or more of various additives such as a thickener, coloring agent, reinforcing agent, filler, curing catalyst, curing accelerator, curing retarder, internal lubricant and the like, if desired.
If a thickener is used, it should be such that it chemically bonds with the hydroxyl and carboxyl groups and ester bonds contained in the resin to form linear or partially cross-linked bonds and thus increase the molecular weight and the viscosity of the unsaturated polyester resin. Examples of such thickeners, include diisocyanates such as toluene diisocyanate, metal alkoxides such as aluminum isopropoxide and titanium tetrabutoxide, oxides of divalent metals such as magnesium oxide, calcium oxide and beryllium oxide, and hydroxides of divalent metals such as calcium hydroxide. The amount of the thickener is normally 0.2 to 10 parts by weight, and preferably 0.5 to 4 parts by weight per 100 parts by weight of the resin composition including the components (a), (b) and (c). Also, a small amount of a highly polar substance such as water may be used as an auxiliary thickener, if desired.
As for the coloring agent, there can be used any of the conventional organic and inorganic dyes and pigments. However, coloring agents having significant heat resistance and transparency, and which do not impede curing of the unsaturated polyester and terminal (meth)acrylate group containing oligomer are preferred.
For the reinforcing agent used in the present invention, fiberglass is often employed. However, organic fibers of vinylon, polyester, phenol, poly(vinyl acetate), polyamide and poly(phenylene sulfide) and inorganic fibers of asbestos, carbon fiber, metal fiber and ceramic fiber, may be used as well. These may be in the forms of stranded, knitted and nonwoven fabric, planar or solid. The reinforcing agent is not limited to such fibers, and plastic foams such as polyurethane foam, phenol foam, vinyl chloride foam and polyethylene foam, hollow hardened products of glass and ceramics, and solid, molded products or honeycomb structures of metals, ceramics, plastics, concrete, wood and paper can also be used.
Examples of the filler include calcium carbonate powder, clay, alumina powder, silica, talc, barium sulfate, silica powder, glass powder, glass beads, mica, aluminum hydroxide, cellulose filament, quartz sand, river sand, white marble, marble scraps and crushed stone. Of these, glass powder, aluminum hydroxide and barium sulfate are particularly preferred in that they provide semi-transparency in curing.
To accelerate the curing, a metal compound may be added to the resin composition if desired. For such a metal compound, metal compound accelerators which are generally used for unsaturated polyester resins are employed. Examples include cobalt naphthonate, cobalt octonate, divalent acetylacetone cobalt, trivalent acetylacetone cobalt, potassium hexoate, zirconium naphthonate, zirconium acetylacetonate, vanadium naphthonate, vanadium octonate, vanadium acetylacetonate and lithium acetylacetonate, and combinations thereof. Also, such accelerator may be used in combination with any other conventional accelerators such as amines, phosphorus containing compounds, and β-diketones.
The amount of addition of such curing accelerators is subject to adjustment with the gelling time, but it is preferably 0.0001 to 0.12 parts by weight of the metal component per 100 parts by weight of the resin composition. In the case of molding at a medium temperature or higher (40° C. or higher), the use of curing accelerators is optional.
Examples of the curing catalyst include such compounds which act on the unsaturated polyester (a), terminal (meth)acrylate group in the main chain of the polymer (b), or poly(meth)acrylate oligomer (c), including azo compounds such as azoisobutyro-nitrile and organic peroxides such as tertiary butyl perbenzoate, tertiary butyl peroctoate, benzoyl peroxide, methyl ethyl ketone peroxide, acetoacetic ester peroxide and dicumyl peroxide. The catalyst is used in an amount of 0.1 to 4 parts by weight, or preferably 0.3 to 3 parts by weight, per 100 parts by weight of the resin composition including including the components (a), (b) and (c).
Redox curing agents such as acetoacetic ester peroxide/cobalt naphthenate and benzoyl peroxide/dimethyl p-toluidine are particularly preferred.
For the curing retarder, hydroquinone, toluhydroquinone, tertiary-butylcatechol and copper naphthenate, may be used, preferably in an amount or 0.0001 to 0.1 part by weight per 100 parts by weight of the resin composition.
For the internal lubricant, conventional higher fatty acids and higher fatty acid esters such as stearic acid and zinc stearate and alkyl phosphoric esters may be used. Such lubricants can be used in a proportion of normally 0.5 to 5 parts by weight per 100 parts of the resin composition.
The resin composition according to the present invention is of a viscosity of preferably 3 poises or less at 25° C. But, it is not always required that the viscosity be 3 poises or less at at all times. So long as the effect of the invention is achieved, a resin with a higher viscosity can be used as long as the viscosity is reduced to 3 poises or less by heating or otherwise at the time of injection into the mold. Such a viscosity allows injection into the R-RIM molding machine with ease. If the viscosity is greater than 3 poises, much time is required for injection, and so the productivity is decreased.
According to the present invention, the molded product is produced by dividing the resin composition into two parts, adding a curing agent (peroxide) to one part (component A) and an accelerator to the other (component A'), circulating these two components A and A' in separate lines respectively under high pressure (injection pressure) of preferably 5 to 200 kg/cm 2 or more preferably 80 to 150 kg/cm 2 , and injecting them in a short time of preferably 0.1 to 30 seconds or more preferably 0.5 to 20 seconds into a mold having a reinforcing agent charged and maintained at a mold temperature of preferably 10° to 80° C. or more preferably 40° to 70° C. and a mold pressure of preferably 5 to 100 kg/cm 2 or more preferably 20 to 50 kg/cm 2 .
According to the invention, molding is performed at a molding temperature of 80° C. or less (mold temperature). If molded at a temperature higher than 80° C., the methyl (meth)acrylate monomer is subject to evaporation to produce air bubbles in, or voids on the surface of, the molded product, resulting in cracking. Accordingly, such temperatures are not desirable.
Also, according to the invention, the molded product has a reinforcing agent charged before it is locked prior to injection. Here, according to the prior art in which the reinforcing agent was added to the composition before injection, it was difficult to provide a high strength as the reinforcing agent was of a fibrous form. Also, according to the conventional RTM, when a reinforcing agent in the form of long filaments is used, if the injection time is reduced, the reinforcing agent is caused to redistribute on account of the high viscosity of the resin composition so that the mechanical strength is not evenly distributed, resulting in a product of poor quality. According to the present invention, such problems are eliminated, and a uniform molded product having a high mechanical strength can be obtained.
The resin composition of the present invention may be cured with heat with various peroxides added or by ultraviolet light or any other active light with various photosensitizers added. In such a case, the properties of rapid curing and remarkable mechanical strength are maintained.
The resin composition of the present invention is distinguished in rapid curing characteristics and low shrinkage at low and moderate temperatures and thus is excellent as a resin composition for RTM method for producing FRP exterior trims for automobiles for which smoothness of surface is required.
EXAMPLES
Now, the present invention be described in detail with reference to examples and reference examples. It should be noted that "parts" in the following indicates parts by weight.
REFERENCE EXAMPLE 1
Preparation of unsaturated polyester [PE-1]
Heating, dehydrating and condensing 540 g of maleic anhydride and 460 g of 1-2 propylene glycol in an inert gas at 220° C. for 10 hours, there was obtained a condensation product giving an acid value of 30. To this, 0.15 g of hydroquinone was added, and the mixture was cooled to 120° C. Then, this solid was dissolved in 600 g of styrene monomer, and there was obtained an unsaturated polyester of a solid content of 60.2%, viscosity of 3.8 poises (at 25° C.) and acid value of 18.6 with the content of unsaturated dibasic acid being 59.9% by weight.
REFERENCE EXAMPLE 2
Preparation of unsaturated polyester [PE-2]
Heating, dehydrating and condensing 237 g of maleic anhydride, 358 g of phthalic anhydride and 405 g of 1,2-propylene glycol in an inert gas at 220° C. for 10 hours, there was obtained a condensation product giving an acid value of 28. To this, 0.15 g of hydroquinone was added, and the mixture was cooled to 120° C. Then, this solid was dissolved in 390 g of styrene monomer, and there was obtained an unsaturated polyester of a solid content of 70.1%, viscosity of 4.0 poises (at 25° C.) and acid value of 17 with the content of unsaturated dibasic acid being 26% by weight.
REFERENCE EXAMPLE 3
Preparation of unsaturated polyester [PE-3]
Heating, dehydrating and condensing 152 g of maleic anhydride, 459 g of phthalic anhydride and 389 g of 1,2-propylene glycol in an inert gas at 220° C. for 10 hours, there was obtained a condensation product giving an acid value of 25. To this, 0.15 g of hydroquinone was added, and the mixture was cooled to 120° C. Then, this solid was dissolved in 600 g of methyl methacrylate monomer, and there was obtained an unsaturated polyester of a solid content of 60%, viscosity of 6.2 poises (at 25° C.) and acid value of 15 with the content of unsaturated dibasic acid being 16.6% by weight.
REFERENCE EXAMPLE 4
Preparation of unsaturated polyester [PE 4]
Heating, dehydrating and condensing 540 g of maleic anhydride and 460 g of 1,2-propylene glycol in an inert gas at 220° C. for 10 hours, there was obtained a condensation product giving an acid value of 29. To this, 0.15 g of hydroquinone was added, and the mixture was cooled to 120° C. Then, this solid was dissolved in 600 g of methyl methacrylate monomer, and there was obtained an unsaturated polyester having a resin solid content of 59.8%, viscosity of 6.2 poises (at 25° C.) and acid value of 16.5 with the content of unsaturated dibasic acid being 59.9% by weight.
REFERENCE EXAMPLE 5
Preparation of epoxy acrylate [AC-1]
In a three-necked flask provided with a thermometer, stirrer and cooler, 1,850 g of "EPICLON R 850" (epoxy resin product of Dainippon Ink & Chemicals, Inc.) obtained through reaction of bisphenol A with epichlorohydrin with an epoxy equivalent of 185 (equivalent to 10 epoxy groups), 860 g of methacrylic acid (equivalent to 10 carboxyl groups), 1.36 g of hydroquinone and 10.8 g of triethylamine were introduced, and the mixture was heated to 120° C. and allowed to react at the same temperature for 10 hours, after which there was obtained liquid epoxy acrylate with an acid value of 3.5, epoxy equivalent of 15,000 or more and color number of 2. Then, dissolving this epoxy acrylate in 2,217 g of methyl methacrylate monomer, there was obtained 4,920 g of epoxy acrylate of the non-volatile component at 55%, acid value at 2, viscosity at 2 poises at at 25° C. and (meth)acrylate group content in the solid at 31.4% by weight.
REFERENCE EXAMPLE 6
Heating, dehydrating and condensing 166 g (1 mol) of isophthalic acid and 152 g (2 mols) of 1,2-propylene glycol in an inert gas at 220° C. for 10 hours, there was obtained a reaction product having a solid component with an acid value of 5. Then, it was cooled to 100° C. Next, 196 g (2 mols) of maleic anhydride was charged, and through heating, dehydration and condensation at 200° C. for 5 hours, there was obtained a reaction product having a solid content of an acid value of 254. To this, 0.15 g of hydroquinone was added, and the mixture was cooled to 140° C. Next, 284 g (2 mols) of glycidyl methacrylate was charged and through reaction at 140° C. for 10 hours, there was obtained a solid reaction product with an acid value of 10. Dissolving this unsaturated polyester acrylate in 508 g of methyl methacrylate monomer, there was obtained 1,270 g of an unsaturated polyester acrylate with a solid content of 60.5%, viscosity of 0.5 poises at 25° C., acid value of 6.1 and the acrylate group content in the solid at 23.4% by weight.
REFERENCE EXAMPLE 7
Preparation of styrene type epoxy acrylate [AC-3]
In a three-necked flask provided with a thermometer, stirrer and cooler 1,850 g of "EPICLON R 850" (epoxy resin product of Dainippon Ink & Chemicals, Inc.) obtained through reaction of bisphenol A with epichlorohydrin with an epoxy equivalent of 185 (equivalent to 10 epoxy groups), 860 g of methacrylic acid (equivalent to 10 carboxyl groups), 1.36 g of hydroquinone and 10.8 g of triethylamine were introduced, and the mixture was heated to 120° C. and allowed to react at the same temperature for 10 hours, after which there was obtained liquid epoxy acrylate with an acid value of 3.5, epoxy equivalent of 15,000 or more and color number of 2. Then, dissolving this epoxy acrylate in 1,800 g of styrene monomer, there was obtained 4,500 g of styrene type epoxy acrylate of a solid content of 60.3%, acid value of 2.1, viscosity of 10 poises at 25° C. and (meth)acrylate group content in the solid of 31.4% by weight.
REFERENCE EXAMPLE 8
Preparation of unsaturated polyester acrylate [AC-4]
Heating, dehydrating and condensing 133 g (0.8 mol) of isophthalic acid and 76 g (1 mols) of 1,2-propylene glycol, and 324 g (1 mol) of ethylene oxide 2 mol adduct of bisphenol A in an inert gas at 220° C. for 9 hours, there was obtained a reaction product having a solid component with an acid value of 3. Then, it was cooled to 100° C. Next, 147 g (1.5 mols) of maleic anhydride was charged, and through heating, dehydration and condensation at 200° C. for 6 hours, there was obtained a reaction product having a solid component of an acid value of 37. To this, 0.16 g of hydroquinone was added, and the mixture was cooled to 140° C. Next, 85 g (0.6 mols) of glycidyl methacrylate was charged and through reaction at 140° C. for 6 hours, there was obtained a solid reaction product with an acid value of 10. Dissolving this unsaturated polyester acrylate in 456 g of methyl methacrylate monomer, there was obtained 1,088 g of an unsaturated polyester acrylate with a solid content of 60.2%, viscosity of 20 poise of 25° C., acid value of 6 and the acrylate group content in the solid of 7.2% by weight.
REFERENCE EXAMPLE 9
Preparation of epoxy acrylate [AC-5]
In a three-necked flask provided with a thermometer, stirrer and cooler 1,300 g of "EPICLON ® 725" (epoxy resin product of Dainippon Ink & Chemicals, Inc.) obtained through reaction of bisphenol A with epichlorohydrin with an epoxy equivalent of 130 (equivalent to 10 epoxy groups), 860 g of methacrylic acid (equivalent to 10 carboxyl groups), 1.36 g of hydroquinone and 10.8 g of triethylamine were introduced, and the mixture was heated to 110° C. and allowed to react at the same temperature for 8 hours, after which there was obtained 2,160 g of a liquid epoxy acrylate with an acid value of 5. Then, dissolving this liquid epoxy acrylate in 1,440 g of methyl methacrylate monomer, there was obtained 3,550 g of epoxy acrylate of a solid content of 6.2%, acid value of 3, viscosity of 0.5 poises at 25° C. and (meth)acrylate group content in the solid of 39.3% by weight.
Characteristics of the resin compositions obtained in Reference Examples 1 through 9 are shown in Table 1.
TABLE 1__________________________________________________________________________ Charge Compositions (A-K) Characteristics (L-Q)Resin A B C D E F G H I J K L M N O P Q__________________________________________________________________________UnsaturatedpolyesterReference 460 540 901 600 60.2 18.6 6.2 59.9Example 1PE-1Reference 405 358 237 913 390 70.1 17 6.8 26Example 2PE-2Reference 389 459 152 916 600 60 15 5.5 6.6Example 3PE-3Reference 460 540 900 600 59.8 16.5 3.2 59.9Example 4PE-4Polymer having a (meth)acrylate grouponly at terminals in the main chainReference 1850 860 2710 2217 55 2 2 31.4 1487Example 5AC-1Reference 152 166 196 284 762 498 60.5 6.1 0.5 23.4 1400Example 6AC-2Reference 1850 860 2710 1800 60.3 2.1 10 31.4 1487Example 7AC-3Reference 76 324 133 147 85 632 456 60.2 6 20 7.2 3660Example 8AC-4Reference 1300 860 2160 1440 61.2 3 0.5 39.3 807Example 9AC-5__________________________________________________________________________ Notes: A 1,2Propylene glycol B Ethylene oxide (2 mol) adduct of bisphenol A C Isophthalic acid D Orthophthalic anhydride E Maleic anhydride F Glycidyl methacrylate G EPICLON ® 850 EPICLON ® 725 H Methacrylic acid I Total solid content of resin J Methyl methacrylate monomer K Styrene monomer L Solid content of resin (%) M Acid value (mg KOH/g) N Viscosity (poise at 25° C.) O Unsaturated dibasic acid content (%) P Methacryloyl content (%) Q Number average molecular weight
EXAMPLES 1 to 4 AND COMPARATIVE EXAMPLES 1 TO 8
As Example 1, the resin PE-1 obtained in Reference Example 1 and the resin AC-1 obtained in Reference Example 5, poly(meth)acrylate oligomer (ARONIX M-9050, product of Toa Synthetic Chemical Industry Co., Ltd.), a low shrinkage agent, 50% benzoyl peroxide, and dimethyl paratoluidine were compounded in the proportions shown in Table 2. The results are also shown in Table 2. Examples 2 to 4 and comparative Examples 1 to 8 were carried out similarly to Example 1. Measurement of the characteristics was made according to the methods shown below.
Appearance: Visual observation
Curing performance: Obtained from a torque-time curve at 50° C. using CURELASTOMETER III (product of Japan synthetic Rubber Company)
Viscosity: Stationary flow viscometer at 25° C. (REOMETER IR-200, product of Iwamoto Seisakusho Co., Ltd.)
RTM molding test: Charging a preforming mat adjusted to a glass content of 30% by weight into a 600×800 mm box type electro-formed nickel/copper mold with epoxy resin backing, the mold was locked at 20 kg/cm 2 . Injection of the resin into the mold was made using an injector, Model IP-6000 of Applicator Co., at a pump pressure of 6 kg/cm 2 , and the duration from the time of start of the injection to the time of the resin flowing out of the clearance on the opposite side was taken as the injection time and shown as such.
Injection time and molding test: Charging a preforming mat adjusted to a glass content of 50% to a 50×100×0.3 cm aluminum mold, the mold was locked under 20 kg/cm 2 . Injection of the resin into the mold was made under an injection pressure of 150 kg/cm 2 with a four mixing head RIM injector, product of Krauss-Maffei, used, and the duration from the time of start of the injection to the time of the resin flowing out of the clearance on the opposite side was taken as the injection time and shown as such.
Forming and tackiness: By visual observation.
Physical properties: JIS Designation K-6911.
EXAMPLE 5
In the same manner as Example 1, 100 parts by weight of the resin composed of PE-1 +AC-1, obtained in Reference Example 1 and 5, respectively, was divided into two parts, each in 50 parts by weight. To one part of the resin, 6 parts by weight of 50% benzoyl peroxide was added, and to the other, 0.2 part by weight of dimethyl para-toluidine was added, and each resin solution was circulated to a four mixing head RIM injector under a pressure of 150 kg/cm 2 and was injected to an aluminum mold having charged thereto a preforming mat preadjusted to a glass content of 50% by weight, maintained at a mold temperature of 50° C. and locked under a pressure of 20 kg/cm2, and thus a mold product was obtained. Physical properties of the mold product thus obtained are shown in Table 2.
The number average molecular weight specified in the invention refers to that value of GPC (gel permeation chromatography) which is determined under the following conditions of measurement:
GPC: Product of Japan Analytical Industry, Model LC-08
Column: SHODEX A 804+A 803+A-802+A 801 (product of Showa Denko)
Solvent: THF (tetrahydrofuran)
Standard sample for calibration curve: Polystyrene (product of Toso)
Detector: Differential refractometer (product of Japan Analytical Industry)
As seen from Table 2, the resin compositions of the present invention were distinguished in the rapid curing performance, crack resistance, tensile strength, tensile modulus of elasticity and Barcol hardness.
TABLE 2__________________________________________________________________________ Curing MoldingResin Composition (A-E) Agent (F-G) Conditions (H-K) Results (L-Q)AA BB CC DD EE FF GG HH II JJ KK LL MM NN OO PP QQ__________________________________________________________________________Example1 PE-1 50 AC-1 50 30 70 100 3 0.1 13 120 60 5 excel -0.02 good 33.5 17.0 610 (swell)2 PE-2 50 AC-1 50 30 70 100 3 0.1 11.8 130 60 5 excel 0.05 good 30.2 15.8 5703 PE-1 70 AC-2 30 30 70 100 3 0.1 10.2 125 60 5 excel 0.02 good 31.5 15.0 5904 PE-1 30 AC-2 70 30 70 100 3 0.1 9.5 100 60 5 fair 0.07 good 35.7 17.5 6805 PE-1 50 AC-1 50 30 70 100 3 0.1 13 120 22 5 excel -0.02 good 33.5 16.2 587 (swell)Compar-ativeExample1 PE-1 100 30 70 100 3 0.1 18 300 75 30 excel -0.05 poor 28.5 15.2 600 (swell)2 AC-1 100 30 70 100 3 0.1 10 80 60 5 poor 0.42 good 39.2 17.3 7003 PE-1 50 AC-1 50 30 70 100 3 0.1 12.5 140 60 5 poor 0.28 good 23.7 14.2 4904 PE-4 50 AC-1 50 30 70 100 3 0.1 14 150 60 10 poor 0.21 poor 29.0 15.5 5855 PE-3 50 AC-1 50 30 70 100 3 0.1 12.5 200 60 20 poor 0.1 poor 29.4 14.5 5126 PE-1 50 AC-3 50 30 70 100 3 0.1 13.8 270 60 30 poor 0.2 poor 33.2 17.2 6307 PE-1 50 AC-4 50 30 70 100 3 0.1 2.5 170 120 15 fair 0.05 poor 30.1 16.0 5508 PE-1 50 AC-5 50 30 70 100 3 0.1 7.5 100 60 5 poor 0.2 good 35.9 17.2 710__________________________________________________________________________ Notes: AA Unsaturated polyester resin (a) BB Polymer having a (meth)acrylate group only at one or both terminals i its main chain (b) CC Poly(meth)acrylate oligomer (c) (ARONIX M9050, product by Toa Synthetic Chemical Industry Co., Ltd.) DD Low shrinkage agent, 30% solution of polyvinyl acetate (number averag molecular weight: about 40,000) in a mixed solvent composed of styrene/methyl methacrylate = (a)/(b)) EE Calcium carbonate (NS100, product by Nitto Funka Co., Ltd.) FF 50% Benzoyl peroxide (part by weight) GG Dimethyl paratoluidine (part by weight per 100 parts by weight of the resin) HH Viscosity at 25° C. (poise) II Curing characteristics at 70° C. (second) JJ Injection time (second) KK Molding time (minute) LL Appearance (surface smoothness), by visual observation MM Shrinkage, according to JISK-6911 NN Rapid curing property, determined based on whether or not 5 minute molding is possible OO Heat resistance (glass transition point (°C.)), according to JISK-7121, DSC method (Tg measurement) PP Flexural strength (kg/cm.sup.2), according to JISK-6911 QQ flexural modulus (kg/cm.sup.2), according to JISK-6911 "excel" excellent
The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
|
Disclosed is a thermosetting resin composition which includes
(a) an unsaturated polyester,
(b) a polymer having a (meth)acrylate group only at one or both terminals of its main chain,
(c) a poly(meth)acrylate oligomer,
(d) a styrene monomer, and
(e) a methyl methacrylate monomer.
Also, a method of molding the resin is disclosed, which includes dividing the thermosetting resin composition into two parts, adding a curing agent to one of the two parts and a curing accelerator to another to form two partial compositions, introducing the two partial compositions into a mold, and allowing the two partial compositions to mix with each other and cure.
| 2
|
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
BACKGROUND OF THE INVENTION
This invention relates to para-ordered aromatic heterocyclic polymers which are soluble in water.
In general, the class of aromatic heterocyclic extended chain polymers and copolymers is well known for their outstanding thermal, physical and chemical properties. These polymers and copolymers generally exhibit excellent modulus and tenacity properties. Although these materials exhibit superior mechanical properties, they have the drawback that they generally can only be fabricated from strong corrosive acids such as polyphosphoric acid or methanesulfonic acid.
Considerably research effort has been directed to structural modifications of these aromatic heterocyclic extended chain polymers and copolymers to promote solubility in solvents other than strong acids. For example, 2-benzthiazole groups attached to a poly(p-phenylene benzobisimidazole) promote solubility in dimethylsulfoxide (DMSO). It would be advantageous if the aromatic heterocyclic extended chain polymers and copolymers were water soluble.
Accordingly, it is an object of this invention to provide para-ordered aromatic heterocyclic polymers and copolymers which are soluble in water.
Other objects and advantages of the invention will be apparent to those skilled in the art.
SUMMARY OF THE INVENTION
In accordance with the present invention, there are provided water-soluble polymers having repeating units of the formula: ##STR4## wherein n has a value of 0.05 to 1.00, M is an alkali metal such as Na, Q is a benzobisazole of the formula ##STR5## wherein X is --S-- or --O--, and R is selected from the group consisting of: ##STR6##
Also provided is a method for preparing the water-soluble polymers above, which comprises treating the corresponding sulfo- or benzthiazo-pendant polymer or copolymer with a hydride to form the polyanion followed by treatment of the polyanion with 2-propanesultone and thereafter isolating the propane sulfonate polymer or copolymer.
DETAILED DESCRIPTION OF THE INVENTION
The polymers and copolymers which can be employed in the method of this invention to prepare the corresponding water-soluble polymers and copolymers must exhibit partial solubility in an aprotic solvent, such as dimethylsulfoxide (DMSO). Polymers and copolymers derived from 2-benzthiazole terephthalic acid, 4,4'-dicarboxy-2,2'-bisbenzthiazolyl biphenyl and 2-sulfoterephthalic acid exhibit solubility in DMSO and can be used for derivatization to the propane sulfonates.
The polymer and copolymer compositions employed in the method this invention are prepared by the polycondensation of 2-benzthiazole terephthalic acid, 4,4'-dicarboxy-2,2'-bisbenzthiazolyl biphenyl or 2-sulfoterephthalic acid with 1,2,4,5-tetraaminobenzene hydrochloride and, optionally, 2,5-diamino-1,4-benzenedithiol dihydrochloride, 4,6-diamino-1,3-benzenedithiol dihydrochloride, 4,6-diaminoresorcinol dihydrochloride, 2,5-diaminohydroquinone dihydrochloride.
4,4'-dicarboxy-2,2'-bisbenzthiazolyl biphenyl can be prepared by condensation of 4,4'-dibromodiphenic acid with o-aminothiophenol in PPA followed by nucleophilic displacement of the dibromo groups with cuprous cyanide in n-methyl-2-pyrrolidinone followed by acid hydrolysis of the dinitriles.
2-sulfoterephthalic acid can be prepared by the sulfonation of terephthalic acid with 100% sulfuric acid with mercury as a catalyst or by the oxidation of 2-sulfo-p-xylene with basic permanganate followed by acid treatment.
The polycondensation is carried out in polyphosphoric acid (PPA). In carrying out the process, stiochiometric amounts of the monomers are first heated at about 40°-80° C. in 77 percent PPA to effect dehydrochlorination of the amino hydrochloride monomer(s). This step is carried out under reduced nitrogen pressure to facilitate removal of the hydrogen chloride. After complete dehydrochlorination, the temperature is lowered to about 50° C. and P 2 O 6 is added to provide about 82-84% PPA. The reaction mixture is then slowly heated under a nitrogen atmosphere to about 190° C., at atmospheric pressure. In general, the concentration of monomers in the acid ranges from about 0.5 to 15.0 weight percent. It is presently preferred to employ monomer concentrations above about 10 weight percent, in order to provide anisotropic reaction mixtures.
Alternatively, the amino hydrochloride monomer(s) may be mixed with PPA, then heated, under vacuum or an inert gas atmosphere to about 40°-80° C. over a period of 3 to 24 hours to dehydrochlorinate the amino hydrochloride monomer(s). At the end of this period, the dicarboxylic acid is added. An additional quantity of P 2 O 5 and/or PPA may be added as required to provide a stirrable mixture and to increase the concentration of PPA to about 82-84%.
It is preferred to carry out the polymerization in stages, i.e., a step-wise heating schedule is employed. Such a schedule is preferred because immediately exposing the reaction mixture to relatively high polymerization temperature may cause decomposition of one or more monomers. The selection of a particular step-wise heating schedule is obvious to one of ordinary skill in the art. An exemplary heating schedule is 60° C. for 4 hours, 100° C. for 2 hours, 160° C. for 24 hours and 190° C. for 4 hours.
At the end of the reaction period, the polymer solution is in a very viscous or semi-solid state. After cooling, the product can be recovered by coagulation in water.
The substituted polymers and copolymers are first treated with a hydride, such as sodium hydride, in anhydrous aprotic solvent, such as DMSO, to form the polyanion. After complete dissolution of the polyanion, excess 2-propanesultone is added and the mixture heated to about 40°-60° C. Following a suitable reaction period, the resulting propane sulfonate is recovered by precipitation in acetone or THF or the like.
The molecular weight of these polymers is commonly indicated by the inherent viscosity of the polymer. The inherent viscosity is commonly determined at a concentration of 0.2 weight percent in methanesulfonic acid (MSA) at 30° C. The inherent viscosity of the propane sulfonate polymers and copolymers is determined in 50% aqueous DMSO containing 1% LiCl. The LiCl is added to prevent polyelectrolyte effects on obtaining solution viscosities.
The polymers and copolymers prepared in accordance with the invention can be processed into fibers and sheets from aqueous solution. The propane sulfonate polymers and copolymers can be converted to the corresponding sulfonic acids by treatment with an acid, such as concentrated HCl.
The following examples illustrate the invention.
EXAMPLE I
Derivatization of Poly(1,7-dihydrobenzo(1,2-d:4,5-d')diimidazo-2,6-diyl(2-(2-sulfo)-p-phenylene))
100 g of anhydrous DMSO and 0.44 g of sodium hydride (60% w/w in mineral oil) (0.264 g, 0.011 mol) were placed in a 250 ml round bottom flask equipped with a mechanical stirrer, thermometer and nitrogen inlet/outlet. The suspension was stirred at room temperature under nitrogen for 30 min followed by heating at 75° C. for 1 hour. The resulting clear, light-green solution was cooled to 40° C. and 1.0 g (0.003 mol) of 2-sulfo poly(p-phenylenebenzobisimidazole) ([η]=14.0 dl/g, MSA, 30° C.) was added. After being stirred for 24 hours at 60° C., the resulting suspension became homogeneous and was converted to a red solution. The solution was cooled to room temperature and 0.85 g (0.007 mol) of 1,3-propanesultone was added. The mixture was stirred at 40° C. for 24 hours, during which time the mixture color changed to yellow. The mixture was heated at 60° C. for 2 more hours to insure complete reaction. The mixture was cooled, then poured into 500 ml of acetone and stirred until the polymer was broken into small pieces. The polymer was filtered and extracted in a soxhlet extraction apparatus with acetone to remove excess 1,3-propanesultone. The polymer was freeze-dried from a benzene slurry, then dried under reduced pressure (0.05 mm) at 100° C. The polymer exhibited an intrinsic viscosity of 6:8 dl/g in DMSO/water/LiCl at 30° C.
EXAMPLE II
Derivatization of Copoly(10%) (1,7-dihydrobenzo(1,2-d:4,5-d')diimidazo-2,6-diyl (90%) (benzo(1,2-d:4,5-d')bisthiazole-2,6-diyl(2-(2-sulfo)-p-phenylene))
100 g of anhydrous DMSO and 0.44 g of sodium hydride (60% w/w in mineral oil) (0.264 g, 0.011 mol) were placed in a 250 ml round bottom flask equipped with a mechanical stirrer, thermometer and nitrogen inlet/outlet. The suspension was stirred at room temperature under nitrogen for 30 min followed by heating at 75° C. for 1 hour. The resulting clear, light-green solution was cooled to 40° C. and 1.0 g (0.003 mol) of the above 10:90 copolymer ([η]=12.0 dl/g, MSA, 30° C.) was added. After being stirred for 24 hours at 60° C., the resulting suspension became homogeneous and was converted to a red solution. The solution was cooled to room temperature and 0.85 g (0.007 mol) of 1,3-propanesultone was added. The mixture was stirred at 40° C. for 24 hours, during which time the mixture color changed to yellow. The mixture was heated at 60° C. for 2 more hours to insure complete reaction. The mixture was cooled, then poured into 500 ml of acetone and stirred until the polymer was broken into small pieces. The polymer was filtered and extracted in a soxhlet extraction apparatus with acetone to remove excess 1,3-propanesultone. The polymer was freeze-dried from a benzene slurry, then dried under reduced pressure (0.05 mm) at 100° C. The polymer exhibited an intrinsic viscosity of 6.1 dl/g in DMSO/water/LiCl at 30° C.
EXAMPLE III
Derivatization of Copoly(25%)(1,7-dihydrobenzo(1,2-d:4,5-d')diimidazo-2,6-diyl(75%)(benzo(1,2-d:4,5-d')bisthiazole-2,6-diyl(2-(2-sulfo)-p-phenylene))
100 g of anhydrous DMSO and 0.44 g of sodium hydride (60% w/w in mineral oil) (0.264 g, 0.011 mol) were placed in a 250 ml round bottom flask equipped with a mechanical stirrer, thermometer and nitrogen inlet/outlet. The suspension was stirred at room temperature nder nitrogen for 30 min followed by heating at 75° C. for 1 hour. The resulting clear, light-green solution was cooled to 40° C. and 1.0 g (0.003 mol) of the above 25:75 copolymer ([η]=12.0 dl/g, MSA, 30° C.) was added. After being stirred for 24 hours at 60° C., the resulting suspension became homogeneous and was converted to a red solution. The solution was cooled to room temperature and 0.85 g (0.007 mol) of 1,3-propanesultone was added. The mixture was stirred at 40° C. for 24 hours, during which time the mixture color changed to yellow. The mixture was heated at 60° C. for 2 more hours to insure complete reaction. The mixture was cooled, then poured into 500 ml of acetone and stirred until the polymer was broken into small pieces. The polymer was filtered and extracted in a soxhlet extraction apparatus with acetone to remove excess 1,3-propanesultone. The polymer was freeze-dried from a benzene slurry, then dried under reduced pressure (0.05 mm) at 100° C. The polymer exhibited an intrinsic viscosity of 6.1 dl/g in DMSO/water/LiCl at 30° C.
EXAMPLE IV
Derivatization of Copoly(50%)(1,7-dihydrobenzo(1,2-d:4,5-d')diimidazo-2,6-diyl(50%)(benzo(1,2-d:4,5-d')bisthiazole-2,6-diyl(2-(2-sulfo)-p-phenylene))
100 g of anhydrous DMSO and 0.44 g of sodium hydride (60% w/w in mineral oil)(0.264 g, 0.011 mol) were placed in a 250 ml round bottom flask equipped with a mechanical stirrer, thermometer and nitrogen inlet/outlet. The suspension was stirred at room temperature under nitrogen for 30 min followed by heating at 75° C. for 1 hour. The resulting clear, light-green solution was cooled to 40° C. and 1.0 g (0.003 mol) of the above 50:50 copolymer ([η]=6.0 dl/g, MSA, 30° C.) was added. After being stirred for 24 hours at 60° C., the resulting suspension became homogeneous and was converted to a red solution. The solution was cooled to room temperature and 0.85 g (0.007 mol) of 1,3-propanesultone was added. The mixture was stirred at 40° C. for 24 hours, during which time the mixture color changed to yellow. The mixture was heated at 60° C. for 2 more hours to insure complete reaction. The mixture was cooled, then poured into 500 ml of acetone and stirred until the polymer was broken into small pieces. The polymer was filtered and extracted in a soxhlet extraction apparatus with acetone to remove excess 1,3-propanesultone. The polymer was freeze-dried from a benzene slurry, then dried under reduced pressure (0.05 mm) at 100° C. The polymer exhibited an intrinsic viscosity of 3.2 dl/g in DMSO/water/LiCl at 30° C.
EXAMPLE V
Derivatization of Copoly(75%)(1,7-dihydrobenzo(1,2-d:4,5-d')diimidazo-2,6-diyl (25%)(benzo(1,2-d:4,5-d')bisthiazole-2,6-diyl(2-(2-sulfo)-p-phenylene))
100 g of anhydrous DMSO and 0.44 g of sodium hydride (60% w/w in mineral oil)(0.264 g, 0.011 mol) were placed in a 250 ml round bottom flask equipped with a mechanical stirrer, thermometer and nitrogen inlet/outlet. The suspension was stirred at room temperature under nitrogen for 30 min followed by heating at 75° C. for 1 hour. The resulting clear, light-green solution was cooled to 40° C. and 1.0 g (0.003 mol) of the above 75:25 copolymer ([η]=8.5 dl/g, MSA, 30° C.) was added. After being stirred for 24 hours at 60° C., the resulting suspension became homogeneous and was converted to a red solution. The solution was cooled to room temperature and 0.85 g (0.007 mol) of 1,3-propanesultone was added. The mixture was stirred at 40° C. for 24 hours, during which time the mixture color changed to yellow. The mixture was heated at 60° C. for 2 more hours to insure complete reaction. The mixture was cooled, then poured into 500 ml of acetone and stirred until the polymer was broken into small pieces. The polymer was filtered and extracted in a soxhlet extraction apparatus with acetone to remove excess 1,3-propanesultone. The polymer was freeze-dried from a benzene slurry, then dried under reduced pressure (0.05 mm) at 100° C. The polymer exhibited an intrinsic viscosity of 4.2 dl/g in DMSO/water/LiCl at 30° C.
EXAMPLE VI
Solubility Properties of Derivatized Systems
A series of polymers prepared from 2-benzthiazole terephthalic acid (polymer 1, below), 4,4'-dicarboxy-2,2'-bisbenzthiazolyl biphenyl (polymer 3, below) and 2-sulfoterephthalic acid (polymers 6 and 7, below), then derivatized as described in the previous Examples. The intrinsic viscosity and water solubility of each of the derivatized sodium sulfonate polymers are given in Table I, below. The sulfonate polymers were converted to the corresponding sulfonic acids by treatment with concentrated HCl. The intrinsic viscosity and water solubility of each of the sulfonic acid polymers are given in Table I, below.
TABLE I______________________________________ [η].sup.bPoly- [η].sup.a Sulfonicmer Sulfonate Solubility Acid Solubility______________________________________1 3.3 Soluble 2.6 Insoluble3 5.0 Soluble 4.4 Insoluble6 4.5 Soluble 6.3 Soluble7 6.8 Soluble 8.5 Soluble______________________________________ Note .sup.a Intrinsic viscosity in 50% Aqueous DMSO/1% LiCl .sup.b Intrinsic viscosity in MSA
Various modifications may be made to the invention as described without departing from the spirit of the invention or the scope of the appended claims.
|
Water-soluble rigid-rod aromatic heterocyclic polymers having repeating units of the formula: ##STR1## wherein n has a value of 0.05 to 1.00, M is an alkali metal, Q is a benzobisazole of the formula ##STR2## wherein X is --S-- or --O--, and R is selected from the group consisting of: ##STR3##
| 2
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application relates to the following two co-pending and commonly owned U.S. patent applications, the disclosures of which are incorporated herein by reference in their entirety: U.S. patent application Ser. No. 10/951,951, titled “Massive Security Barrier”, filed on Sep. 28, 2004 by Roger Allen Nolte; and U.S. patent application Ser. No. 11/019,043, titled “Cabled Massive Security Barrier”, filed on Dec. 20, 2004 by Roger Allen Nolte and Barclay J. Tullis. The subject matter of the later patent application, at the filing date of the present patent application, has not been publicly disclosed, in public use, or on sale. The latter patent application is a Continuation-In-Part of the former patent application. Both of these patent applications are commonly owned by Kontek Industries, Inc. of New Madrid, Mo., and the current patent application, at the time this invention was made, was under an obligation of assignment to the same Kontek Industries, Inc. of New Madrid (also known as Kontek and as Kontek Industries).
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to passive barriers located on the ground and interconnected to establish a longitudinal wall that can provide security from terrorist threats by at least slowing, and preferably stopping in a short distance, a vehicle that collides with it, and by providing at least partial protection against blast wave forces, thermal energy, and flying debris from a nearby explosion event.
2. Description of the Related Art
Security zones for protecting sensitive groups of people and facilities be they private, public, diplomatic, military, or other, can be dangerous environments for people and property if threatened by acts of terrorism. Ground anchored active anti-ram vehicle barriers, bollards, and steel gates may stop a vehicle but may do little against a blast wave or blast debris. Earthen berms, sand-filled steel walls, massive concrete or plate steel walls anchored into the ground, or concrete panels laminated with steel sheeting and anchored into the ground have been used to shield against both terrorist vehicles and bombs. But none of these ground-anchored barriers are portable for ease of relocation, and all risk the possibility of interfering with underground utilities and other underground hazards.
However, both U.S. patent application Ser. No. 10/951,951 filed on Sep. 28, 2004 and titled “Massive Security Barrier” and U.S. patent application Ser. No. 11/019,043 filed on Dec. 20, 2004 and titled “Cabled Massive Security Barrier”, both incorporated herein by reference, disclose barriers that are portable for ease of relocation and do not endanger underground utilities when being deployed, installed, or removed. U.S. patent application Ser. No. 10/951,951 discloses barriers, each with at least one rectangular tie-bar of steel cast permanently within concrete or other solid material and extending longitudinally between opposite sides of the barrier, wherein adjacent barriers are coupled side-against-side by means of strong coupling devices between adjacent tie-bars, and wherein no ground penetrating anchoring means is involved. But since the tie-bars are cast within the barriers, they cannot be changed out or upgraded without removing and replacing the solid material as well. U.S. patent application Ser. No. 11/019,043 discloses barriers of solid material with tunnels extending between opposite sides, wherein adjacent barriers are coupled side-against-side with cables passing through the tunnels and anchored to sides of at least some of the barriers by anchoring devices. But since cables through tunnels between adjacent barriers are less able to resist lateral displacement between adjacent barriers compared to that when using rigidly coupled tie-bars, the use of cables limits the relative shortness of stopping distance that a wall can achieve, where stopping distance is the maximum distance any portion of a wall moves before all the kinetic energy causing an external force is absorbed.
U.S. Pat. No. 6,474,904 to Duckett et al. titled “Traffic Barrier with Liquid Filled Modules”, although not in the field of massive security barriers for protection against terrorist threats, discloses a traffic barrier design that uses a attachment members (similar in some respects to a tie-bar) through a tunnel within a cavity shaped by a plastic shell of a module body for containing water or other fluid. Duckett et al. also uses abutment members to constrain longitudinal positions of tie-bars relative to module bodies, but not relative lateral positions. However, Duckett et al. does not disclose or suggest the use of a massive block of solid material, the coupling of massive blocks side-against-side, the enablement of mutual rotation between adjacent blocks caused by a colliding vehicle or explosive blast sufficiently strong as to cause breakage of portions of the blocks that interfere with such rotation while at the same time maintaining continuity of and between coupled tie-bars, or the use of tunnels with entrance sizes closely matched to tie-bar sizes to constrain the positions of coupled ends of tie-bars relative to barrier blocks. And Duckett et al. doesn't disclose or suggest the use of side cavities to protect or constrain coupling devices and/or their retainers.
What is needed is a massive-security-barrier wall system made of massive security barriers that can be coupled into a row along the ground or other supporting surface, wherein each barrier has at least one strong tie-bar passing through it from one side of the mass of solid material of the barrier to its opposite side, wherein adjacent barriers are interconnected side-against-side by coupling the tie-bars between those adjacent barriers, wherein the tie-bar(s) of each barrier are constrained longitudinally and horizontally by the mass of solid material of that barrier to resist lateral displacement between adjacent barriers, and wherein the tie-bars can be selected at the time barriers are assembled into a barrier wall. What is needed also is the capability of exchanging or upgrading tie-bars in the field without having to replace the masses of solid material, and without the additional cost of scrapping that material. In other words, what is needed is a massive security barrier system that uses tie-bars through masses of solid material without having the tie-bars cast into the masses of solid material. The current invention provides such a system with such barriers.
BRIEF SUMMARY OF THE INVENTION
The invention is pointed out with particularity in the appended claims. However, some aspects of the invention are summarized herein.
The invention includes a massive security barrier module, a security wall, and a method of providing security from a terrorist threat, the method by the assembly of massive security barriers to form a security wall. The invention improves over the prior art by combining into a massive security barrier at least one tie-bar through at least one tunnel, wherein the tunnel penetrates through the mass of solid material (also called a block or barrier block) of the barrier. The invention uses coupling devices, and retainer devices as well in some embodiments, to both retain a tie-bar to a barrier block and to couple barrier blocks together side-against-side. A security wall is constructed by coupling or otherwise linking two or more such massive security barriers side-against-side to form a longitudinal wall that can provide security from terrorist threats by being able to withstand both vehicle collisions and explosive blasts that can provide sufficient external force to a) cause at least a portion of such a wall to slide across the ground or other supporting surface and b) if sufficient force is applied to break away interfering material, to cause at least some adjacent barriers to rotate relative to one another and not become uncoupled from one another. Each massive security barrier includes a mass of solid material having a slidable bottom surface, two opposite side surfaces each with at least one cavity, one or more tunnel passages extending through the mass of solid material between its opposite sides, and one or more tie-bars (also called metal beams) each having two opposite ends spaced longitudinally apart positioned in at least one of the tunnels with the two opposite ends extending respectively outward into two of the cavities. The mass of solid material is of durable material and preferably of high strength concrete. Each tie-bar is preferably made of high strength steel and typically has a cross-sectional area greater than that of an ordinary rebar rod used to reinforce concrete structures. Multiple blocks as described can be positioned on top of the ground, road-surface, parking surface, or other supporting surfaces, and coupled longitudinally to one another, with tie-bars end-to-end, and with adjacent barrier blocks side-against-side to establish a protective barrier wall. Within this disclosure, the term “end-to-end” should be taken to mean any of the following: truly end-to-end, butt-end-to-butt-end, generally end-to-end, end-overlapping-end, having interleaved ends, approximately end-to-end, or any other equivalent structural relationship that permits two tie-bars to be joined together near one each of their ends, extends their overall combined length, and provides a combined structure that will support tension and compression forces longitudinally and shear forces laterally. The coupling devices that serve as means for coupling can be, or (in some embodiments) retainer devices (also called retainers) that function as means for retaining are, sized relative to the sizes of tunnel entrances to block the coupling devices from entering the tunnels, i.e. they can prevent longitudinal translation of tie-bars within a barrier. Either or both a) the sizes of coupling devices (and separate retainer devices when used) relative to the sizes of the cavities or b) the sizes of the cross-sections of the tie-bars relative to the entrances of the tunnels, horizontally constrain lateral translation at locations within the blocks. Such a wall can withstand great longitudinal tension and can absorb and endure great amounts of mechanical and thermal energy. When loaded laterally (and horizontally), such as by forces from a nearby explosive blast or by a collision from a moving vehicle, such a wall can act at least initially as a structural beam, with at least one chain of tie-bars in tension, and with the solid material (e.g. concrete) in compression on the side of the wall facing the blast or vehicle. With sufficient tensile strength in a chain of tie-bars as the wall changes its shape by moving over the ground, vertical edges of the solid material (i.e. front or rear portions of the sides of blocks) in compression can be designed to fail by absorbing significant energy, and as a result, adjacent barriers can rotate or hinge relative to one-another as their inter-coupling devices swivel or the tie-bars near the couplings bend.
One of the embodiments of the invention is a method for providing protection from a terrorist threat, the method comprising: a) aligning multiple barriers into a row between an expected safe side and a threat side, wherein each barrier is aligned side-against-side with another of the multiple barriers to form an adjacent pair respectively; and b) using means for coupling and means for retaining to couple and retain each adjacent pair in the row; wherein the row extends longitudinally from a first barrier to a second barrier; wherein each of the barriers comprises a mass of solid material and a tie-bar; wherein each mass of solid material comprises two opposite sides, two cavities with one in each of the two opposite sides, and a tunnel through the mass of solid material between the two cavities; and wherein each of the barriers further comprises a tie-bar that extends through the tunnel of that barrier and has two end-portions each of which penetrates at least a portion of one of the two cavities of that barrier; whereby at least all excepting the first and second barriers of the row have sufficient strength to remain coupled throughout a terrorist event that is one selected from the group consisting of a colliding terrorist's vehicle and a terrorist's explosive blast; and whereby forces from the terrorist event can be strong enough to cause at least some of the coupled barriers to slide across a supporting surface, and can cause breakage of solid material where the solid material interferes with rotation between adjacent barriers. The method can further comprise using means for coupling and means for retaining, to retain each of the first and second barriers. The general shape of a lateral cross-section of a tunnel can be any shape that will accommodate a tie-bar, e.g. circular, elliptical, oval, square, rectangular, polygonal, multi-sided, and irregular. A tunnel should be large enough that a tie-bar extending though it can be at least wiggled to adjust its position relative to a tie-bar of an adjacent barrier with which it is to be coupled. At least one instance of the means for retaining can be located between an instance of the means for coupling and one of the tunnels. And an instance of means for coupling can itself serve also as an instance of means for retaining.
According to one aspect of the above embodiment, at least one instance of means for coupling can be comprised of a pin or a bolt, wherein at least two of the end portions coupled by the means for coupling each includes a hole that receives the pin or bolt. And at least one tie-bar can have a laterally larger cross-sectional area in at least one of its end portions than along its mid-portion, and wherein at least one instance of means for coupling comprises an enclosure that laterally encircles that end portion and obstructs it from being pulled out of the enclosure.
Another embodiment of the invention is a security wall comprising: a) a row of coupled barriers, each barrier comprising respectively: i) a mass of solid material that comprises two opposite sides, two cavities with one in each of the two opposite sides, and a tunnel through the mass of solid material between the two cavities, and ii) a tie-bar that extends through the tunnel and has two end-portions each of which penetrates at least a portion of a respective one of the two cavities; wherein each barrier is aligned side-against-side with another of the multiple barriers to form an adjacent pair; and b) for each adjacent pair an instance of means for coupling the tie-bar of one of the barriers of that adjacent pair to the tie-bar of the other barrier of that adjacent pair, and for each adjacent pair at least one instance of means for retaining in one of the cavities between the barriers of that adjacent pair for retaining the instance of means for coupling from entry into the tunnel that opens into said one of the cavities; whereby the coupled barriers have sufficient strength to remain coupled throughout a terrorist event that is one selected from the group consisting of a colliding terrorist's vehicle and a terrorist's explosive blast; and whereby forces from the terrorist event can be strong enough to cause at least some of the coupled barriers to slide across a supporting surface, and can cause breakage of solid material where the solid material interferes with rotation between adjacent barriers. The security wall can be further comprised of: a) at least two additional instances of means for coupling; and b) at least two additional instances of means for retaining; wherein the two additional instances of means for coupling and the two additional instances of means for retaining are installed at ends of the row. The general shape of a lateral cross-section of at least a portion of at least one of the tunnels can be at least approximately one selected from the group consisting of circular, elliptical, oval, square, rectangular, polygonal, multi-sided, and irregular; and wherein the cross-sectional area of that tunnel can be large enough that of the tie-bar extending through that tunnel can be wiggled within that tunnel. A tunnel should be large enough that a tie-bar extending though it can be at least wiggled to adjust its position relative to a tie-bar of an adjacent barrier with which it is to be coupled. At least one of the instances of means for retaining can be located between one of the instances of means for coupling and one of the tunnels. And at least one of the instances of means for coupling can comprise one of the instances of means for retaining.
According to one aspect of the above embodiment, at least one of the instances of means for coupling can be comprised of a pin or a bolt, and wherein at least two of the end portions coupled by the element each includes a hole that receives the pin or bolt. And at least one tie-bar can have a laterally larger cross-sectional area in at least one of its end portions than along its mid-portion, and wherein at least one instance of means for coupling comprises an enclosure that laterally encircles that end portion and obstructs it from being pulled out of the enclosure.
Another embodiment of the invention is a massive security barrier module comprising: a) a mass of solid material having a slidable bottom surface, wherein the mass has two opposite sides, a front, and a back, wherein each side has a front edge near the front, wherein each side has a back edge near the back, wherein each of the two opposite sides each contains one of a pair of opposite cavities, and wherein at least one tunnel extends between the pair of opposite cavities and through the mass; b) at least one tie-bar extending through the tunnel and into the cavities; c) means for coupling the tie-bar to other tie-bars of similar and adjacent massive security barrier modules, the adjacent massive security barrier modules being side-against-side with said massive security barrier module, and the other tie-bars retained at sides that are remote from the sides of said massive security barrier module; and d) means for retaining the means for coupling from entry into the tunnel; whereby the massive security barrier module has sufficient strength to maintain attachment with the adjacent massive security barrier modules when said massive security barrier module is subjected to an external impulsive force from a terrorist act sufficiently strong to rotate the modules relative to one another and cause at least one of the edges that structurally interferes with that rotation to break; and whereby energy from a security-threat event is absorbed by the break and further attenuated by the bottom surface of said massive security barrier module sliding across a supporting surface. And at least one instance of the means for coupling can comprise an instance of the means for retaining. At least one instance of the means for coupling can be comprised of a pin, a bolt, or an enclosure. Another embodiment of the invention is similar to the massive security barrier module described above in this paragraph, except that said mass of solid material is comprised of at least two individual segments that key into one another, and only one of which includes the tunnel for the tie-bar, wherein the tie-bar can be cast within the other of the two segments without requiring a tunnel; whereby the segments of the module can be handled and shipped independently.
OBJECTS AND ADVANTAGES OF THE INVENTION
Objects and advantages of the present invention include a security barrier that is massive, durable to vehicle collisions, durable to explosive blasts, energy absorbing, portable, inexpensive to manufacture, inexpensive to deploy, inexpensive to upgrade or downgrade with changes in tie-bars, inexpensive to relocate, inexpensive to remove, able to be firmly coupled to adjacent barriers, able to transfer rotational forces to adjacent barriers, able to transfer longitudinal tension forces to adjacent barriers, able to transfer compressive forces to adjacent barriers, resistant to rolling, resistant to sliding, has a high coefficient of friction with the ground (or other supporting surface), available in a variety of architectural designs and surface appearances, providing of mounting fixtures for flags and cameras and the like, providing of chases or conduits for utilities, and non threatening to utilities located below the ground.
The same objects and advantages of the invention that apply to a single barrier extend to barrier walls constructed by coupling adjacent barriers to one another in a longitudinal side-against-side row of barriers. Parts of the invention and its preferred embodiments include means for coupling tie-bars end-to-end.
The barriers can be transported by truck, positioned at a security site by using readily available heavy lifting equipment, and can be longitudinally inter-connected by means of field-installable mechanical coupling hardware. The invention does not require ground-penetrating anchoring devices, so installation, relocation, and later removal does not endanger underground utilities. And since the tie-bars are not cast into concrete or other solid material of the barriers, but rather are positioned in at least slightly larger tunnels within the concrete or other solid material of the barriers, the tie-bars can be wiggled within the tunnels to better enable alignment with adjacent tie-bars of neighboring barriers, can be selected at the time of installation for strength capability, and can be repaired, upgraded, or otherwise replaced in the field without having to scrap any mass of solid material. Another advantage of the invention is that cables can optionally also be passed through the tunnels to be used as a secondary strength system in case a tie-bar fails, and this would permit such a wall to be pushed still farther from its initial position but remain a connected barrier.
Further advantages of the present invention will become apparent to the ones skilled in the art upon examination of the drawings and detailed description. It is intended that any additional advantages be incorporated herein.
The various features of the present invention and its preferred implementations may be better understood by referring to the following discussion and the accompanying drawings. The contents of the following discussion and the drawings are set forth as examples only and should not be understood to represent limitations upon the scope of the present invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The foregoing objects and advantages of the present invention for a massive security barrier and security wall of such barriers (and its method of assembly) may be more readily understood by one skilled in the art with reference being had to the following detailed description of several embodiments thereof, taken in conjunction with the accompanying drawings. Within these drawings, callouts using like reference numerals refer to like elements in the several figures (also called views), alphabetic-letter-suffixes where used help to identify copies of a part or feature related to a particular usage and/or relative location, a single prime can denote a part or feature at an opposite location relative to an un-primed part or feature respectively, a numeric suffix following an alphabetic-letter-suffix denotes a modification to a part, and a double (or more) prime as an only suffix also denotes a modification to a part. Within these drawings:
FIG. 1 shows a perspective view of two massive security barriers, one on the left and the other on the right in the view, coupled together side-against-side to form a short massive security wall.
FIG. 2 shows an enlarged view of the barrier on the left from the view shown in FIG. 1 .
FIG. 3 shows a perspective view of three massive security barriers coupled together side-against-side to form a security wall.
FIG. 4 shows a perspective view of four massive security barriers coupled together side-against-side to form a security wall that has some of its vertical edges damaged but remains secured together.
FIG. 5 shows a barrier without the presence of coupling hardware or retainer hardware, revealing tie-bars within tunnels within a block or mass of solid material.
FIG. 6 shows a barrier with the presence of retainer hardware but without the presence of coupling hardware.
FIG. 7 shows a first example of means for retaining that is a retainer which can be used to prevent one or two coupling devices near the ends of two tie-bars in a common barrier block from entering either of two tunnels in the barrier.
FIG. 8 shows a second example of means for retaining that is a retainer which can be used to prevent one or two coupling devices near the ends of two tie-bars in a common barrier from entering either of two tunnels in the barrier.
FIG. 9 is a sectional view from FIG. 1 showing means for coupling and means for retaining, wherein a coupling device and two retainers are used to couple the two barriers together sides-against-side with the tie-bars of one barrier positioned end-to-end respectively with the tie-bars of the other barrier.
FIG. 10 is similar to FIG. 9 , but wherein the two retainer devices are not being used.
FIG. 11 is similar to FIG. 9 , but wherein the two retainer devices have added features with which to fill at least some of the otherwise empty space between the coupling device and the nearest sides of the barriers.
FIG. 12 is a perspective view showing a tie-bar with an oval-shaped hole near each of its ends.
FIG. 13 is a close-up view of one of the ends of the tie-bar shown in FIG. 12 .
FIG. 14 is a perspective view of an end of a tie-bar that has it's thickness increased relative to the mid-portion of the tie-bar.
FIG. 15 is a front view showing one example of means for coupling two tie-bars end-to-end.
FIG. 16 shows a perspective view of two parts of an opened enclosure device that can be used to couple two tie-bars end-to-end.
FIG. 17 shows a perspective view of the enclosure of FIG. 16 closed about the ends of two tie-bars and thus serving as means for coupling the two tie-bars together.
FIG. 18 shows an enlarged view of the barrier as seen on the left in FIG. 1 , only its mass of solid material is modified to be comprised of two individual segments that key into one another.
FIG. 19 shows one of the segments of the barrier of FIG. 18 , designed with tunnels for tie-bars.
FIG. 20 shows a modified version of the segment of barrier shown in FIG. 19 , designed without tunnels and having tie-bars cast in place within the segment.
DETAILED DESCRIPTION OF THE INVENTION
The following is a detailed description of the invention and its preferred embodiments as illustrated in the drawings. While the invention will be described in connection with these drawings, there is no intent to limit it to the embodiment or embodiments disclosed. On the contrary, the intent is to cover all alternatives, modifications and equivalents included within the spirit and scope of the invention as defined by the appended claims.
FIG. 1 shows a perspective view of one embodiment of the invention, that being two massive security barriers 113 A and 113 B adjacent to one another, the massive security barrier 113 A on the left and the massive security barrier 113 B on the right in the view, coupled together side-against-side into a coupled pair of massive security barriers 101 to form a short security wall 103 . (Two massive security barriers adjacent to one another are referred to herein as an adjacent pair, independent of whether they are coupled or not.) The barriers 113 A and 113 B are sitting on top of a supporting surface such as a ground surface 135 . One skilled in the art should appreciate that such a supporting surface could be, for example, the ground surface of a lawn, the surface of an open field, the surface of a parking lot, the surface of a roadway, the surface of a shoulder of a roadway, the surface of a plaza, etc. In this embodiment, the massive security barrier 113 A is comprised of a mass of solid material 111 A and two tie-bars ( 161 A and 163 A called out in the cross-sectional view of FIG. 9 ) whose left-hand ends 121 A and 123 A are visible in this view. Also, the massive security barrier 113 B is comprised of a mass of solid material 111 B and two tie-bars ( 161 B and 163 B called out in the cross-sectional view of FIG. 9 ). It should be appreciated by one skilled in the art that other embodiments of the invention could be comprised of only one tie-bar per barrier, or more than two tie-bars per barrier. It should also be appreciated by one skilled in the art that other embodiments of a security wall by the invention can be comprised of a row of multiple barriers preferably numbering greater than merely the two illustrated.
In regard to FIG. 1 , the mass of solid material 111 A has two opposite sides 129 A and 129 A′, and the mass of solid material 111 B has two opposite sides 129 B and 129 B′. The two masses of solid material 111 A and 111 B are shown adjacent to one another with sides 129 A′ and 129 B against one another (i.e. at least nearly touching one another) thereby defining an interface region 115 . Within each side of each barrier is a cavity into which the one or more tie-bars associated with that barrier penetrate. The mass of solid material 111 A of barrier 113 A has cavities 117 A and 117 A′. The mass of solid material 111 B of barrier 113 B has cavities 117 B and 117 B′. Tie-bar ends 121 A and 123 A are visible in this view extending into cavity 117 A at the far left of the view. In cavity 117 A at the left end of the security wall 103 , a coupling pin 171 A is visible along with its head 173 A. The coupling pin 171 A extends through both tie-bar ends 121 A and 123 A, through holes 131 A (not visible in this view, but visible in FIGS. 5 , 6 , and 12 ) in the upper tie-bar 121 A and 133 A in the lower tie-bar 123 A.
In regard to FIG. 1 , holes such as hole 133 A are in both ends of each tie-bar and are oval shaped with extension parallel to the length-wise dimension of its corresponding tie-bar. Such extensions can accommodate deviations in the accuracy of the placement of the holes when inserting a coupling pin (such as coupling pin shown with head 173 in this view between the two barriers 113 A and 113 B) during installation of a security wall (such as 103 ). These oval shaped holes are also used to alleviate tension between coupled tie-bars during the very initial interaction between coupled barriers when a security wall of which the barriers are apart is first struck by a moving vehicle, a period in time during which the security wall begins to change shape as barriers begin to slide across the supporting surface 135 and as some of the masses of solid material that interfere with mutual rotation of adjacent barriers begins to break away.
In regard to FIG. 1 , also visible is a retainer 149 A that both tie-bars with ends 121 A and 123 A extend through. In cavity 117 B′ at the right end of the security wall 103 , the head 173 B′ is visible of coupling pin 171 B′ (the body of pin 171 B′ is not visible in this view) along with a retainer 149 B′, both in a similar arrangement as the coupling pin 171 A and retainer 149 A shown at the left end of the security wall 103 , only attached to the tie-bars of barrier 113 B instead. Within the interface region 115 , the cavity 117 A′ of barrier 113 A and the cavity 117 B of barrier 113 B together form a combined cavity 119 between these adjacent barriers 113 A and 113 B. Within this combined cavity 119 , the head 173 of a coupling pin 171 (pin 173 is not visible or labeled in this view but is visible and labeled in the sectional view of FIG. 9 ) and two retainers (not labeled in this view but labeled in the sectional view of FIG. 9 as 149 A′ and 149 B) are visible. Note that the head 173 of coupling pin 171 , and the coupling pin 171 itself (the pin coupling the two barriers 113 A and 113 B together in the interface region 115 and visible in FIG. 9 ), could each alternatively be labeled with a suffix of A′ or B because they can be considered as either the coupling pin at the right-hand side of the left barrier or the coupling pin at the left-hand side of the right barrier. It will be readily appreciated by one skilled in the art that after completion of installation of a security wall such as 103 , it is advisable to protect the otherwise exposed tie-bar ends and means for coupling (and means for retaining if used) with protective covers and/or sealing means to conceal the presence of the cavities, discourage tampering, and keep out rain and snow.
FIG. 2 shows an enlarged perspective view of the massive security barrier 113 A as it might be configured for storage, shipment, or handling before being connected to one or two other barriers. All that is shown in this view is also shown in FIG. 1 with one exception being that FIG. 2 shows callouts for a top surface 141 A, a bottom surface 143 A, a front surface 145 A, and a back surface 147 A of the mass of solid material 111 A of barrier 113 A. Another exception is that FIG. 2 also shows outer vertical edges 151 A, 153 A, 151 A′, and 153 A′ formed at the intersections of the side surfaces 117 A and 117 A′ with the front surface 145 A and the back surface 147 A. Another exception is that FIG. 2 shows at the right of the view the head of a coupling pin with a callout of 173 A′ instead of 173 as it would be labeled if shown connecting to another barrier. And another exception is that a retainer plate 149 A′ is also shown at the right of the view. It will be readily appreciated by one skilled in the art that the shapes of the cavities, such as 117 A and 117 A′, are ones which allow access to coupling devices from above, that a drain hole (not shown) is desirable near the bottom of each adjacent pair of cavities, and that there should remains ample solid material at outer vertical edges of a mass of solid material to protect what is in the cavities formed between two adjacent barriers (as cavity 119 between barriers 113 A and 113 B shown in FIG. 1 ). One skilled in the art will also readily appreciate that the assembly shown is not the only configuration in which to store, ship, or handle a barrier, and that one might choose to store, ship, or handle the various components independently.
FIG. 3 shows a perspective view of three massive security barriers 113 A, 113 B, and 113 C coupled together side-against-side to form a security wall 103 ″ that rests on a ground surface 135 . Each barrier 113 A, 113 B, and 113 C is comprised of a mass of solid material 11 A, 11 B, and 11 C respectively. The side 129 A of barrier 113 A forms one end of the wall 103 ″, and the side 129 C′ forms the other end of the wall 103 ″. Between barriers 113 A and 113 B is an interface region 115 where the side 129 A′ of barrier 113 A is against the side 129 B of barrier 113 B. Between barriers 113 B and 113 C is an interface region 115 where the side 129 B′ of barrier 113 B is against the side 129 C of barrier 113 C. This massive security wall 103 ″ is much like, but longer by one barrier, than the security wall 103 shown in FIG. 1 . To change the wall 103 of FIG. 1 into the wall 103 ″ of FIG. 3 , the one additional barrier 113 C has been provided and positioned side-against-side to barrier 103 B, and an additional coupling device along with two additional retainer devices have been provided and installed.
FIG. 4 shows a perspective view of four massive security barriers 113 A, 113 B, 113 C, and 113 D coupled together side-against-side in a row to form a security wall 103 ′″ that has some of its vertical edges damaged but remains secured together. To change the wall 103 ″ of FIG. 3 into the wall 103 ′″ of FIG. 4 , the one additional barrier 113 D has been provided and positioned side-against-side to barrier 103 C, and an additional coupling device along with two additional retainer devices have been provided and installed. The wall 103 ′″ is shown in a non-straight line to illustrate a shape that might be caused by a terrorist vehicle having collided with the front of the wall 103 ′″ and dragging it along the ground. It is to be noted that vertical edges have been broken by compression in the masses of solid material 111 A, 111 B, and 111 C near the front of the wall resulting from collision-caused forces that were sufficient to cause at least some rotation between adjacent barriers 113 A and 113 B, between adjacent barriers 113 B and 113 C, and between adjacent barriers 113 C and 113 D. Such a pattern of rotation directions might result from a vehicle having crashed into the front of barrier 113 B.
In regard to FIG. 4 , one skilled in the art will appreciate that end portions of the tie-bars at the left end of the barrier 113 A, and end portions of the tie-bars at the right end of the barrier 113 D, of the security wall 103 ′″ in this view, can be retained from entering tunnels within the barriers 113 A and 113 D by using devices designed to anchor one or more ends of tie-bars to a barrier.
FIG. 5 shows barrier element 113 A in a view that is enlarged even further, shown with a middle portion of the barrier 113 A removed in order to fit into the view both sides 129 A and 129 A′ of the barrier 113 A. In this view, coupling pins and retainers are not present as they are in FIG. 2 , thus revealing in FIG. 5 that the mass of solid material 111 A includes a first tunnel 125 A and a second tunnel 127 A. Tunnels 125 A and 127 A are located in this embodiment with one over the other, the tunnel 125 A being above the tunnel 127 A. With one tunnel over another, a single coupling pin can be used to connect both tie-bars of one barrier to a similar pair of tie-bars in an adjacent barrier, as the coupling pin with head 173 couples barrier 113 A to 113 B shown in FIG. 1 .
In regard to FIG. 5 , the cross-sectional shapes of the tunnels 125 A and 127 A are shown in this implementation to be rectangular and bigger but not much bigger than the rectangular cross-sectional shapes of the tie-bars having ends 121 A and 123 A visible at the left-hand side of the view. One skilled in the art will readily appreciate that the cross-sectional shapes and sizes of the tunnels and tie-bars need not be constant over their lengths, but that typically they would be, and that the cross-sectional shape of a tunnel is not limited to rectangular, but could instead be square, circular, elliptical, triangular, polygonal, or even irregular.
In regard to FIG. 5 , the cross-sectional shape of a tie-bar, such as that with ends 121 A and 121 A′, is typically rectangular but can be of other shapes as is discussed below in regard to FIG. 16 , and a tie-bar is typically made of high-strength steel.
In regard to FIG. 5 , one skilled in the art will also readily appreciate that a barrier, such as 113 A, could be made with only a single tunnel 125 A and a single tie-bar as having tie-bar ends 121 A and 121 A′, or could be made with more than a single tie-bar in any one tunnel 125 A.
In regard to FIG. 5 , a mass of solid material, such as 111 A, which is also called a block, is typically shaped as a rectangular block but could have alternative shapes such as having beveled edges, and any of its surfaces could be other than flat. A mass of solid material, such as 111 A, is typically made of high-strength concrete and would typically include an inner structure of strengthening rebar as known in the prior art. And a mass of solid material, such as 111 A, can also typically include additional features such as a) hooks or loops in the top to aid manufacturers, distributors, and installers in lifting and positioning the mass of solid material, b) recesses in the bottom surface for use by fork-lifting equipment and for use in permitting the passage of water drainage, c) features to support ancillary objects such as surveillance cameras and lighting fixtures, and d) chases for routing communications and power cables or other utilities.
In regard to FIG. 5 , one skilled in the art will readily appreciate that a tunnel can be made into a mass of solid material (concrete for example) most conveniently by casting the material using a casting form that can accept and position a tube, whereby the tube defines the tunnel and can remain with the finished block when the block is removed from the form, the tube thus becoming a permanent part of the cast block. Alternatively, the tube can be coated at least on the outside with a release agent so that the tube can eventually be removed from the block. Also, alternatively, a tunnel can be defined by casting into the block a roll of bubble-wrapping material that can later be removed, or a tie-bar can be wrapped with bubble-wrapping material and then cast into place after which the bubble-wrapping material can be broken down with hot gas, a hot poker, or other tools.
FIG. 6 is similar to FIG. 5 and shows the barrier 113 A with the presence of retainers 149 A and 149 A′ but without the presence of coupling hardware. It can be readily appreciated that retainers 149 A and 149 A′ block entrances to the tunnels which they hide in this view. One of the purposes of using retainers such as these (they are sometimes optional) is that they can help to prevent the ends of tie-bars from being pulled into the entrances of the tunnels under applied applied tension to the tie-bars and given coupling devices that might otherwise deform sufficiently to be pulled into the tunnels along with ends of the tie-bars. When there are two tie-bars positioned along side of one another as illustrated in this embodiment, it is convenient to share one retainer at each of the barrier with both tie-bars, although this too is optional.
FIG. 7 shows a first example of a retainer 149 (means for retaining) which can be used to prevent one or two coupling devices near the ends of two tie-bars in a common barrier from entering either of two tunnels in the barrier. In the upper portion of the retainer 149 is a slotted hole 155 for location partly around an upper tie-bar, and a slotted hole 155 ′ for location partly around a lower tie-bar. An advantage of using a retainer with slotted holes instead of holes without slots is that such a retainer can be put into place about two tie-bars, before the coupling device is put into place. This can be done by lowering the retainer into a cavity alongside the tie-bars, such as cavity 119 shown in FIG. 1 if the cavity 119 is deep enough horizontally into the sides of the blocks, and then rotating the retainer in such a manner that the tie-bar ends move into the slots of the slotted holes.
FIG. 8 shows a second example of a retainer 149 ″ (means for retaining) which can be used to prevent one or two coupling devices near the ends of two tie-bars in a common barrier from entering either of two tunnels in the barrier. In this embodiment, however, there are no slots but only holes 157 and 157 ′. In this case, the installation of retainers can be accomplished for example by either a) positioning a first barrier block against a second barrier block and locating any desired retainers 149 ″ before slipping the last tie-bars for those two blocks into place, or b) slipping the retainer 149 ″ over two tie-bars already positioned within a barrier block and then positioning that block next to what becomes its adjacent neighbor to form an adjacent pair of blocks. And of course retainers of the type as 149 in FIG. 7 can also be installed in these ways.
In regard to FIGS. 7 and 8 , the shapes of retainers 149 and 149 ″ can be other than the rectangular shapes illustrated, the optimum shape being dependent upon the size and shape of any tunnel entrances they are designed to block, and depending upon the size(s) of the cavities within which they are situated in the sides of the barrier blocks.
FIG. 9 is a sectional view from FIG. 1 showing the coupling pin 171 (means for coupling) with its head 173 used to couple the two barriers 113 A and 113 B together sides-against-side with the tie-bars 161 A and 163 A of one barrier positioned end-to-end respectively with the tie-bars 161 B and 163 B of the other barrier. Also shown are the two retainers 149 A′ and 149 B (both are means for retaining) located to either side of the coupling pin 171 . In this cross-sectional view, note that the cross-section from FIG. 1 is taken from a position nearer the front surface 145 A (seen in FIG. 2 ) than the back surface 147 A (seen in FIG. 2 ). The position of the cross-section is such as not to cut into the coupling pin 171 or head 173 or either tie-bar 161 A or 163 A, but does cut into the retainers 149 A′ and 149 B and the masses of solid material 111 A and 111 B and their tunnels 125 A, 127 A, 125 B and 127 B. In this embodiment, the coupling pin 171 is shown with a threaded end 175 and fastened into place with washers 179 and a nut 177 . One skilled in the art will readily appreciate that the relative vertical positioning of the upper tie-bars 161 A and 161 B relative to one another, and the relative vertical positioning of the lower tie-bars 163 A and 163 B relative to one another, can be in any of a variety of arrangements and not just that shown with the tie-bars 161 B and 163 B positioned above the tie-bars 161 A and 163 A. For example, two tie-bars of one barrier can be located between two tie-bars of an adjacent barrier.
In regard to FIG. 9 , for illustrative purposes only, a small gap is shown between a side of the barrier 113 A and a mutually facing side of barrier 113 B, in the interface region 115 ; but this gap in practice should be kept as small as is practical and smaller than approximately the diameter of the illustrated coupling pin 171 . Preferably the two barriers 113 A and 113 B would be touching one another at their mutually facing sides. The purpose of keeping the gap at the interface region 115 as small as practical is to force portions of the solid material to have to be broken away from front and/or rear surfaces (such as front and rear surfaces 145 A and 147 A of barrier 113 A shown in FIG. 2 ) that include at least a portion of one of the vertical edges of one of the barriers (such as the vertical edges shown on barrier 113 A in FIG. 2 as edges 151 A, 153 A, 151 A′, or 153 A′) before significant mutual rotation can occur between adjacent barriers (such as between barriers 113 A and 113 B).
In regard to FIG. 9 , one skilled in the art will readily recognize that the coupling pin 171 that is shown coupling both upper tie-bars 161 A and 161 B together, as well as coupling both lower tie-bars 163 A and 163 b together, could be replaced with a coupling arrangement involving a pin (or one or more bolts) coupling the upper tie-bars that are separate from a pin (or one or more bolts) coupling the lower tie-bars. Another embodiment could use one coupling pin to both couple the upper tie-bars and to couple the lower tie-bars, but wherein either no threads or nut are used at the lower end of the coupling pin, or wherein threads and a nut are used just below the upper tie-bars either instead of or in addition to the threads and nut at the bottom end of the coupling pin.
FIG. 10 is similar to FIG. 9 , but wherein the two retainer devices 149 A′ and 149 B are not being used.
FIG. 11 is similar to FIG. 9 , but wherein the retainers 149 A 1 ′ and 149 B 1 are of modified form compared to the retainers 149 A′ and 149 B shown in FIG. 9 . These retainers 149 A 1 ′ and 149 B 1 have the added features 191 A′ and 191 B respectively that fill at least some of the otherwise empty space between the coupling pin 171 and what would otherwise be the locations of the previously shown retainers 149 A′ and 149 B respectively. In this manner, the coupling pin 171 (or some other choice of a coupling device) is afforded added protection under stress against bending or shifting its location relative to the other components shown in this view.
FIG. 12 is a perspective view showing a tie-bar 161 A with an oval-shaped hole 131 A near the tie-bar end 121 A, and an oval-shaped hole 131 A′ near the other tie-bar end 121 A′. In this view, the tie-bar 161 A is shown with its larger surfaces in a generally horizontal plane, as oriented in the embodiment of FIG. 1 . However, tie-bars such as 161 A can also be oriented with their larger surfaces in a generally vertical plane.
FIG. 13 is a close-up view of the end 121 A of the tie-bar 161 A shown in FIGS. 1-2 , 5 - 6 , 9 - 11 , and 12 . One of the disadvantages of having a hole 131 A near the end 121 A of this tie-bar 161 A is that sufficiently strong tension forces along the length of the tie-bar, when reacted against by forces in a coupling pin located in the hole 131 A, can result in failure of the tie-bar around the pin. The end 121 A can be made stronger by locating the hole farther away from the very end of the tie-bar and also by making the tie-bar wider and/or thicker (i.e. in directions lateral to the length of the tie-bar 161 A).
FIG. 14 is a perspective view of an end 121 A 1 of a modified tie-bar 161 A 1 that has it's thickness increased relative to that of the mid-portion of the tie-bar, requiring the hole 131 A 1 ′ to be deeper than illustrated in the previous views, and resulting in a tie-bar end 121 A 1 that is stronger than that of tie-bar end 121 A as shown in FIG. 13 . Since only the end portion 121 A 1 is made thicker, it is then possible, without weakening the rest of the tie-bar, to have a shelf-like step feature 195 A 1 . Depending upon how this step feature 195 A 1 is to be used in cooperation with alternative means for coupling, this step feature might have an abrupt step as illustrated or a gradual step as might be produced by a fillet of weld material.
FIG. 15 is a front view (or top view in an alternative embodiment) showing one example of means for coupling two modified tie-bars 161 A 1 and 161 B 1 together end-to-end. Whereas a modified (shorter) coupling pin is shown here with head 173 ″ and threads 175 ″ and used with washers 179 and a nut 177 , it will be readily appreciated by one skilled in the art that if the tie-bars 161 A 1 and 161 B 1 are to be oriented with their larger surfaces in a vertical plane, that multiple bolts could be used in place of a single coupling pin, and that this would provide equivalent means for coupling two tie-bars together. Since the tie-bars 161 A 1 and 161 B 1 have thicker ends 121 A 1 ′ and 121 B 1 , the coupling shown is a stronger one than if the tie-bars were not modified to have thicker ends and were the same thickness throughout their lengths as the thickness of the portions of the tie-bars 161 A 1 and 161 B 1 seen in this view to the left of the step feature 195 A 1 ′ and to the right of step feature 195 B 1 respectively.
FIG. 16 shows a perspective view of two enclosure parts 211 and 215 of an opened enclosure assembly that can be used, when closed and fastened to one another, to couple two modified tie-bars 161 A 2 and 161 B 2 at least approximately butt-end-to-butt-end without requiring any holes that would otherwise weaken the tie-bars 161 A 2 and 161 B 2 . The tie-bar ends 121 A 2 ′ and 121 B 2 are modified to have thicker ends than the middle portion of the tie-bars 161 A 2 and 161 B 2 respectively, and have to have step features 195 A 2 ′ and 195 B 2 respectively. When the two enclosure parts 211 and 215 are brought together to enclose the ends 121 A 2 ′ and 121 B 2 of the tie-bars 161 A 2 and 161 B 2 , their inner shapes are made to conform generally to the shapes of the tie-bar ends 121 A 2 ′ and 121 B 2 , thus using the step features 195 A 2 ′ and 195 B 2 to effectively lock the two tie-bars 161 A 2 and 161 B 2 together butt-end-to-butt-end, and thus coupling them together securely. The thicker portions created by the step features 195 A 2 ′ and 195 B 2 of the ends 121 A 2 ′ and 121 B 2 extend into a cavity or recess 213 in the enclosure part 211 . Multiple holes 217 in both enclosure parts 211 and 215 are used with bolts to secure the two parts 211 and 215 together. One skilled in the art can appreciate that other embodiments can be configured in the same spirit as that illustrated here. For example, the tie-bars could be made even thicker with a step feature (such as 195 A 2 ′ and 195 B 2 ) on both large faces of the ends of each tie-bar, and that the enclosure needed to attach them butt-end-to-butt-end could be made of two enclosure parts both having a respective recess such as part 211 shown. Another modification that can be made is to oversize the recess 213 to allow some play of the tie-bar ends 121 A 2 ′ and 121 B 2 to rotate somewhat in a plane parallel to the larger faces of the tie-bars. And another modification can be to have step features on not one or two sides of an end portion of a tie-bar, but on all four sides of a tie-bar having a square or rectangular cross-section end and to enclose two such tie-bars into a coupling enclosure that has recesses to accommodate each of the step features.
FIG. 17 shows a perspective view of the parts shown in FIG. 16 but wherein the two enclosure parts 211 and 215 are shown here as closed and fastened about the ends 121 A 2 ′ and 121 B 2 of two tie-bars 161 A 2 and 161 B 2 and thus serving as means for coupling the two tie-bars 161 A 2 and 161 B 2 together.
FIG. 18 shows an enlarged view of the barrier 113 A as seen on the left in FIG. 1 , except the mass of solid material is shown here to be comprised of two individual segments 111 A 1 and 111 A 2 that key into one another. The two segments are shown as separate from one-another but touching one another along the dividing line 303 A between segments, and along vertical edges 301 A of the segments. The dividing line 303 A generally has this shape throughout the heights of the segments, i.e. from top to bottom. Whether the mass of solid material 111 A consists of two segments 111 A 1 and 111 A 2 (as seen here in FIG. 18 ), or consists of only one single mass of solid material (as shown in FIG. 1 ), is optional, but in either case it is comprised of tunnels that extend all the way from the cavity 117 A on the left to the cavity 117 A′ on the right. One skilled in the art will readily appreciate that the dividing line 303 A is only one configuration of many that could be used to shape the interfacing ends of the two segments 111 A 1 and 111 A 2 or “sub-blocks”, and that the shape of the dividing line 303 A shown here demonstrates a stepped-back-and-forth shape that can provide the interface with strength to resist shearing laterally and horizontally between the two sub-blocks. The shape of the dividing line 303 A shown here can eliminate or at least reduce horizontal shear stress laterally. The tie-bar ends 121 A and 123 A of the tie-bars 161 A and 163 A are shown here on the left, but the tunnels 125 A and 127 A are not visible in this figure.
FIG. 19 shows one segment 111 A 2 of the two segments 111 A 1 and 111 A 2 of the barrier 113 A of FIG. 18 , designed with tunnels 125 A 2 and 127 A 2 for tie-bars. Channels that are the extensions of the tunnels 125 A 2 and 127 A 2 are visible in this view and given the call-out designations of the tunnels since when interfaced with the other segment 111 A 1 , these channels complete mid-portions of the tunnels 125 A 2 and 127 A 2 by aligning with similar channels in the other segment 111 A 1 . It can be readily appreciated by one skilled in the art that the dividing line 303 A shown in FIG. 18 is one that permits the two segments 111 A 1 and 111 A 2 to be symmetrical and therefore identical, and that this reduces the need for manufacturers to make two different types of segments.
FIG. 20 shows a modified version 111 A 2 ′ of the segment 111 A 2 shown in FIG. 19 , designed without tunnels and having tie-bars 161 A and 163 A cast in place within the segment 111 A 2 ′. Such a modified segment 111 A 2 ′ can be interfaced with a segment such as 111 A 2 shown in FIG. 19 . One skilled in the art can readily appreciated that such a combination of segments 111 A 2 and 111 A 2 ′ can permit a complete barrier in which a means for retaining coupling devices are not required as the tie-bars are cast within the segment 111 A 2 ′.
One skilled in the art will readily appreciate that the installation and assembly of a security wall such as illustrated in FIG. 1 , if involving larger numbers of barriers than merely two, can involve placing into location and coupling one additional barrier at a time, either always at the same one end of a row or at either end of a row, or placing into location a group of adjacent barriers and proceeding to couple selected adjacent pairs sequentially down the row or in any order of sequence.
One skilled in the art will appreciate that other structure for means for coupling and arrangements of one or more tie-bars in massive barriers can be used. One example would be the rotation of the tie-bar(s) 90 degrees about their longitudinal axes and coupling them with one or more pins or bolts and nuts, in which case any mutual rotation of adjacent barriers would incur bending of the tie-bars near the cavities as portions of the mass of solid material that interfere with the rotation break away. Other examples would include, but not be limited to, the use of clamping devices, couplings as used to couple railway cars together, interlocking mechanisms, mechanisms such as used to hook a trailer to a tractor, and equivalent linking devices used to attach two bodies to one another and allow some relative mutual rotation between the two bodies. Such alternative embodiments for coupling devices are considered herein to be other equivalents of means for coupling barrier blocks together.
One skilled in the art will appreciate that other means for retaining can be used than those described above. Since the purpose of a retainer in this invention is to constrain the end(s) of one or more tie-bars from being pulled into a tunnel, and possibly also to constrain the end(s) from translating laterally relative to a nearby tunnel entrance, it can be appreciated by one skilled in the art that equivalent means for retaining can be any retainer device that can serve as an obstruction to an end of one or more tie-bars (or to a coupling means to which the tie-bar end(s) is/are attached) in either or both the lateral and longitudinal directions. If it is to provide restraint in the lateral direction, such obstruction would at least resist lateral movement of a tie-bar end from moving outsides of the cavity in a barrier within which it was installed. If it is to provide restraint in the longitudinal direction, such an obstruction would at least resist longitudinal movement of a tie-bar end from moving into a tunnel. One skilled in the art will readily appreciate that if the structure of means for coupling is larger laterally than the entrance to a tunnel, or larger enough to restrict lateral motion within a cavity of a barrier into which it is installed, then it can serve in either case respectively as means for retaining in the longitudinal or lateral directions. And one skilled in the art will readily appreciate that structures of means for coupling that simultaneously couple multiple tie-bars of one barrier to those of an adjacent barrier intrinsically serve as means for retaining. It is therefore intended that all such equivalents of means for coupling and means for retaining should be considered equivalents to those illustrated in the drawings and previously disclosed in this specification.
One skilled in the art will appreciate that shapes for the mass of solid material comprising a barrier can be other than that shown in the illustrated embodiments within this specification. For example, the sides of the barrier blocks can be made in a shape that permits features in the side of one barrier block to key into complementary features in the oppositely facing side of an adjacent barrier block, this to strengthen shear resistance to resist lateral displacements between adjacent barriers and thus potentially reduce the shear forces experienced by coupling devices when a security wall experiences a terrorist event intended to breach the wall. In another example, the opposite sides of a barrier block don't necessarily have to be parallel, but could be at an angle to one another as to accommodate a change of longitudinal direction somewhere along a row of barriers.
Under “Objects and Advantages of the Invention” presented above, it was stated that the invention comprises barrier blocks that have bottoms that are resistant to sliding over the ground (or over another supporting surface), that the bottom of a block should have a high coefficient of friction with the supporting surface. One skilled in the art will readily appreciate that the energy required to move or otherwise slide a block over a supporting surface can be effectively increased with some types of supporting surfaces by incorporating a tread-like surface or even cleats or spikes on the bottom of barrier blocks. Where it is known that there are no underground utilities to be damaged, ground anchors (e.g. piers) can be used to anchor barriers firmly to the ground at some locations along a wall, but still allowing other locations to slide. Barrier blocks or tie-bars can be tethered loosely to ground anchors by means of cables having a fixed length of slack and thereby designed to bring a moving wall to an earlier halt than otherwise after a given distance of sliding, or even tethered taught with a frictional braking means to feed out cable while absorbing kinetic energy from the wall as it is dragged from its installed position.
Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art will appreciate that any arrangement configured to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments of the invention. It is to be understood that the above description has been made in an illustrative fashion, and not a restrictive one. Combinations of the above embodiments, and other embodiments not specifically described herein will be apparent to those of skill in the art upon reviewing the above description. The scope of various embodiments of the invention includes any other applications in which the above structures and methods are used. Therefore, the scope of various embodiments of the invention should be determined with reference to the appended claims, along with the full range of equivalents to which such claims are entitled.
|
Barrier elements provide security from terrorist threats by ability to withstand both vehicle collisions and explosive blasts. Each barrier element is prefabricated to include a massive block of durable material, preferably of high strength concrete, with at least one tunnel extending at least partially between respective cavities in two opposite sides of the block. Each barrier element also includes at least one beam that is preferably made of steel and extends through one such tunnel. Multiple blocks are positionable slidably on top of the ground side-against-side with their beams coupled longitudinally to one another at least approximately end-to-end. Retainer means can be used to block coupling means from entry into the tunnels. Forces from a vehicle collision or an explosive blast can cause barrier elements to rotate relative to one-another when the couplings between beams hinge or bend as the durable material that interferes with the rotation breaks away.
| 4
|
BACKGROUND OF THE INVENTION
This invention relates to tufting machines, and more particularly to a looper apparatus for a narrow gauge, multiple-needle tufting machine adapted to form loop pile and cut pile in the same row of stitching.
In multiple-needle tufting machines having conventional gauges of 1/4" or greater, loop pile and cut pile have been formed in the same row of stitching by looper apparatus, such as that disclosed in the Card U.S. Pat. No. 3,084,645, issued Apr. 9, 1963. In the prior Card patent, the looper apparatus includes a hook having a smooth, pointed bill extending in the direction opposite from the direction of fabric feed. A looper clip is fixed to the needle side of each hook and extends along, but is laterally spaced from and below the lower or bottom edge of, the hook, and then terminates in a free end or clamp portion biased into engagement against the free or pointed end portion of the hook. In the prior Card apparatus, the speed of the yarn fed to the needles is selectively controlled by a pattern control mechanism. Normal lengths of yarn are fed to the needles for making a normal length loop pile which is secured and held upon the bill of the looper apparatus and subsequently cut by a knife to form a normal length cut pile tuft. On the other hand, when the pattern control mechanism starves the yarn feed, tension is applied to the yarn caught on the hook and as the hook retracts, the yarn forces the clamping end of the looper clip away from the bill, so that the loop is released and shortened, but is not cut, to thereby form a shorter uncut pile loop.
However, since the trend in the tufting industry is to employ more narrow needle gauges for forming tufted fabrics, such as carpet, the hooks, looper clips and knives become more crowded, as the gauge of the needles is reduced. Where the gauge is reduced to 3/16 of an inch, the knives must be set with more care, thereby requiring more time, so that the looper clips will not interfere with the knives.
When the gauge is reduced to 5/32 of an inch, the setting of knives becomes extremely critical. When the gauge is reduced to 1/8 of an inch, production of tufting fabrics including loop pile and cut pile in the same row of stitching formed by adjacent hooks, knives and looper clips, becomes practically impossible.
Where the gauge is so narrow, the looper clip of one looper interferes with the knife of the adjacent looper.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a looper apparatus for a narrow gauge, multiple-needle tufting machine for forming loop pile and cut pile in the same row of stitching, which avoids the above enumerated problems.
In the looper apparatus for a narrow gauge loop/cut pile tufting machine, made in accordance with this invention, the same type of hooks and knives are used as were employed in the conventional tufting machines, such as those disclosed in the prior Card U.S. Pat. No. 3,084,645.
However, each looper clip attached to a hook has been substantially modified to avoid striking or otherwise interfering with the knife cooperating with the adjacent loop hook.
The looper clip made in accordance with this invention still includes a basic mounting portion, which is preferably fixed to the shank of the hook, and a free end clamping portion biased into engagement with the needle side of the free end or pointed end portion of the hook bill. However, the main body portion of the looper clip connecting the mounting portion to the clamping portion extends above or spans the major portion of the bill. The connecting portion of the looper clip is entirely above the cutting zone of the hook, and specifically is above the path of the reciprocable adjacent knife on the adjacent looper, so that no portion of the looper clip, during the entire operation of the looper apparatus, will engage or interfere with the reciprocably moving, adjacent knife cooperating with the adjacent hook.
Where the hooks and knives are transversely aligned, all portions of the looper clips are transversely disaligned with the knives or knife paths in any operative position.
Thus, each looper clip made in accordance with this invention is preferably made from a unitary spring steel material and is generally arch-shaped, convex upward, so that the main body portion connecting the mounting portion and the clamping portion is at least spaced above the lower cutting edge of the bill, and preferably spaced above the top edge of the bill.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1, is a fragmentary, sectional elevation of a portion of a narrow gauge, staggered needle tufting machine incorporating this invention, disclosing the hooks and knives in cutting positions;
FIG. 2 is an opposite side, fragmentary, elevational view similar to FIG. 1, disclosing the hooks cooperating with the needles in non-cutting position;
FIG. 3 is an enlarged, fragmentary section taken along the line 3--3 of FIG. 1; and
FIG. 4 is a further enlarged section, similar to FIG. 3, but disclosing only two of the hooks and looper clips cooperating with the needles for catching or engaging loops.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in more detail, FIGS. 1 and 2 disclose a typical needle bar 10 supporting a plurality of needles 11 in a first or rear transverse row and a plurality of needles 12 in a second or front transverse row spaced longitudinally forward of the first row of needles 11. The needle bar 10 is adapted to reciprocably move between its lower position disclosed in FIG. 2 penetrating the base fabric 15, and an upper position, not shown, above the base fabric 15, by a push rod 13, driven by conventional means, not shown.
As best disclosed in FIG. 3, the needles 11 in the first row and the needles 12 in the second row are alternately staggered transversely of the tufting machine, and are preferably equi-distant from each other, as well as being equi-distantly staggered.
Supported upon a needle plate 14 for movement longitudinally from front to rear in a feeding direction through the tufting machine is the base fabric 15. Each needle 11 carries a yarn 16 and each needle 12 carries a yarn 17 through the base fabric 15 upon each stroke of the needle bar 10.
The looper apparatus 20 made in accordance with this invention may include staggered hooks. However, the looper apparatus 20 disclosed in the drawings includes the transversely aligned hooks 21 and 22 having shanks 23 and 24, and transversely aligned throats 25 and 26. However, bills 27 and 28 of the hooks 21 and 22 are of different lengths so that the free ends 41 and 42 of the bills 27 and 28 are staggered correspondingly with the needles 11 and 12. Each shank 23 and 24 is adapted to be received in a respective slot 29 in the reciprocal hook bar 30.
Furthermore, each hook 21 and 22 is adapted to cooperate with a corresponding knife 31 and 32, respectively, all of which knives are also transversely aligned.
The looper apparatus 20 thus far described in substantially the same as that disclosed in the Card U.S. Pat. No. 4,003,321, used Jan. 18, 1977.
Each of the knives 31 and 32 are identical and mounted in transverse alignment in corresponding knife holders 33 fixed to the reciprocal knife shaft 34 adapted to be rocked or reciprocated in a conventional manner. Each knife 31 and 3 is adapted to cooperate with its corresponding hook 21 and 22 in order to cut loops 35 to form long cut pile tufts 36 formed upon the bills 27 and 28.
The yarns 16 and 17 are fed to the respective needles 11 and 12 through yarn guide 39, fixed to the needle bar 10, from a pattern control yarn feed mechanism 40, of any conventional type, such as that disclosed in the prior Card U.S. Pat. No. 3,084,645.
The pattern control yarn feed apparatus 40 is adapted to selectively reduce the speed of the yarn 16 or 17 fed to the corresponding needle 11 or 12 in order to starve the feed, and create additional tension in the corresponding yarn. Thus, after a loop 35 is formed upon a bill, such as bill 27 in FIG. 1, and additional tension is created in the yarn 16 fed to that particular hook 21, then hook 21 is retracted, and the tensioned loop 35 is backdrawn or pulled off the pointed end 41 of the bill 27 to form a short uncut loop 44.
In order to assist in holding the long loops 35 upon the respective bills 27 and 28, a resilient finger, spring clip or looper clip 45 or 46, respectively, is mounted upon each corresponding hook 21 and 22. Each of the looper clips 45 and 46 may be identical, except in their lengths which correspond to the respective lengths of the bills 27 and 28.
Considering the looper clip 46, disclosed in FIG. 2, as representative of the structure of all the looper clips, the clip 46 is preferably made of a unitary spring steel material, having a free end or clamp portion 48 and an intermediate or connecting portion 49 connecting the mounting portion 47 and the clamp portion 48. The mounting portion 47 is disclosed as being in a substantially vertical attitude and fixed to the rear portion of the bill 28 by screws or rivets 50, or any other convenient type of fastener means. Extending substantially parallel to and above the top edge of the bill 28 is the connecting portion 49, a front portion of which depends to form the creased clamping portion 48, biased into engagement against the free end portion or pointed end portion 42 of the bill 28.
In FIG. 2, the knife 31', which is adjacent to the looper clip 46 and adapted to cooperate with the adjacent hook 21, not shown, but which would be located in front of the plane of the drawing FIG. 2, is disclosed in phantom. The phantom position of the knife 31' in FIG. 2 illustrates that regardless of its operative position, it will not engage, or interfere with, any portion of the looper clip 46. Since each knife 31 and 32 cooperates with the bottom edge of the corresponding bill 27 and 28 and the respective throats 25 and 26, and moves in a substantially elliptical cutting zone relative to those surfaces, the general shape of each looper clip 45 and 46 is generally arched, convex upward, so that any clip 45 or 46 will not interfere with or engage the adjacent knife cooperating with the adjacent looper. It will be particularly noted that the mounting portion 47 is located rearward of the corresponding throat 26, and the connecting portion 49 is located substantially above, not only the lower edge, but also the upper edge, of the corresponding bill 27 and 28, so that the path of the knife is completely clear of any portion of the corresponding looper clip 45 or 46.
When all of the hooks 21 and 22 are transversely aligned, as well as the knives 31 and 32, then no portion of the looper clips 45 and 46 are in transverse alignment with the knives in any position. In other words, all of the looper clips 45 and 46 are transversely disaligned from the cutting zones of their corresponding hooks, or any portion of the paths of the knives.
Otherwise, the looper clips or spring clips 45 and 46 function in the same manner as they do in the prior Card U.S. Pat. No. 3,084,645, insofar as the holding of the long loops 35 upon the respective bills to permit cutting thereof, and the yielding against the tension of the backdrawn yarns in order to create the short uncut pile loops 44.
However, only the looper clips 45 and 46 are adapted to operate successfully where the needle gauges are as small as 1/8 of an inch, a gauge in which looper apparatus such as those disclosed in the prior Card U.S. Pat. No. 3,084,645 could not successfully function.
It will be understood that the clamping portions 48 of the respective spring clips 45 and 46 may be constructed in a similar manner to the clamping portions of the spring clips in the prior Card U.S. Pat. No. 3,084,645. That is, the clamping portion 48 may have a vertical crease therein, with its free end portion flaring laterally away from the corresponding pointed end of the bill 27 or 28, in order to guide the respective needle 11 or 12 between the respective spring clip 45 or 46 and its corresponding bill 27 or 28, as disclosed in FIG. 4.
After the needles 11 and 12 have moved upward above their respective spring clips 45 and 46, the clamping portion 48 will immediately spring back into engagement with the corresponding pointed ends 41 and 42 to prevent any loops formed upon the respective bills 27 and 28 from being pulled off the respective hook 21 or 22, unless the yarn in that particular loop is backdrawn because of the slow or starved feeding of the pattern control yarn feed apparatus 40.
The elasticity of each of the spring clips 45 and 46 is such that the backdrawn yarn will force the clamping portion 48 away from the hook bill to release the tensioned loop 44.
|
A looper apparatus for a narrow gauge, multiple-needle tufting machine including transversely spaced loopers or hooks having spring clips or looper clips attached thereto and cooperating with knives to form cut pile and loop pile in the same row of stitching, in cooperation with a controlled yarn feed, in which the spring clips span or extend over the cutting zone of the hooks, so that each spring clip will not interfere with the adjacent knife of an adjacent hook.
| 3
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention is in the field of missiles and methods of configuring and/or assembling missiles.
[0003] 2. Description of the Related Art
[0004] For certain missile systems, for example, high-kinetic-energy anti-tank missiles and cruise missile interceptors, it is desirable to accelerate a projectile to high speed, such as supersonic or hypersonic speeds. At such speeds the projectile intercepts the target in a minimum amount of time, and has sufficient energy to penetrate and destroy the target. However, boosting the projectile to the required speed necessitates use of a large rocket motor. Moreover, to assure that adequate kinetic energy is delivered to the target, a heavy projectile is required. When combined, these two requirements may result in a missile having an extraordinarily high pre-launch weight. In tactical deployment, excessively heavy missiles make forward-staging, loading, down-loading, storage and other handling operations slow and difficult. Missile weights that exceed established thresholds for manual handling may require special equipment such as autoloaders.
[0005] An exemplary tactical kinetic energy anti-tank missile utilizes a rocket motor weighing from 65 to 70 pounds, and a projectile weighing between 15 and 25 pounds. To these figures must be added the weight of any control surfaces, electronics, actuation systems, and supporting structural elements. Consequently, the total prelaunch weight of such a missile may easily exceed 100 pounds.
[0006] From the foregoing it will be appreciated that it would be desirable to avoid the handling difficulties associated with missiles having a high weight.
SUMMARY OF THE INVENTION
[0007] A modular missile assembly includes a pair of modules which are separately transported and handled until just prior to firing, when they are coupled together. A forward payload-carrying module includes a forward canister which encloses a missile payload section, for example, consisting of a penetrator rod, fins, and ancillary subassemblies. An aft booster module includes a missile propulsion section, encased in an aft canister. Prior to firing, suitable forward and aft modules are selected, are individually loaded into a launch tube, and are coupled together. In this coupling the missile payload section and the missile propulsion section are coupled together to form a missile, and the forward and aft canisters are likewise coupled together to form a combined canister assembly. Division of the missile into separate payload and booster modules facilitates handling as compared to unitary missiles. The modular design also allows increased flexibility, for example, allowing a single booster module to be used with different types of payload-carrying modules, carrying different types of missile payload sections, which may be tailored for use with different kinds of targets.
[0008] According to an aspect of the invention, a missile assembly includes a forward payload-containing module having a first coupling mechanism at a back end; and an aft booster module having a second coupling mechanism at a front end. The first and second coupling mechanisms are operatively configured to couple the modules together in a launch tube.
[0009] According to another aspect of the invention, a method of assembling a missile includes the steps of individually loading a pair of missile modules into a launch tube; and coupling the modules together in the launch tube.
[0010] According to yet another aspect of the invention, a missile payload section includes a missile payload section which in turn includes a penetrator rod, fins coupled to the penetrator rod, and means operatively configured for coupling to a corresponding missile propulsion section, wherein the means for coupling is at an aft end of the payload section; a canister which fits around the payload; and a cap removably secured to an aft end of the canister. The cap, when secured, covers the means for coupling.
[0011] To the accomplishment of the foregoing and related ends, the invention comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the invention. These embodiments are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0012] In the annexed drawings:
[0013] [0013]FIG. 1 is a side view of a modular missile assembly of the present invention;
[0014] [0014]FIG. 2 is a side view showing the modules of the missile of FIG. 1 prior to connection;
[0015] [0015]FIG. 3 is an exploded view of the forward payload-carrying module of the missile assembly of FIG. 1;
[0016] [0016]FIG. 4 is an exploded view of the aft booster module of the missile assembly of FIG. 1;
[0017] [0017]FIG. 5 is a flowchart illustrating steps in the assembly of the missile assembly of FIG. 1;
[0018] [0018]FIG. 6 is a side view illustrating the loading of the modules of the missile assembly of FIG. 1 into a launch tube of a launcher;
[0019] [0019]FIG. 7 is a side view of a missile assembly embodying the present invention, which separates during flight;
[0020] [0020]FIG. 8 is a side view of a missile payload section for a missile of the present invention, the payload section including an articulated nose section;
[0021] [0021]FIG. 9 is a side view of a missile propulsion section for a missile assembly of the present invention which utilizes a torque motor to impart spin; and
[0022] [0022]FIG. 10 is a side view of a missile payload section for use in a modular missile assembly of the present invention, the missile payload section including a torque motor in its forward payload-carrying module.
DETAILED DESCRIPTION
[0023] A modular missile assembly includes a forward payload-containing module and an aft booster module. The forward module includes a forward canister containing a missile payload section including a payload such as a projectile for striking a target. The aft module includes an aft canister containing a missile propulsion system such as a rocket motor. The forward and aft modules may be handled separately until firing is desired. Then the modules are loaded into a launch tube and connected together, thereby completing assembly of the missile. By having the modules separate until firing is desired, handling is facilitated, since each of the modules weighs far less than the combined missile. Furthermore, use of separate modules enables greater flexibility in missile payloads. Multiple varieties of payload modules, for example for use with different targets, may be manufactured to be compatible with a single type of booster module. Selection of the payload module may be made in the field prior to firing. Since only a variety of payload modules need be maintained in inventory, as opposed to a variety of complete missiles, inventories and therefore costs may be reduced.
[0024] Turning now to FIG. 1, a modular missile assembly 10 of the present invention is shown. The missile assembly 10 includes a forward payload-carrying module 12 and an aft booster module 14 . The modules 12 and 14 are coupled together via a coupling 16 . As described below in greater detail, the forward module 12 includes a forward canister 18 which encloses a missile payload section 20 , and the aft module 14 includes an aft canister 22 which encloses a missile propulsion section 24 . The propulsion section 24 may include subsystems and subassemblies, such as electronics, controls, and deployable stabilizing fins. The coupling connects the payload section 20 and the propulsion section 24 together to form a modular missile 26 . The coupling 16 also connects the canisters 18 and 22 together to form a canister assembly 27 .
[0025] Turning now to FIGS. 2 - 4 , details may be seen of the modules 12 and 14 . The missile payload section 20 includes a penetrator rod 28 , as well as fins 30 which are coupled to the penetrator rod. The penetrator rod 28 may be made of a heavy material, for example tungsten or depleted uranium, selected to penetrate a desired target. It will be appreciated that a variety of sizes, shapes, and/or materials may be employed in the penetrator rod 28 .
[0026] The fins 30 may be stabilizing fins for stabilizing flight of the missile 26 . Alternatively or in addition, the fins 30 may be canted so as to impart and/or maintain rotation of the missile 26 while the missile is in flight. The fins 30 may include folded portions which deploy as the payload section 20 emerges from the forward canister 18 and/or from a launch tube.
[0027] The payload section 20 may include other items such as a secondary propulsion system, a chemical energy target defeat mechanism, sensors and micro-electronics. The sensors and the micro-electronics may be utilized to aid in guiding the missile 26 to its intended target. It will be appreciated that the missile 26 may be guided by any of a variety of known means. For example, actuators may be used to move one or more of the fins 30 , thereby altering the trajectory of the missile 26 .
[0028] A forward cap 32 may be removably secured to the forward canister 18 until just prior to the connection of the forward module 12 to the aft module 14 . The forward cap 32 covers and protects a forward connection 34 at the back end of the payload section 20 . The forward cap 32 may also be secured to the payload section 20 , thereby holding the payload section in place relative to the forward canister 18 , prior to the assembly of the missile 10 .
[0029] It will be appreciated that the forward cap 32 may be secured to the forward canister 18 and/or to the payload section 20 by any of a variety of conventional means, including connections involving quick-release clamps, pins, springs, threaded fasteners, or other connections, tabs, and/or the mating together of indexed parts.
[0030] The aft booster module 14 includes an aft connection 40 which is operatively configured to couple to the forward connection 34 of the forward module 12 , the connections 34 and 40 being configured to combine to form the coupling 16 . The connections 34 and 40 may be any of a variety of suitable well-known means of connection. For example, the connections 34 and 40 may include a mechanical index system where features on one of the connections 34 and 40 has a corresponding mirror image feature on the other connection. For example, the connections may involve a pilot shaft on one component, or a positioning and locking mechanism on the outer edges of the connections 34 and 40 . It will be appreciated that a variety of suitable locking mechanisms may be employed, such as, for example, mechanisms involving springs and/or tabs.
[0031] The coupling 16 formed by connecting the connections 34 and 40 together may be merely a mechanical connection. Alternatively, the coupling 16 may include a connection for other purposes, for example, including a communication link between the payload section 20 of the forward module 12 and the propulsion section 24 of the aft booster module 14 . As noted above, the coupling 16 may also include a connection between the forward canister 18 and the aft canister 22 .
[0032] The aft connection 40 is located on a protruding portion 48 of the propulsion section 24 . When the missile 10 is assembled, the protruding portion 48 extends into the forward canister 18 and pushes the payload section 20 forward relative to the forward canister 18 . A tip 50 of the penetrator rod 28 may thereby extend beyond a front edge 54 of the forward canister 18 . A removable aft cap 56 may be used to cover the protruding portion 48 and the aft connection 40 , prior to the assembly of the modules 12 and 14 to form missile assembly 10 .
[0033] The missile propulsion section 24 may be of conventional design, for example, including a solid fuel rocket having one or more nozzles. As is well known, some or all of the nozzles may be canted to provide spin to the missile 26 , if desired. In addition, some or all of the nozzles may be tiltable, for example, to provide steering for the missile. An example of a mechanism for tilting missile nozzles may by seen in U.S. Pat. No. 3,200,586, the detailed description and figures of which are incorporated herein by reference.
[0034] The aft canister 22 may have protuberances such as lugs 60 . The lugs 60 may be used to index the missile assembly 10 relative to a launch tube.
[0035] Turning now to FIG. 5 a flowchart is shown of a method 100 for selecting components and assembling the missile assembly 10 . The method 100 is advantageous in that its steps may be performed in the field immediately prior to the firing of the missile 26 . As indicated before, this may increase flexibility as to the types of payloads employed, may reduce field inventory requirements, and/or may reduce or avoid handling problems associated with heavy missiles.
[0036] In step 102 , the desired forward and aft modules 12 and 14 are selected. The forward module 12 may be selected from a variety of types of forward modules. For example, a variety of types of modules with different payloads may be maintained for use with different types of targets. For example, it may be desirable to use a lighter payload for a lightly-armored target, such as a helicopter, while using a heavier payload for a heavier target, such as a tank. Further, it may be desirable to have practice rounds which utilize less expensive payloads.
[0037] It will also be appreciated that a variety of types of aft booster portions may be maintained. For example, different types of booster portions may be used to provide different amounts of thrust and/or different thrust characteristics.
[0038] Once the modules 12 and 14 have been selected, the module caps 32 and 56 are removed in step 104 , and the modules are loaded into a launch tube in step 106 . As illustrated in FIG. 6, the forward payload-carrying module 12 may be loaded into a front end 108 of a launch tube 110 of a launcher 114 . The aft booster module 14 may be loaded in a back end 118 of the launch tube 110 . It will be appreciated that alternatively the modules 12 and 14 may be loaded in the same end of the launch tube 110 , if desired. It will also be appreciated that there may be a set order for the loading of the modules 12 and 14 , or alternatively that the modules may be loaded in either order.
[0039] In step 120 , the modules 12 and 14 are coupled together within the launch tube 110 . Modules 12 and 14 are coupled as described above, through use of the coupling 16 , to thereby form the missile assembly 10 . After coupling, the missile 10 may be fired from the launcher 114 in a convention manner. After firing, the coupled canister of the modules 12 and 14 (the forward canister 18 and the aft canister 22 ) may be removed from the launch tube 110 as a single piece.
[0040] It will be appreciated that it may be possible to assemble the modules 12 and 14 of the missile assembly 10 wholly or partially outside of the launch tube 110 . However, such outside assembly may result in handling difficulties due to a need to handle the fully-assembly missile assembly 10 .
[0041] What follows now are several additional embodiments of the invention. The details of certain common similar features of the additional embodiments and the embodiment or embodiments described above are omitted in the description of the additional embodiments for the sake of brevity. It will be appreciated that features of the various additional embodiments may be combined with one another and may be combined with features of the embodiment or embodiments described above.
[0042] [0042]FIG. 7 shows a modular missile assembly 210 which includes a missile 226 which separates into two parts during flight. The missile assembly 210 includes a forward payload-carrying module 212 , which is coupled to an aft booster module 214 via a coupling 216 . The forward module 212 includes a payload section 220 , which is coupled to a missile propulsion section 224 of the aft module 214 . During flight, the missile 226 separates along a separation line 270 . The part of the missile 226 which is forward of the separation line 270 continues along toward the intended target. The part of the missile 226 which is behind the separation line 270 is jettisoned. Jettisoning the rear part of the missile 226 reduces deceleration on the remaining part of the missile, which would otherwise occur due to aerodynamic drag forces on the rear section. Thus, range and/or accuracy of the missile may be improved.
[0043] Separation along the separation line 270 may be accomplished by any of a variety of suitable mechanisms. For example, separation may be triggered by a system that senses mechanically the difference in forces between the forward and aft portions of the missile after the rocket motor has burned out. Alternatively, an accelerometer may be used as a trigger to decouple the parts of the missile. As another example, the decoupling of the parts may be set to occur after a certain given time from launch. The decoupling along the separation line 270 may be a purely passive event, or may alternatively involve use of active components such as electromechanical, pyrotechnic, or other small devices to aid in the separation.
[0044] It will be appreciated that the separation line 270 may be located on the missile 226 other than at the location shown in FIG. 7. The separation line 270 may be located on the payload section 220 , at the coupling between the payload section 220 and the propulsion section 224 , or somewhere along the propulsion section 224 . It will be appreciated that the separation mechanism may be incorporated as part of the coupling 216 between the modules 212 and 214 .
[0045] Turning now to FIG. 8, an alternate embodiment missile payload section 420 includes an articulated nose portion 421 . The articulated nose portion advantageously provides steering with minimal effect on external projectile packaging, minimum drag characteristics, and smooth, continuous steering. It is well known that a simple steering mechanism can be achieved by always pointing the nose toward the target, therefore allowing resultant aerodynamic forces to fly the payload section 420 toward the target.
[0046] It will be appreciated that a variety of actuation implementation systems may be employed to articulate the nose. U.S. Pat. No. 4,399,962, the detailed description and figures of which are incorporated herein by reference, is an example of employment of pyrotechnic devices to articulate a nose section. U.S. Pat. No. 4,793,571, the detailed description and figures of which are incorporated by reference, discloses use of piezolectric devices to articulate a nose. U.S. Pat. No. 4,998,994, the detailed description and figures of which are incorporated by reference, discloses a self-aligning projectile nose. Also, a variety of suitable mechanical means for articulating the nose may be employed. Examples of mechanical articulation of nose sections may be found in U.S. Pat. Nos. 4,579,298 and 4,925,130, detailed descriptions and figures of which are incorporated by reference, and in pending, commonly-owned U.S. application Ser. No. 09/610,920, titled “Articulated Nose Missile Control Actuation System,” filed Jul. 6, 2000, which is incorporated herein by reference in its entirety.
[0047] [0047]FIG. 9 shows an alternate embodiment missile propulsion section 424 which includes nozzles 425 along the perimeter of the propulsion section. The nozzles 425 may be used to impart a spin or torque to the missile during or shortly after launch. It is well known that imparting a spin to a missile may improve its accuracy. Further details regarding use of circumferentially-placed nozzles to impart a spin to a missile may be found in pending, commonly owned U.S. application Ser. No. 09/659,147, entitled “Propulsive Torque Motor,” filed Sep. 11, 2000, which is herein incorporated by reference in its entirety.
[0048] As mentioned earlier, It will be appreciated that other well-known methods are available for imparting a spin or a torque to a missile. Examples of such other methods may be found in U.S. Pat. Nos. 4,497,460 and 5,078,336, the descriptions and figures of which are herein incorporated by reference.
[0049] [0049]FIG. 10 shows an alternate embodiment missile payload section 620 which incorporates a propulsive torque motor. In an exemplary embodiment, the payload section 620 includes a pressurized gas source. Pressurized gas may be ejected through nozzles 623 at a front end 625 of the payload section. The nozzles 623 the pressurized gas in a direction having a tangential component relative to the missile payload section, thereby imparting a spin to the missile. Further details of an example of such a torque motor may be found in the above-referenced U.S. application Ser. No. 09/659,147, entitled “Propulsive Torque Motor.”
[0050] Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.
|
A modular missile assembly includes a pair of modules which are separately transported and handled until just prior to firing, when they are coupled together. A forward payload-carrying module includes a forward canister which encloses a missile payload section, for example, consisting of a penetrator rod, fins, and ancillary subassemblies. An aft booster module includes a missile propulsion section, encased in an aft canister. Prior to firing, suitable forward and aft modules are selected, are individually loaded into a launch tube, and are coupled together. In this coupling the missile payload section and the missile propulsion section are coupled together to form a missile, and the forward and aft canisters are likewise coupled together to form a combined canister assembly. Division of the missile into separate payload and booster modules facilitates handling as compared to unitary missiles. The modular design also allows increased flexibility.
| 5
|
This is a continuation of application Ser. No. 08/286,852 filed on Aug. 5, 1994 now U.S. Pat. No. 5,517,392.
BACKGROUND OF THE INVENTION
This invention relates to a hand-held flashlight and in particular to such a flashlight having a flexible core which may be pulled or twisted relative to a power end housing and/or a working end housing.
In co-pending U.S. patent application, Ser. No. 08/286,313 filed Aug. 5, 1994 now U.S. Pat. No. 5,521,803 concurrently herewith in the names of Lee Eckert, Robert Kubicko and Julian Watt entitled "Flashlight With Flexible Core" and assigned to the same assignee as the assignee hereof, there is disclosed a flashlight with a flexible core. In the flashlight, a pair of conductive wires electrically connect a source of power to a power using implement. A flexible spine surrounds a pair of conductive wires and includes a plurality of interconnected universally rotatable members. A resilient sleeve engages the outer surface of the rotatable members forming the spine. Each end of the spine is connected to a corresponding anchor. One anchor connects one end of the spine to the power end housing and a second anchor connects the other end of the spine to the working end housing of the flashlight.
Each of the anchors fits within a corresponding bore formed in each of the two housings of the flashlight. The opposite ends of the resilient sleeve fit over the outer surface of a corresponding anchor and are thus sandwiched between the inner surface of the bore of one of the housings and the outer surface of the anchor held within the bore.
The flexible spine of the flashlight enables the flashlight to be bent, coiled or draped into various positions. Both the torsional and pulling forces applied to the flexible spine and to the resilient sleeve as a consequence of the bending, coiling or draping of the flexible core into various positions have a tendency to separate the core from the flashlight housings.
Accordingly it is an object of this invention to prevent the resilient sleeve of a flashlight having a flexible core from being separated from the housing sections of the flashlight either through torsional or axial forces and to prevent damage to the flexible spine and internal conductors due to excessive torsional action.
SUMMARY OF THE INVENTION
The foregoing object and other objects of this invention are attained in a flashlight including a base housing forming a power end for the flashlight and having a longitudinally extending bore having at least one battery housed therein. A working end housing is spaced from the base and supports a reflector, a lens and a light bulb. The working end housing includes means defining a longitudinally extending bore. A flexible core assembly connects the base housing to the working end housing and includes a pair of conductive wires electrically connecting the battery to the light bulb, a flexible spine surrounding the pair of conductive wires and including a plurality of interconnected and universally rotatable members, and a resilient sleeve member engaging an outer surface of each of the rotatable members forming the spine. A first anchor is connected to a first end of the flexible core and has a portion extending within the bore of the base housing. The first anchor includes first gripping means underlying the sleeve of the flexible core and the base housing bore includes second gripping means overlying the sleeve of the flexible core sandwiching the sleeve between the first and second gripping means. A second anchor is connected to a second end of the flexible core and has a portion extending within the bore of the working end housing. The second anchor includes third gripping means underlying the sleeve of the flexible core and said working end housing bore includes fourth gripping means overlying the sleeve of the flexible core to sandwich the sleeve between said third and fourth gripping means.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective, exploded view illustrating features of the flashlight of the invention;
FIG. 2 is a side elevational view, partially in section, of the flashlight of FIG. 1;
FIG. 3 is a side elevational view with portions broken away to illustrate further details of the flashlight;
FIG. 4 is an enlarged elevational view illustrating details of a portion of the flashlight of the present invention;
FIG. 5 is an enlarged elevational view of a further portion of the flashlight of the invention;
FIG. 6 is a perspective view of the flashlight in a somewhat folded position illustrating the manner in which the two housings of the flashlight may be joined together;
FIG. 7 is a perspective exploded view of a portion of the flashlight;
FIG. 8 is a view similar to FIG. 7 showing the parts in their assembled state;
FIG. 9 is an exploded perspective view of a further portion of the flashlight;
FIG. 10 is an exploded perspective view of a subassembly of the flashlight;
FIG. 11 is an enlarged sectional view taken along line 11--11 of FIG. 12;
FIG. 12 is a fragmentary sectional view of a portion of one of the housings of the flashlight illustrating details thereof;
FIG. 13 is an enlarged sectional view taken along line 13--13 of FIG. 12; and
FIG. 14 is an end view taken along line 14--14 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the various figures of the drawing, there is disclosed a preferred embodiment of the present invention. In referring to the various figures of the drawing, like numerals shall refer to like parts.
Referring specifically to FIG. 1, there is disclosed a flashlight 10 having a first housing 12 and a second housing 14. Housings 12 and 14 are spaced apart and are connected together through a flexible core 16. Housing 12 serves as the power end of the flashlight and contains therewithin batteries 78 and 80 (see FIG. 2) used as the primary source of electrical power for the flashlight. Batteries 78 and 80 may be standard C-cells.
Housing 14 functions as the working end of flashlight 10 and includes a lens 50. As shown in FIG. 2, housing 14 also has mounted therewithin reflector 90 and bulb 92. A switch 20 is provided to selectively connect bulb 92 to the source of electrical power such as batteries 78 and 80.
Housing 14 is generally L-shaped and includes a generally cylindrically-shaped elongated leg 25 and a somewhat rectangularly-shaped shorter leg 24 extending from leg 25. Leg 24 mounts lens 50, reflector 90, and bulb 92.
Housing 12 includes a bore 13 and leg 25 of housing 14 includes a similar bore 15. One end of flexible core 16 is inserted into bore 15 and the other end is inserted into bore 13. Each end of core 16 has an anchor 22 to be more fully described hereinafter which is inserted into one of the bores 13, 15 for joining flexible core 18 to housings 12 and 14.
Referring primarily to FIGS. 2-10, additional features of flashlight 10 shall now be described in detail. Flexible core 16 includes an outer resilient sleeve 18 made from a resilient elastomeric material such as a thermoplastic rubber sold by the Monsanto Corporation under the trademark "Santoprene." Referring particularly to FIG. 4 a flexible spine 28 is contained within sleeve 18. Spine 28 comprises a plurality of interconnected universally rotatable members. Each universally rotatable member comprises a male end portion 28A and a female end portion 28B. The male end portion 28A has an outer surface comprising a frustum of a sphere and the female end portion 28B has a mating inner surface comprising a frustum of a sphere which is dimensioned so that, when the male end portion 28A is inserted into the female end portion 28B, there is frictional contact between the mating outer and inner surfaces 28A and 28B. These frictional forces function as retaining means to hold one member of the flexible spine 28 at any desired location relative to an interconnected member. These frictional forces may be overcome which permits interconnected members to be moved relative to each other so that their longitudinal axes may either be in or out of alignment. The interconnected segments have relatively unrestricted rotational movement therebetween. The segments of the flexible spine 28 are produced by Lockwood Products, Inc. and are made from acetal plastic or other suitable material. Electrical conductors 54 and 56 are disposed within flexible spine 28. One end of conductors 54, 56 is connected to housing 12 and the other end of the conductors is connected to working end housing 14.
Sleeve 18 provides a protective cover over spine 28. The sleeve maintains an attractive appearance of the flashlight even when the individual members of spine 28 are skewed relative to each other.
An anchor 22 is connected to each end of flexible core 16. One of the anchors is inserted into bore 13 of housing 12 and the other of the anchors is inserted into bore 15 of housing 14. Anchor 22 includes a ball portion 64, a main body portion 66 which includes a plurality of upstanding ribs 34 and a somewhat rectangularly shaped portion 30. The height of center rib 34A is somewhat greater when compared to the height of the other ribs 34 of each anchor 22. As will be more fully described hereinafter, portion 30 has an open end facing away from body portion 66 for receiving strain relief 32 therewithin. Each rib 34 includes a ramp-like leading surface 34B for expanding the material of sleeve 18 outwardly to enable each end of the sleeve to be emplaced about an anchor.
Strain relief 32 includes a pair of longitudinally spaced slots 47. Strain relief 32 mounted within housing 14 receives contacts 36, 38 in slots 47 while strain relief 32 mounted in housing 12 receives contacts 42, 46 in slots 47. The strain relief electrically connects conductors 54,56 to the contacts in each housing 12, 14. Contact 42 in housing 12 is, in turn, connected to negative strip conductor 45 while contact 42 is connected to positive conductor 44. (See FIG. 3) Conductors 44 and 45 are, in turn, connected to batteries 78 and 80. Housing 12 includes a removable battery cap 40. Contacts 36, 38 are connected to conductors 58, 60 in housing 14.
As shown, switch 20 is in series with conductor 58. As is known to those skilled in the art, switch 20 is normally open and is closed to connect bulb 92 to batteries 78, 80 via the various electrical conductors and contacts noted previously.
Referring specifically to FIGS. 1 and 6, one of the housings, for example housing 12 includes an upstanding rib 26. Rib 26 includes a relatively thin elongated portion 27 connected to a relatively wide elongated portion 29. The other of the housings, for example housing 14 includes a groove 68 whose length is generally coextensive with the length of upstanding rib 26. Groove 68 is generally U-shaped and includes a pair of spring clips 52. Spring clips 52 are placed within groove 68 in a portion which overlies relatively narrow portion 27 of rib 26. If it is desired to reduce the overall length of flashlight 10, for example, for storage purposes, or for holding the flashlight for use in a conventional hand-held manner, core 16 is folded so that the core forms a generally U-shape so that housing 12 lies in the same vertical plane as housing 14. As shown specifically in FIG. 6, when core 16 is folded as described, rib 26 underlies U-shaped groove 68. To join the two housings together, rib 26 is snapped into groove 68. Relatively narrow portion 27 of rib 26 is inserted between the opposed faces of spring clips 52 which forces the opposed faces outwardly. When the rib is inserted into the groove, the opposed faces of the spring clip are forced inwardly to lock the rib within groove 68 to positively join the two housings together.
As described previously, each end of flexible core 16 includes an anchor 22. One of the anchors is inserted into bore 13 and the other of the anchors is inserted into bore 15. During testing, it has been found that twisting or turning the flexible core to obtain a desired configuration for the flashlight produces forces which tend to pull the sleeve from either or both bores of the housings or twist either end of sleeve 18 relative to bores 13 or 15. To prevent the undesired occurrence of the separation of sleeve 18 from one or both housings and the undesired twisting of sleeve 18 relative to the housings, grasping means, to be more fully described hereinafter, have been added to both bores 13, 15 and anchors 22.
Referring specifically to FIGS. 11-14, each bore 13, 15 is provided with a plurality of circumferentially spaced inwardly extending ridges respectively 100 and 102. Ridges 100 and 102 extend radially inwardly towards the surface of sleeve 18. In addition, each bore includes a pair of 180 degree circumferentially spaced grooves 104 which underly ribs 34A when each anchor 22 is placed in a respective bore 13, 15.
Housing 14 includes four circumferentially spaced ridges 100 whereas housing 12 includes 12 circumferentially spaced ridges 102. The length of each ridge 100 is greater than the length of each ridge 102. As shown in FIG. 13, the cross-sectional shape of each ridge 100 (or 102) is similar to a shark's tooth so that the outer surface of the sleeve engaged by each ridge 100, 102 is firmly grasped to sandwich the sleeve between the outer surface of anchor 22 and the outer surface of each ridge. This arrangement prevents the sleeve from being twisted relative to each bore 13, 15 and prevents the sleeve from being separated from one or the other of housings 12, 14.
To further prevent any undesired twisting or longitudinal movement of the sleeve, ribs 34A act to force the resilient material of sleeve 18 into the underlying grooves 104. The combination of ribs 34A and grooves 104 further prevent twisting of sleeve 18.
A further feature of the flashlight relates to strain relief 32. Strain relief 32 includes a hub portion 48 having a relatively enlarged boss 48A formed at one end of the hub. The other end of the hub does not have an enlarged boss similar to boss 48A and the end of the hub lies in the same vertical plane relative to the vertical plane of the end face of body portion 30 of anchor 22.
Each housing 12, 14, includes a relatively large inwardly extending boss 69 and a second circumferentially spaced relatively smaller boss 69A. When each anchor 22 and its associated strain relief 32 is inserted into one of the bores 13, 15, enlarged boss 48A of strain relief 32 is aligned with relatively smaller boss 69A of the housing and the flat surface 48B of the hub is aligned with relatively large boss 69 of the housing. In effect, the strain relief can only be inserted within the bore in one position due to the relationships established by bosses 48A, 69A and 69B and the flat surface 48B of hub 48. The foregoing enables anchor 22 and strain relief 32 to be used with a polarized plug. A screw 67 or similar means is inserted through boss 69, hub 48 and boss 69A to affix each anchor 22 to its respective housing.
While a preferred embodiment of the present invention has been described and illustrated, the invention should not be limited thereto but may be otherwise embodied within the scope of the following claims.
|
A flashlight includes a flexible core comprising a pair of conductive wires which electrically connect a source of power to a power using implement. A flexible spine surrounds the pair of conductive wires and includes a plurality of interconnected universally rotatable members. A resilient sleeve engages the outer surface of the rotatable members forming the spine. The flashlight includes a working end housing and a base housing. A first anchor connects one end of the flexible core to the base end housing and a second anchor connects the other end of the flexible core to the working end housing. The outer surface of the resilient sleeve is restrained against relative twisting or longitudinal movement with respect to each housing.
| 5
|
PRIORITY CLAIM
[0001] The present invention claims priority to U.S. Provisional Patent Application Ser. No. 60/618,640 filed Oct. 13, 2004.
TECHNICAL FIELD
[0002] The present invention relates to the driving of fluorescent lamps, and more particularly, to methods and protection schemes for driving cold cathode fluorescent lamps (CCFL), external electrode fluorescent lamps (EEFL), and flat fluorescent lamps (FFL).
BACKGROUND
[0003] In large panel displays (e.g., LCD televisions), many lamps are used in parallel to provide the bright backlight required for a high quality picture. The total current at full brightness can easily exceed the current limitations determined by governmental regulations. For example, the current limit as stated in Underwriters Laboratory (UL) standard UL60950 must not exceed 70 mA when the power inverter is shorted by a 2000 ohm impedance. However, the secondary side current in a typical 20-lamp backlight system may exceed that amount of current.
[0004] Traditional protection schemes measure the lamp currents, transformer primary current, or transformer current in general. Then, these currents are limited to below the maximum safe currents. However, this approach still has drawbacks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a schematic diagram showing a first embodiment of the present invention.
[0006] FIG. 2 is a schematic diagram showing a second embodiment of the present invention.
[0007] FIG. 3 is a schematic diagram showing a third embodiment of the present invention.
[0008] FIG. 4 is a graph showing current versus the voltage on the feedback node in accordance with the present invention.
DETAILED DESCRIPTION
[0009] The present invention relates to an apparatus and method for driving discharge lamps in large panel applications with overcurrent protection. The present invention can offer, among other advantages, a nearly symmetrical voltage waveform to drive discharge lamps, accurate control of lamp current to ensure good reliability, and protection schemes that limit circuit current under short circuit conditions.
[0010] FIG. 1 shows a simplified schematic diagram of one embodiment of the present invention. In general, EEFL and FFL devices have higher impedance than CCFL devices because they use external electrodes. The intrinsic capacitance greatly increases the series impedance. The impedance of a lamp is typically between 120 Kohm and 800 Kohm Even with 30 lamps in parallel, the total impedance is still greater than 4 Kohm. As specified in UL60950, the impedance at short circuit is tested at 2 Kohm. Therefore, the present invention uses impedance as one way to differentiate the short circuit conditions from the normal operating conditions. There are several embodiments of the present invention described below.
[0011] Turning to FIG. 1 , a full-bridge inverter circuit 101 is used to drive a lamp load 103 through a transformer 105 . The lamp load 103 is shown as a single element, but is intended in some embodiments to represent multiple CCFLs, EEFLS, and/or FFLS. FIG. 1 also shows a control and gate driver circuit 107 which performs two main functions: (1) provide the appropriate control signals to the transistors of the full-bridge inverter 101 and (2) receive feedback to monitor various parameters.
[0012] The circuit of FIG. 1 monitors the AC amplitude of the transformer secondary side voltage as one of the parameters used in order to determine whether or not to initiate a protection protocol. The capacitors C 1 , C 2 , C 3 , the leakage inductance of transformer, and the magnetizing inductance of transformer (if it is small enough) forms a filter circuit that converts the square wave voltage generated by the full bridge inverter switches (Q 1 -Q 4 ) into a substantially sinusoidal waveform input to the lamp load 103 .
[0013] As noted above, the control and gate drive 107 generates the gate drive waveforms with appropriate duty cycle to regulate the lamp current to its reference current limit. The control section 107 also receives feedback on the lamp current (the current on the secondary side of the transformer 105 ). Capacitors C 2 and C 3 are also used as a voltage divider when sensing the transformer or lamp voltage. Resistor R 1 is typically a very large resistor forcing a zero DC bias on a voltage feedback node.
[0014] Note that if the peak of the transformer voltage (the AC sine wave) on the secondary side (or load side) on node VL does not exceed a preset threshold V TH (for example, 40% of the normal operating voltage on node VL), this indicates a possible short circuit condition. A safety current threshold I SAFE is used as a current limit when there is a possible short circuit condition. The preset threshold V TH may also, for example, be set between 25 to 55 percent of the normal operating voltage.
[0015] In one embodiment, I SAFE is the RMS value I RMS of the normal operating current or the average rectified value I RECT,AVG (I REC,AVG =I RMS *2*sqrt(2)/π). Thus, an under-voltage detection block (such as a comparator) 109 , which can be implemented using a myriad of circuits, is used to compare the voltage on node VL to V TH . If VL is less than V TH for at least one switching cycle, the under-voltage detection block 109 will indicate the short circuit condition to a current limit selection block 111 and then choose the safety current I SAFE as the current limit. Otherwise, the under voltage detection block 109 will indicate to the current limit selection block 111 to choose the “normal” current limit, which in one embodiment is determined by an external brightness command level, I BRT . However, it should be appreciated that the normal current limit in some embodiments is not limited to I BRT , and instead may be set by other controllable parameters.
[0016] Note that if the negative AC amplitude of the transformer voltage never decreases below the preset threshold V TH (for example, 40% of the normal operating voltage), the short circuit protection current, preferably, RMS value I RMS or the average rectified value I RECT,AVG , is smaller than the safety current I SAFE .
[0017] A variant implementation of FIG. 1 is shown in FIG. 2 . In FIG. 2 , resistor R 2 biases VL to V TH . Thus, if the input voltage to the under voltage detector 109 never drops below zero volts for at least one switching cycle, the AC amplitude of VL will be smaller than V TH , indicating a short circuit condition.
[0018] In UL60950, the standard short circuit impedance of 2 kohm is much smaller than the lamp impedance for a CCFL, EEFL, or FFL. Therefore, the secondary or lamp current in a lamp application will be smaller than the current flowing through a 2 kohm load for the UL60950 test.
[0019] FIG. 3 shows another implementation of the present invention. In this embodiment, R TH is set where R TH /(I+C 3 /C 2 ) is between 2 kohm and the minimum lamp impedance. By choosing R TH /(I+C 3 /C 2 ) higher than 2 kohm, it can be guaranteed that the short circuit current is lower than the safety current, as shown below. As seen in FIG. 3 , a RMS converter 301 converts the feedback lamp voltage VL into a RMS value first and outputs a signal denoted VLRMS. Similar to FIG. 2 , R 2 is used to eliminate the dc bias in the feedback voltage VL. Note that the value of R 2 is chosen to be significantly higher than the lamp impedance. Next, the short circuit analyzer 303 is used to output a current limit that is the minimum of VL/R TH and I BRT . The resulting current limit is shown in FIG. 4 . The heavy line is for normal operation current. The shaded area shows the LCC (Limited Circuit Current) protection region where VL may be smaller than I SAFE *R TH .
[0020] As long as (1+C 3 /C 2 )*V TH /I RMS >=1.4*2 Kohm, the circuit will guarantee that the short circuit current is always smaller than the safety current and the inverter operates properly with large lamp current which is greater than the safety current.
[0021] Note also that the short circuit current can be measured by a single resistor or capacitor in a fixed frequency inverter, and by the parallel combination of the resistor and capacitor in a variable frequency inverter.
[0022] The examples shown previously sense the voltage on the secondary side with a grounded sense. In other embodiments, the voltage and/or current may be sensed on the primary side. Still alternative, a differential sense scheme for floating drive inverters may be used. Furthermore, the teachings of the present invention may be used with other inverter topologies, including push-pull, half-bridge, etc.
[0023] From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.
|
The present disclosure introduces a simple method and apparatus for converting DC power to AC power for driving discharge lamps such as a cold cathode fluorescent lamp (CCFL), an external electrode fluorescent lamp (EEFL), or a flat fluorescent lamp (FFL). Among other advantages, the invention allows the proper protection under short circuit conditions for applications where the normal lamp current is greater than safe current limit.
| 7
|
This application claims priority from provisional application Ser. No. 61/061,403, filed Jun. 13, 2008, the entire contents of which are herewith incorporated by reference.
BACKGROUND
Winches can be used to move various objects and scenery, especially in a stage lighting environment. In some applications for a winch, the distances over which force application are carried out can vary.
For example, when lifting scenery on a stage, the width of the scenery depends on the specific scenery being lifted. This width correspondingly sets the width over which the lifting needs to occur, e.g., when lifting is carried out by the two far sides.
Also, the supports for the lifting may be separated by varying widths.
SUMMARY
The present application describes a winch with movable end parts that allow it extend across variable length supports and to carry out lifting across those variable lengths.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A-1C show the “tab” winch in multiple extended positions with different distances between the pulling areas;
FIG. 2 illustrates a “tab” drum used according to an embodiment; and
FIG. 3 illustrates the way that variable width lifting.
DETAILED DESCRIPTION
According to an embodiment, a winch is described which can vary in width and hence can vary the locations of its outer extent.
Another embodiment describes special operations which enable a reduced-thickness winch. This can facilitate the use of this winch in certain applications, such as overhead and in limited space areas.
The basic diagram of the winch in multiple different configurations is shown in FIGS. 1A-1C .
The main part of the winch includes a special drum for unwinding cable from two different locations at the same time. The inventors call this a yoyo drum 100 . The yoyo drum 100 has a power plant that causes its rotation. Two extendable arms 110 , 120 are coupled to the yoyo drum 100 and can be extended relative thereto. Each arm 110 , 120 has an idler at its very end. The arm 110 has the idler 111 , and the arm 120 has the idler 121 .
In operation, the cable pays onto and off of the drum 100 at two different locations simultaneously. One cable goes along arm 110 to idler 111 , and is raised or lowered by the idler. The other cable goes along arm 120 to idler 121 , and is simultaneously and synchronously raised or lowered from both spots.
FIG. 2 shows a detail of the yoyo drum from its side, illustrating the two tabs in the drum and those tabs can each hold their own supply of cable. The yo-yo drum 100 includes two different tabs, 200 , 205 . Each tab forms a slot that holds a stack of cable such as 210 . The cable can be stacked in each slot up from one side of the driven element, while simultaneously fed or taken up on the other tab from the driven element.
The special design allows the yoyo drum to hold cable only within a “tab” in the drum, and hence allows the drum to be very thin, even though it is a double cable supply drum. In the embodiment, the drum can be about the same thickness as the arms that extend and retract, so that the drum can fit within whatever thickness the arms can fit in. In one embodiment the drum is no thicker than the arms. In another embodiment, the drum is no more than 1.5 times the thickness of the arm.
The embodiment enables reconfiguring between multiple different crossbar sizes. For example, the crossbar elements such as 110 includes two portions 115 , 116 , which slide relative to one another. The portion 116 is smaller in outer cross section than the portion 115 , and hence the portion 116 fits within the portion 115 . Fasteners such as screws and nuts 117 hold the portion 115 relative to the portion 116 .
Other ways of holding the two arm parts together can also be used. For example, a clamp system could be used to hold the parts relative to each other. A threaded system could be used where one rod is threaded within the other.
Thus the lengths of the arms can each be independently adjusted to any desired length. Hence, this winch can be reconfigured between any desired set of crossbar lengths.
FIG. 3 illustrates how the distance 310 between the arms 315 , 316 can be reconfigured. The distance W is based on the distance between holding portions 351 , 352 on the item to be lifted 350 . The movement of the winch cable causes the item 350 to go up and down.
Although only a few embodiments have been disclosed in detail above, other embodiments are possible and the inventors intend these to be encompassed within this specification. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way. This disclosure is intended to be exemplary, and the claims are intended to cover any modification or alternative which might be predictable to a person having ordinary skill in the art. For example, other sizes, materials and connections can be used. Other structures can be used to receive the magnetic field. In general, an electric field can be used in place of the magnetic field, as the primary coupling mechanism. Other kinds of antennas can be used. Also, the inventors intend that only those claims which use the-words “means for” are intended to be interpreted under 35 USC 112, sixth paragraph. Moreover, no limitations from the specification are intended to be read into any claims, unless those limitations are expressly included in the claims.
Where a specific numerical value is mentioned herein, it should be considered that the value may be increased or decreased by 20%, while still staying within the teachings of the present application, unless some different range is specifically mentioned. Where a specified logical sense is used, the opposite logical sense is also intended to be encompassed.
|
A winch with adjustable arms allowing the length to be adjusted. The winch can have a very thin drum to allow it to fit in confined spaces.
| 1
|
TECHNICAL FIELD
This invention relates to control of aircraft propeller pitch and propeller speed at high flight speeds. This invention is used with a propeller speed control which governs propeller speed during flight by controlling propeller pitch.
BACKGROUND ART
It is known in the prior art to govern propeller speed by controlling propeller pitch. It is also known to provide dynamic compensation for the propeller speed control which is a function of the propeller speed passed through a lead network. There is however no lead compensation which provides near optimum governor dynamic compensation at both low and high flight speeds.
FIG. 1 illustrates the prior art governor and the improved governor in accordance with this invention. The typical prior art governor consists of an integrator 11 acting on propeller pitch, the propeller and propeller inertia 12. Since the control variable is propeller speed at the output of 12, this term is also fed back to the input at summing junctions 13 and 14. It is also known to incorporate the speed derivative feedback in the propeller electronic SYNCHROPHASER® which provides a lead compensation in the propeller speed governing loop. This lead compensates for the combined inertia lag of the propeller and power turbine.
Electronic hardware constraints often require that a constant value of the lead time constant (K2), FIG. 1, be used at all operating conditions. It is known that the inertia lag time constant at high flight speeds is much smaller than the time constant at low flight speeds. Selection of the time constant for lead compensation must therefore be compromised to a smaller time constant value for high flight speed stability than the optimal which would be selected for good low flight speed governing characteristics. This results in less than optimum lead compensation during low flight speeds.
DISCLOSURE OF THE INVENTION
This invention is the placement of a switch 19 in the derivative feedback path of a propeller speed control. The switch is used to inhibit the derivative feedback when it is no desired and/or not required. The derivative inhibit switch is controlled by logic which turns the switch off when a predetermined airspeed is reached.
This invention is directed to the problem of dynamic compensation when the propeller pitch is used to govern propeller speed. Ideally, the dynamic compensation should be varied in value in accordance with flight conditions and engine power.
Present-day control hardware constraints usually require that the dynamic compensation be a constant value at all operating conditions. The choice of the constant value of dynamic compensation must therefore be a compromise. This compromise yields degraded governing stability at some operating conditions.
The foregoing and other objects, features and advantages of the present invention will become more apparent in the light of the foregoing detailed description of the preferred embodiments thereof as illustrated in the accompanying drawing(s).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a typical propeller speed governor of the prior art and a speed inhibit means 19 in accordance with this invention.
FIG. 2 is a logic flow diagram for the speed derivative inhibit logic.
FIG. 3 shows the speed derivative inhibit in accordance with this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention inhibits the speed derivative at high flight speeds. In the prior art, dynamic compensation is usually provided by a speed derivative feedback such as that shown in FIG. 1. The derivative feedback is provided by the block 10 which provides a leading component in the feedback to the governor.
A method and apparatus is disclosed for improving the dynamic compensation and time constant match at low flight speeds by deleting the speed derivative path at high speeds. The dynamic compensation is deleted in the portion of the flight envelope where it is not needed. This speed derivative inhibit deletes the dynamic compensation at high flight speeds where it is not needed. When the speed derivative is deleted at high flight speeds, it also becomes possible to increase the derivative feedback at low flight speeds, and therefore provide even better governor dynamic compensation in the low flight speed region.
A constant indicated airspeed (KAIS) has an approximate constant value of the inertia lag time constant in a control in accordance with FIG. 1. Therefore, a constant value of indicated air speed (KIAS) can be selected which defines the limits above which the dynamic compensation is not required and can be deleted. Deleting the propeller governing dynamic compensation from this portion of the flight envelope permits the lead time constant (K2) block 10, FIG. 1, to be increased so that the dynamic compensation is closer to the optimum value at the lower flight speeds.
Deleting the speed derivative path by switch 19 (block 10) is only one method for inhibiting the governing dynamic compensation. Other methods which may be employed include a switch in the lead feedback path, a disconnect in the lead feedback path, a change of the constant K2 to zero, a removal of power from the leading feedback path, or other methods for inhibiting the dynamic compensation.
In FIG. 2 there is shown the control logic for generating a signal, FISD=0, or FISD=1 which provides a derivative inhibit command for the leading feedback control loop. In this embodiment, the dynamic compensation of the propeller pitch governor is improved by inhibiting the speed derivative path in the propeller speed control at flight speeds where compensation is not needed or desirable. Inhibit is accomplished by turning off switch 19.
FIG. 3 shows a block diagram general description of the method for computing the inhibit command signal (FISD). This block diagram shows that sensed indicated airspeed (VKIAS) is used in the speed derivative inhibit logic to compute FISD. The output FISD is used to control switch 19 of FIG. 1. The speed derivative inhibit logic block in FIG. 3 is described in detail in FIG. 2. Referring to FIG. 2, the sensed indicated air speed VKIAS is passed through a hysteresis band HVKIAS (15) to yield an air speed signal VKIASH. A indicated air speed signal (VKIASH) in excess of a constant value VKISD (block 16) will command the speed derivative inhibit FISD=1 (block 17). Also, if VKIASH is less than VKISD, the speed derivative inhibit command will be zero. FISD=0 (block 18).
The hysteresis band, HVKIAS (block 15). prevents the inhibit signal FISD from continuously cycling between 0 and 1 when the indicated air speed VKIAS is near VKISD, the predetermined constant indicated air speed value.
Referring now to FIG. 1, switch 19 provides feedback from block 10 when FISD=1 and no feedback when FISD=0.
Although the invention has been shown and described with respect to a best mode embodiment thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and deletions in the form and detail thereof may be made therein without departing from the spirit and scope of this invention.
|
A propeller speed governor having a derivative feedback of propeller speed and having a means such as a switch to open the derivative feed back loop when airspeed exceeds a predetermined amount is shown and described. This derivative inhibit is used to provide improved dynamic compensation at high and low speeds.
| 1
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser. No. 13/240,326, filed Sep. 22, 2011, which, in turn, is a continuation of U.S. application Ser. No. 11/412,983, filed Apr. 28, 2006 (now U.S. Pat. No. 8,044,880), the contents of which are incorporated herein by reference.
BACKGROUND
[0002] The present invention relates to a projection type image display device provided with an unauthorized use inhibiting mechanism. These days, uses of projection type image display devices inclusive of projectors are rapidly spreading in a variety of applications, such as presentation at conferences, lecturing in the fields of education, viewing films at home theaters, and so on. Because of the relative easiness of carrying the display devices, though they are expensive products, damages of theft of the display devices are tending to increase. As countermeasures against theft and unauthorized use of them, manufacturers are providing the products with such functions as to nullify changes made to settings and to lock the screen with use of password protection. An example of such art is disclosed in Japanese Patent Unexamined Publication No. 2004-77967.
[0003] According to the above mentioned art disclosed in Japanese Patent Unexamined Publication No. 2004-77967, a user at the time when starting up the device is requested to input his password and, only when the input password coincides with the password previously input by the rightful user, operation of the device is allowed and, thereby, unauthorized use of the device is prevented. However, it has been necessary even for a rightful owner of the device, when he uses the device, to input his password for verification of his ownership and therefore operation of the device has been very troublesome.
SUMMARY
[0004] The present invention is aimed at providing a projection type image display device that has an unauthorized use preventing function and yet can keeps its operability from deterioration.
[0005] To give an embodiment of the present invention, it is arranged in a projection type image display device such that first information indicative of a condition, while being used, of the device is stored in a memory, a condition, while being used, of the projection type image display device is detected at predetermined timing by a detector, and the use of the projection type image display device is restricted when a second condition, while being used, of the device detected on the basis of the first information stored in the memory disagrees with the condition, while being used, of the device indicated by the first information.
[0006] To give another embodiment of the present invention, it is arranged in a projection type image display device such that a setting value of a specific function of the device is stored in a memory at predetermined timing and when a processor detects that a change to the setting value has been made, the use of the projection type image display device is restricted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a block diagram of a projection type image display device according to a first embodiment.
[0008] FIG. 2 is a flowchart showing a start-up process of an unauthorized use preventing system.
[0009] FIG. 3 is a drawing showing an embodiment of password registration.
[0010] FIG. 4 is a flowchart showing an operating process of an unauthorized use preventing system.
[0011] FIG. 5 is a drawing showing an embodiment of password registration.
[0012] FIG. 6 is an example of installation of an angle sensor.
[0013] FIG. 7 is a drawing showing a condition of a ceiling fixture of a projection type image display device.
[0014] FIG. 8 is a drawing showing an example of giving an alarm with use of a logo seal.
[0015] FIG. 9 is a block diagram of a projection type image display device according to a second embodiment.
[0016] FIG. 10 is a block diagram of a projection type image display device according to a third embodiment.
[0017] FIG. 11 is a block diagram of a projection type image display device according to a fourth embodiment.
[0018] FIG. 12 is a drawing showing the fourth embodiment.
[0019] FIG. 13 is a block diagram of a projection type image display device according to a sixth embodiment.
[0020] FIG. 14 is a block diagram of a projection type image display device according to a seventh embodiment.
[0021] FIG. 15 is a drawing showing a fixed state of a projection type image display device.
[0022] FIG. 16 is a block diagram of a projection type image display device according to an eighth embodiment.
[0023] FIG. 17 is a drawing showing release of the unauthorized use preventing system according to a tenth embodiment.
[0024] FIG. 18 is a drawing showing a screen of a twelfth embodiment in which an image is inversed up-side-down.
[0025] FIG. 19 is a drawing showing a screen of the twelfth embodiment in which an image is scrambled.
[0026] FIG. 20 is a drawing showing a screen of the twelfth embodiment in which an image is blanked.
[0027] FIG. 21 is a block diagram of twelfth embodiment in which an alarm is given.
[0028] FIG. 22 is a drawing showing the screen of the twelfth embodiment in which an alarm is given.
[0029] FIG. 23 is a block diagram of a projection type image display device according to a thirteenth embodiment.
[0030] FIG. 24 is a drawing showing an example in which an alarm is given by lighting of an LED in the thirteenth embodiment.
[0031] FIG. 25 is a drawing showing correcting value storing areas in a nonvolatile memory 103 in a ninth embodiment.
DETAILED DESCRIPTION
[0032] A preferred embodiment of the present invention will be described below with reference to the accompanying drawings. In every drawing that follows, elements having like function will be marked with like marks and description of the components once described will be omitted thereafter.
[0033] In the following embodiment, occurrence of a theft is presumed by detection of a change in an installation condition or setup condition of a projection type image display device (hereinafter may sometimes be briefly called “device” unless it incurs a question) and thereby a system preventing an unauthorized use of the device following the theft is realized. In the installation condition and setup condition of the device, there are included various types of conditions whose changes are detectable. The installation conditions for example include (1) the attitude of the device, (2) the orientation of the device, (3) the place of installation, (4) the condition of an input to the input terminal, and (5) the fixing condition of the device. The setup conditions for example include (1) focus/zoom setup condition of the lens, (2) the projected image distortion correcting value, and (3) the projected image inversion setup condition. According to each of the conditions, the objects to be inspected vary as shown in Table 1. Details about them will be discussed later. Hereinafter, the above mentioned conditions will be generically called “used conditions” of the projection type image display device.
[0000]
TABLE 1
Example
Object to be detected
Installed
{circle around (1)} Attitude of Device
Angle with Gravity
condition
{circle around (2)} Orientation of Device
Direction of Installed Device
{circle around (3)} Place of Installation
Landscape around Device, etc.
Projected distance, Distance from Wall, etc.
{circle around (4)} Condition of Input to Input Terminal
Types of Input Signal, etc.
Whether Connector/Plug is put in, etc.
{circle around (5)} Fixing Condition of Device
Whether Device is fixed, etc.
Setup
{circle around (1)} Lens Focus, Zoom Setup Condition
Position of lens, etc.
Condition
{circle around (2)} Projected Image Distortion Correcting Value
Recorded Correcting Value in Memory, etc.
{circle around (3)} Projected Image Inversion Setup Condition
Setup Condition Recorded in Memory, etc.
[0034] In the present invention, occurrence of theft is presumed by a change in the installation condition (the attitude, in this case,) of the device, and when a change is detected, authentication of the user (judgment, for example, by an input password). Thus, the complicated operation (procedure) of authentication check routinely practiced so far can be simplified, the frequency of the authentication check is decreased, and troublesome operations can be lightened.
[0035] FIG. 1 is a block diagram of a projection type image display device according to a first embodiment. Referring to FIG. 1 , reference numeral 101 denotes the projection type image display device, 111 denotes an input terminal to which a video signal (not shown) is input, 110 denotes an input signal processing unit performing predetermined image processing on the video signal input from the input terminal 111 , 104 denotes an image processing unit performing image processing, such as decoding and scaling, and on-screen displaying, on a video signal output from the input signal processing unit 110 , 112 denotes a projecting optical unit for magnifying and projecting an image processed in the image processing unit 104 , and 113 denotes a screen for displaying an image projected thereon. Reference numeral 105 denotes an operating button unit made up of a plurality of buttons disposed on an enclosure, not shown, of the device, 106 denotes a remote controller (hereinafter briefly called “RC”) using an infrared remote control signal (hereinafter, briefly called “IR remote signal”) for remote controlling the projection type image display device, 107 denotes an IR sensitive element for sensing an IR remote signal from the RC 106 , 108 denotes an angle sensor detecting an attitude angle formed between the device and gravitation and used as a mechanism to read out a change in the attitude of the device from a change in the detected values, 109 denotes an I/O controller for controlling inputs from the IR sensitive element 107 and the angle sensor 108 , 102 denotes a Central Processing Unit (hereinafter called “CPU”) for performing operation control of the entirety of the projection type image display device, and 103 denotes a memory for storing a program for controlling the CPU 102 and various data such as the used conditions of the device and passwords. A video signal (not shown) input from the input terminal 111 is subjected to predetermined processing in the input signal processing unit 110 and the image processing unit 104 , and an optical image (picture image) corresponding to the video signal is projected, for example, onto the screen 113 by the projecting optical unit 112 . ON/OFF control of the device and operations for functions performed by the device, settings in the device and the like are performed by the operating button unit 105 or the RC 106 , and the CPU 102 performs processing corresponding to operated buttons (not shown) of the operating button unit 105 or corresponding to an IR remote signal received through the IR sensitive element 107 and the I/O controller 109 .
[0036] For example, when start-up setting of a system for preventing an unauthorized use of the projection type image display device has previously been made ready by an operation with use of operating button unit 105 , the CPU 102 obtains, when the power to the device is turned on, an attitude angle of the projection type image display device detected by the angle sensor 108 , through the I/O controller 109 . The obtained attitude angle is checked up with an attitude angle previously registered in the memory 103 by a rightful user, whereby the amount of change in the attitude angle is calculated. The CPU 102 judges whether a theft has occurred based on the amount of change and determines whether an authentication check of the user is to be made or not. If the CPU 102 determines that the authentication is not necessary, it permits the user to perform operations that follow. If not, it carries out the authentication of the user. In the event that the password previously stored in the memory 103 by the rightful user is then input with use, for example, of the operating button unit 105 , it permits the operation of the device. The above mentioned processing made by the CPU 102 will be described in detail with use of a flowchart.
[0037] There are types of angle detectors having one sensitive axis, two sensitive axes, and three sensitive axes. Any of those types can be used as the angle sensor 108 . As the memory 103 for storing detected attitude angle data, EEPROM and FLASHROM can for example be mentioned. Incidentally, when a function equivalent to that of the I/O controller 109 is incorporated in the CPU 102 , each device connected to the I/O controller may be directly connected to the CPU.
[0038] Processing operations of the CPU 102 related to an unauthorized use preventing system will be described now with the use of flowcharts of FIG. 2 and FIG. 4 . FIG. 2 is a flowchart showing processes for system start-up setting of the unauthorized use preventing system. After the power is turned on, if instructions to start the unauthorized use preventing system are issued from operating button unit 105 or the RC 106 of FIG. 1 , the CPU 102 starts a system start-up process of the unauthorized use preventing system at step (hereinafter briefly called “S”) 201 , i.e., it detects, via the I/O controller 109 and with use of the angle sensor 108 , the used condition of the device at that time, particularly, in the present embodiment, the attitude angle α indicating the attitude of the device as shown in FIG. 3 , and stores the value in the memory 103 (S 202 ). Then, it displays a password registration requesting screen 301 as shown in FIG. 3 by use of the image processing unit 104 to urge the user to register the password for user authentication. If the password is registered by the user with use of the operating button unit 105 or the RC 106 , the CPU 102 registers the password in the memory 103 (S 203 ). Here, a password means designation of a string of numbers, characters, or displayed special marks in a specific sequence or depressing specific buttons or RC keys in some order. Then, it is registered in the memory 103 that the projection type image display device has the unauthorized use preventing system started up (S 204 ) and after the start-up process of the unauthorized use preventing system is ended (S 205 ), normal operation of the device is started.
[0039] FIG. 4 is a flowchart showing operating processes of an unauthorized use preventing system which starts upon power-on. Referring to FIG. 4 , upon the power to the projection type image display device is turned on, the CPU 102 starts the operation of the unauthorized use preventing system (S 401 ) and confirms at start whether the unauthorized use preventing system start-up setting is ready (on) by checking the set-up condition of the unauthorized use preventing system stored in the memory 103 (S 402 ). If it is found that the start-up of the unauthorized use preventing system is not set at S 402 , proceeding advances to S 410 , where the device as it is is allowed to operate normally. If, on the other hand, it is found that the start-up of the unauthorized use preventing system is set at S 402 , the used condition of the device, i.e., the attitude angle α indicating the attitude of the device is detected with use of the angle sensor 108 (S 403 ) and the thus detected attitude angle (hereinafter called “detected angle”) is checked up with the attitude angle α that is stored in the memory 103 (S 404 ). In the checkup of the detected angle with the registered attitude angle at this time, by taking the accuracy of the angle sensor 108 into consideration, a margin, for example, of ±2 degrees or so may be allowed for the detection error of the angle sensor. Upon the checkup of the detected angle with the registered attitude angle, if it is found that they are coincident with each other or within the margin of error, it is considered that there has been made no change to the used condition (namely, the attitude of the device in this case) and therefore there has occurred no theft, and processing advances to S 410 , where the device as it is allowed to start its normal operation and the process of operating the unauthorized use preventing system is ended (S 411 ). If the detected angle disagrees with the registered attitude angle at S 404 , occurrence of a theft is presumed and therefore normal operations other than the power-off operation are inhibited at S 405 , the password inputting requesting screen 501 shown in FIG. 5 is displayed with use of the image processing unit 104 to urge inputting of a password (S 406 ), and then it is determined whether the input password coincides with the registered password at S 407 . Needless to say, normal operations other than the power-off operation are inhibited until the registered password is input with use of the operating button unit 105 or the RC 106 . When the input password is found to be coincident with the registered password at S 407 , the password inputting requesting screen 501 is erased (S 408 ), the prohibition of normal operations is cancelled (S 409 ), normal operations are started (S 410 ), and the operating process of the unauthorized use preventing system is ended (S 411 ). At this time, in the event that wrong password have been input a predetermined number of times (for example five times) in succession, it may be practiced to inhibit even inputting of a password and make the use of the device completely impossible.
[0040] In the present embodiment as described above, it is arranged such that, if a change in the used condition of the device (i.e., a change in the attitude angle in the case of the present embodiment) has been detected, an unauthorized use following a theft of the device is presumed and an authentication check is conducted. If, however, no change has been detected, it is judged that there is involved no unauthorized use following a theft and, hence, the step of authentication check is omitted. By making such an arrangement, a troublesome authentication check during the normal operation can be eliminated. Namely, complicated operations of authentication check are eliminated to simplify the operations of the system. Thus, it is made possible to realize an unauthorized use preventing system of projection type image display devices, while preventing its operability from being lowered.
[0041] Incidentally, there is a type of projection type image display device originally provided with an angle sensor for such purpose as correction of projected image distortion (so-called “keystone distortion”) due to the attitude angle of the device. In such case, by using the sensor also for the detector of a used condition, the need for newly adding an angle sensor can be eliminated and a cost increase can be suppressed.
[0042] If the one having two sensitive axes or three sensitive axes is used as the angle sensor 108 , then by disposing the device such that both a plane formed by two crossing axes of the sensitive axes and a plane formed by the direction of the gravitational force and the direction of the projection are held parallel to each other, it is made possible not only to detect the attitude angle but also to discriminate whether the device is placed on the floor or fixed onto the ceiling, and therefore the attitude angle of the device can be defined more finely. When, for example, an angle sensor 108 having two axes as the sensitive axes as shown in FIG. 6 is used, by disposing it such that the plane formed by the sensitive axis 601 and the sensitive axis 602 and a plane formed by the direction of gravitational force 603 and the projected direction 604 are parallel to each other, the attitude angle can be detected by use of the sensitive axis 601 and discrimination between installation on the floor and installation on the ceiling can be made by use of the sensitive axis 602 . Here, the above mentioned installation on the floor means a style of installation with the top face of the device turned upward. And, the installation on the ceiling means the installed state of the device turned upside down from the installed state on the floor, an example thereof being a style of installation as seen when the device 101 is fixed onto the ceiling 702 with use of fixings (ceiling fixtures) 701 or the like as shown in FIG. 7 .
[0043] Further, in addition to the use of the unauthorized use preventing system described in the present embodiment, if a logo seal 801 giving an alarm to the effect that the device will not operate normally if its installed condition is wrongly changed is attached onto the enclosure of the projection type image display device 101 where the seal is easy to see, it is made possible to let surrounding people to notice that the unauthorized use preventing system is in operation and, thus, it is made possible to prevent a theft more effectively.
[0044] FIG. 9 is a block diagram showing a projection type image display device according to a second embodiment. Although occurrence of a theft has been presumed in the first embodiment on the basis of a change in the attitude angle, the orientation of the device as an aspect of the used conditions (refer to Table 1) is detected in the present second embodiment with use of the geomagnetic sensor 901 shown in FIG. 9 instead of the angle sensor 108 , and thereby occurrence of a theft is presumed on the basis of a change in the installed orientation of the device. Otherwise, the present embodiment is like the first embodiment and therefore explanation of the same will be omitted.
[0045] A third embodiment will be described now. FIG. 10 is a block diagram showing a projection type image display device according to the third embodiment. While occurrence of a theft has been presumed in the first embodiment on the basis of a change in the attitude angle, a projected distance or a distance from a wall is detected in the third embodiment with use of the distance sensor 1001 as shown in FIG. 10 instead of the angle sensor 108 and a change in the place of installation as an aspect of the used conditions (refer to Table 1) is read out from a change in the detected distance and, on the basis of the change, occurrence of a theft is presumed. Otherwise the present embodiment is like the first embodiment and therefore explanation of the same will be omitted.
[0046] A fourth embodiment will be described below. FIG. 11 is a block diagram showing a projection type image display device according to the fourth embodiment. While occurrence of a theft has been presumed in the first embodiment on the basis of a change in the attitude angle, the CPU 102 in the fourth embodiment detects a landscape with use of the monitor camera 1101 shown in FIG. 11 instead of using the angle sensor 108 and reads out a change in the place of installation from a detected change in the landscape around the device, and thereupon presumes occurrence of a theft based on the readout change. As an example of detecting the landscape around the device, a method can be mentioned in which a monitor camera 1101 is disposed at a side of a projection lens and the landscape 1201 in the projected direction is detected and registered as the landscape around the device. If, in the above described method, a landscape other than the registered landscape has been detected, the normal operation of the apparatus thereafter may be inhibited.
[0047] Although, in the first embodiment, occurrence of a theft has been presumed on the basis of a change in the attitude of the device detected with use of an angle sensor, a fifth embodiment is carried out in the configuration of FIG. 1 but without using the angle sensor 108 . In the present fifth embodiment, the CPU 102 detects a change in a signal input from the input terminal 111 with use of the input signal processing unit 110 and reads out, from the detected change in the signal, a change in the condition of an input to the input terminal, and thereby presumes occurrence of a theft. As an example of detecting a change in the input signal, such a method can be mentioned as to register a condition of an XGA, 85 Hz, signal being input to an RGB signal input terminal and to inhibit the normal operation of the device in the event that inputting of a signal other than the registered signal is detected.
[0048] A sixth embodiment will be described now. FIG. 13 is a block diagram showing a projection type image display device according to the sixth embodiment. Although, in the first embodiment, occurrence of a theft has been presumed on the basis of a change in the attitude of the device, the angle sensor 108 is not used in the sixth embodiment as shown in FIG. 13 but insertion of the connector or plug 1301 into the input terminal 111 is detected and a change in the condition of input to the input terminal is read out from whether or not the connector or plug 1301 is inserted, and thereby occurrence of a theft is presumed. As an example of detecting whether or not the connector or plug is inserted into the input terminal, such a method can be mentioned as to detect whether or not an RCA plug is inserted by using an RCA jack provided with a switch for the input terminal, and thereupon a condition of its being inserted is registered. And, then, if a state of the plug being not inserted is detected, a normal operation of the device is inhibited.
[0049] A seventh embodiment will be described now. FIG. 14 is a block diagram showing a projection type image display device according to the seventh embodiment and FIG. 15 is a drawing showing the projection type image display device being in its fixed condition. Elements in FIG. 14 having corresponding functions to those of elements in FIG. 1 are denoted by corresponding reference numerals and description of the same is omitted.
[0050] The present embodiment is favorably applied to the arrangement of the projection type image display device 101 fixed for example onto the ceiling 702 by the use of the fixture (ceiling fixture) 701 as shown in FIG. 7 . In the present embodiment, a change in the fixed condition is read out from whether or not the device is fixed to a fixing member (the ceiling in the present example) by the use of the fixing screw 1401 and the switch 1402 shown in FIG. 14 and FIG. 15 and occurrence of a theft is presumed on the basis of the read out change.
[0051] While, in the first to seventh embodiments, occurrence of a theft has been presumed on the basis of a change in the “installed condition,” of the used conditions shown in Table 1, i.e., a change in (1) attitude of device, (2) orientation of device, (3) place of installation, (4) condition of input into input terminal, and (5) fixed condition of device, the presumption of occurrence of a theft in an eighth embodiment is made on the basis of a change in “setup condition” of device. FIG. 16 is a block diagram showing the projection type image display device according to the eighth embodiment. Elements in FIG. 16 having functions like those of elements in FIG. 1 are denoted by like reference numerals and description thereof is omitted.
[0052] In the present embodiment, as shown in FIG. 16 , the position of the projection lens 1601 of the projecting optical unit 112 is detected with use of the potentiometer 1602 and a change in the focus/zoom setup condition is read out from a detected change in the position of the projection lens, and on the basis of the detected change, occurrence of a theft resulting in an unauthorized use of the device is presumed.
[0053] A ninth embodiment will be described now. Instead of using a change in the zoom/focus setup condition detected with the use of the potentiometer for the presumption of occurrence of a theft in the eighth embodiment, a correcting value of the projection distortion (so-called keystone distortion) is used in the present ninth embodiment. Depending on the attitude of the device or the distance of the device to the screen, a distortion occurs in a projected image. Therefore, in order to compensate for the distortion, it is generally practiced to apply distortion correcting processing on the image data to be projected. In the present embodiment, parameters for the image correcting process are stored and recorded in the memory. The CPU 102 compares the projected image distortion (so-called keystone distortion) correcting value setup and recorded in the memory 103 by the user the last time with the projected image distortion correcting value previously registered by the rightful user, and thereby reads out a change in the projected image distortion correcting value and, on the basis of the change, presumes occurrence of a theft followed by an unauthorized use of the device. The hardware arrangement in this case is like that shown in FIG. 1 with the angle sensor 108 excluded therefrom. However, the nonvolatile memory 103 is arranged such that a storage area for storing a correcting value 1 that is registered by the rightful user according to the system start-up setting process of FIG. 2 and a storage area for storing a correcting value 2 that is changed in the course of other normal processing are separated from each other as shown in FIG. 25 .
[0054] In the case of the present embodiment, the correcting value 2 that is revised while the device is being started up is used for detecting an unauthorized use. Therefore, up to one time of unauthorized use might be permitted. For example, when an unauthorized use preventing system by means of password check is not provided or a lock by means of password check is unjustly released, it becomes possible to make an unauthorized use. In the case of an unauthorized use, it frequently becomes necessary to revise the projection image distortion correcting value because the place of installation or position of installation varies. In such case, the revised value is stored in the nonvolatile memory 103 as the correcting value 2. More specifically, when a request is made for a revision of the correcting value, it is judged whether the system is in its course of processing the system start-up setting shown in FIG. 2 or in its course of processing a normal routine. If it is in the course of the system start-up setting, the correcting data is stored in the area of the correcting value 1, whereas if it is in the course of the normal routine, the correcting value 2 is stored in the area of the correcting value 2. At a start-up the next time, the stored correcting value 2 is compared with the correcting value 1 stored by the rightful user and if they do not coincide with each other, the operation is judged to be made by an unauthorized use.
[0055] Incidentally, the checkup of the correcting values may not necessarily be performed at power-on of the system but may be performed at predetermined timing. Such a system may also be made, in which, once power to a device is turned off at a power-off request, on condition that the correcting value 1 has not coincided with the correcting value 2 and a right password has not been input several times, starting up of the device the next time is inhibited. In this case, the nonvolatile memory 103 will be provided with a flag to inhibit a start-up of the device and a process to set this flag will be made at the time of the power-off. When the system is in its state starting up its unauthorized use preventing system, the start-up process will be started after checking the state of that flag inhibiting the start-up of the device.
[0056] Further, during the course of the above described processes in which the system start-up of FIG. 2 is performed at power-on of the device, if a change to the setting is made, even if it is made by a rightful user, a request for inputting a password according to FIG. 4 will without fail be made. Hence, it is desired that the system start-up of FIG. 2 is carried out immediately before a power-off request is made. Accordingly, the system may be adapted such that a popup suggesting the system start-up is displayed on the screen when there is made a power-off request. Otherwise, such a configuration may be made in which inputting of a password is requested when a change to the setting is made.
[0057] Although, referring to FIG. 25 , a configuration has been described in which a first correcting value input by a rightful user and a second correcting value changed during the course of normal processing are separately stored in the memory 103 and the change to the correcting value is detected by comparing both the values, such a configuration may also be made in which the correcting value storage area is provided by one area and a flag indicating that a change has been made is stored in the memory 103 . In this case, the CPU 102 may check the flag at predetermined timing, such as when the device is started up or the power is turned off, and thereby find that a change has occurred and put limitations on the use of the device. Further, while normal operations other than power-off were inhibited in the first embodiment when occurrence of a theft was presumed on the basis of a change made to the used condition of the device, it may be adapted in the case of the present embodiment such that the operation of changing the projected image correcting value is inhibited.
[0058] In a tenth embodiment, the CPU 102 compares the condition of a projected image inversion setting (so-called, mirror setting) set up by the user of the device last and recorded in the memory 103 with the condition of a projected image inversion setting previously registered by a rightful user, reads out a change in the condition of the projected image inversion setting, and presumes occurrence of a theft followed by an unauthorized use. Also in this embodiment, a set condition 1 registered by the rightful user through the processes of FIG. 2 and a set condition 2 set by the rightful user or an unauthorized user in normal conditions are respectively stored in separate storage areas of the nonvolatile memory 103 . As with the ninth embodiment, at least one time of unauthorized use might be permitted. The condition 2 of the projected image inversion setting set up at this time and the set up condition 1 are compared with each other and occurrence of an unauthorized use is detected according to whether the contents of the setting coincide or not. As with the ninth embodiment, the timing of the comparison is not limited to that of power-on. Although, in the case of the first embodiment, a change in the used condition of the device was read out and normal operations other than turning off of the power were inhibited when a theft is presumed on the basis of the read out, an operation to change the projected image inversion setting may be inhibited in the case of the present embodiment.
[0059] While the first embodiment to the tenth embodiment have been described above, the examples of the installed conditions of the device in the first to tenth embodiments, i.e., (1) the attitude, (2) the orientation, (3) the place of installation, (4-1) the input signal to the input terminal, (4-2) whether a plug or connector is inserted into the input terminal and (5) whether the device is fixed to a fixing member, and the examples of setup condition of the device described in the eighth to tenth embodiments; i.e., (1) focus/zoom setup condition of the lens, (2) the projected image distortion correcting value, and (3) the projected image inversion setup condition may be combined at will. By using combination at will of these conditions, the accuracy of presumption of occurrence of a theft and an unauthorized use that follows can be enhanced.
[0060] An eleventh embodiment will be described now. By providing the RC 106 with a function of outputting a signal for releasing an unauthorized use preventing system, the user authentication performed by means of a password check in embodiment 1 can also be performed by the releasing signal from the RC.
[0061] When the used condition of the device detected when the device is started up and the registered used condition are different, the CPU 102 displays the screen 1701 requesting for depressing a release button on the RC as shown in FIG. 17 and inhibits normal operations other than the power-off operation until it receives the system releasing signal from the RC. When the system releasing signal is received, it erases the screen 1701 requesting for depressing the release button and enables normal operations. If the rightful user keeps the device and the RC in different places so as to prevent the theft of both the RC and the device at the same time, it is made possible to provide the release button on the RC with a function equal to that of a password. Thus the present embodiment can provide the same advantage as obtained in the first embodiment.
[0062] Although, in the first embodiment, it is arranged, when the used condition detected at the time of starting up of the projection type image display device is different from the registered used condition, such that the normal operations of the device is inhibited, but the manner of restriction is not limited to this. When it is aimed not to allow the device to operate normally, the device may be caused to make an abnormal operation. For example, the inverted screen 1801 processed to look up-side-down as shown in FIG. 18 may then be constantly displayed. Or, the scrambled screen 1901 processed to be scrambled as shown in FIG. 19 , or the blank screen 2001 as shown in FIG. 20 may be displayed. Further, as shown in FIG. 21 and FIG. 22 , the sound signal generator 2101 , amplifier 2102 , and built-in speaker 2103 may be provided on the projection type image display device so that an alarm is given.
[0063] A thirteenth embodiment will now be described. In the present embodiment, instead of the logo seal 801 shown in FIG. 8 that was described at the end of the description of the first embodiment, there is provided an LED 2301 as shown in FIG. 23 and the LED 2301 is placed on the enclosure of the image display device 201 at its portion easily seen from the surrounding as shown in FIG. 24 . While the unauthorized use preventing system is being started up, the LED 2301 is lighted or flashed on and off to notify the surrounding people of the start-up of the unauthorized use preventing system so as to effectively prevent a theft of the device.
|
A projection type image display device provided with an unauthorized use preventing system includes a button unit or a remote controller for operating the display device, a condition memory for storing information indicating at least one use condition in an authorized use of the display device, a password memory for storing a password for releasing a restriction on the use of the display device, a detector for detecting a used condition of the display device at a power on timing, and a processor for imposing restrictions on the use of the display device when the use condition detected by the detector does not match the at least one use condition indicated by the information stored in the condition memory and for relieving the restriction based upon input of the password.
| 6
|
TECHNICAL FIELD
[0001] The present invention relates to the technical field of coal resource development, particularly relates to a gas injection apparatus with controllable gas injection point, gas injection process and gasification method.
BACKGROUND ART
[0002] Shaftless underground gasification technologies mainly employ the directional drilling and reverse burning to construct gasification channel, and inject gasification agents such as air and oxygen/steam to conduct underground gasification to produce coal gas. Its advantage lies in that gas production of single gasifier is large. Its disadvantage lies in that position of burning zone is not stable, loss rate of the gas is high, and it is necessary to add auxiliary boreholes if the gasification channel is very long.
[0003] To solve the problems above, Lawrence Livermore national laboratory in USA has developed controlled retraction injection point (CRIP), which makes the injection point retract to form new burning zone by burning a section of the casing-tube so that the injection point can move towards the gas injection well, as shown in FIG. 1 . The igniter has many pipes, which can carry fluid from ground to the underground. Start the igniter, the silane from one pipe encountered in the air will cause spontaneous combustion, the spark will ignite propane from another pipe, and the flame will burn off a section of the casing-tube and further ignite the coal seam. In Thulin, Belgium, the underground gasification test designs that the injection tube employs concentric annular tubes, wherein the center tube can move within the annular tube. There are three thermocouple electric wires and two combustible hollow pipes in the center tube. One hollow pipe is used for delivering triethylborine, which will burn once meets air, and CH 4 . The other hollow pipe is filled with oxygen. An igniter is fixed at the end of the center tube.
[0004] The advantage of CRIP technology is that the gasification process can be effectively controlled, while its disadvantage is that this technology requires multiple ignitions to ignite the coal seam at different distance location within a directional well before gasification. Because the gas injection point movement is discontinuous, the gasification is unstable, and the apparatus for ignition and gas injection has complicated structure and is expensive, the ignition process is complicated, difficult to control and not safe enough.
SUMMARY OF THE INVENTION
[0005] Aiming to solve a series of problem of existing CRIP process in the shaftless underground coal gasification including multiple ignition, complicated device, discontinuous gas injection point movement and unstable gasification process, the present invention provides a reverse burning ignition and gasification method of controllable gas injection point movement of shaftless underground gasification, thereby achieving the goal of improving gasification stable control and safety performance and reducing the production cost. The present invention also provides a gas injection apparatus and a gas injection process with controllable gas injection point.
[0006] The present invention is based on the techniques of directional drilling and coiled tubing, utilizes the principle of directional drilling cooperating with coiled tubing to realize the movement of gas injection point and adjusting gasification agent injection parameter to control the reverse combustion, finally achieves the goal of modulating movement and burning rate of flame working face position to conduct reverse burning ignition and gasification of the underground coal seam.
[0007] To achieve this goal, the present invention employs the following technical solutions: One goal of the present invention is to provide a gas injection apparatus with controllable gas injection point. The gas injection apparatus comprises a directional well channel. The directional well channel is disposed with coiled tubing. The coiled tubing is connected with oxygen/oxygen-enriched gas line. The annular space between the coiled tubing and the directional well has connection to an auxiliary gasfication agent line and a steam line. The start end of the coiled tubing is disposed with gas injector head and the terminal end is disposed with a nozzle.
[0008] The coiled tubing is sealed by a blowout preventer (box) and placed in the well.
[0009] The second goal of the present invention is to provide a gas injection process with controllable gas injection point. In the gas injection process, the oxygen/oxygen-enriched gas is delivered by the coiled tubing deposited within the directional well channel. The oxygen/oxygen-enriched gas, and the auxiliary gasification agent delivered through the annular space between the coiled tubing and the directional well will be uniformly mixed at the nozzle location at the terminal end of coiled tubing. The mixed gasification agent enters the predetermined gasification location of the coal seam through the directional well channel or the pore channels within the coal seam.
[0010] The oxygen/oxygen-enriched gas and auxiliary gasification agent are mixed at the position of nozzle at the terminal end of the coiled tubing, that is, within the drill-hole or the channel.
[0011] The gas injection point movement control of the present invention during the gas injection, can realize gas injection position change by lifting and lowering action to control movement of the coiler tubing and nozzle.
[0012] The directional well channel of the present invention is formed with directional drilling method. Directional drilling technology is one of the most advanced well drilling technologies in the field of petroleum exploration and development in the current time. It is a well-drilling process technology that utilizes special under-well tools, measurement devices and process technology to effectively control the well trajectory, making drilling bit drill to the predetermined underground position along a specific direction. It is widely used in oilfield development in current. Directional drilling technology can economically and effectively develop petroleum resources with limited ground and underground conditions and greatly improve petroleum production and reduce well-drilling cost, thus it is good to natural circumstance protection and has significant economical and social benefit.
[0013] The directional drilling method of the present invention preferably employ any one of directional well drilling technology, horizontal well drilling technology, lateral drilling technology, radial horizontal well technology, multilateral well technology, cluster wells technology and extended reach well technology in petroleum or coal seam gas drilling technologies. The directional well channel is longer than 10 meters.
[0014] The directional well channel of the present invention is unsupported channel or supported channel. In practical implementation process, whether supporting the channel or not is determined according to the factors such as coal rock and geological condition.
[0015] The supported channel utilizes sieve-tube support and/or casing-tube support, preferably sieve-tube support or the combination of sieve-tube support and casing-tube support. In the practical implementation process, different support pattern can be selected according to the factors that influence reverses burning ignition speed, such as support tube intensity, coal gangue and coal water. Preferably, sieve-tube support or combination of sieve-tube support and casing-tube support is employed to improve the contact area of gasification agent and coal seam to be ignited.
[0016] The support tube materials are combustible materials, more preferably organic materials, most preferably glass fiber reinforced plastics or PE pipe materials. During the implementation process, organic materials such as glass fiber reinforced plastics or PE pipe materials are preferred due to factors such as intensity or burning features.
[0017] The oxygen/oxygen-enriched gas is provided by the gasification agent preparation system. The oxygen-enriched gas is a mixed gas composed of oxygen and one or both of nitrogen and carbon dioxide, wherein the concentration by volume of oxygen is larger than 21%.
[0018] The auxiliary gasification agent is one of nitrogen, carbon dioxide and water, or mixture thereof. A person skilled in the art can select one or two of the gases according to the gas injection requirement. The nitrogen is provided by a nitrogen production device. The carbon dioxide is provided by a decarbonization device. The auxiliary gasification agent has the following functions: firstly, it will take part in the underground gasification reduction reaction, such as CO 2 or H 2 O; secondly, its remixing with oxygen/oxygen-enriched gas can reduce the oxygen concentration of the mixed gasification agent, thereby protecting gasification process and equipment.
[0019] During gasification process, the oxygen content of the auxiliary gasification agent delivered between the coiled tubing and directional well wall should be controlled to prevent self-burning of coal seam or gas injection string tempering in the delivery process. The oxygen concentration is determined by the lower limit of oxygen concentration which can cause the coal self-burning. For the thickness of loose coal seam is less than 0.5 meter, the oxygen concentration by volume of the auxiliary gasification agent is generally required to be less than 5%.
[0020] For the coiled tubing and nozzle of the present invention can select the formed materials and equipment of the current petroleum and natural gas industry. In coiled tubing selection, the processing parameters such as oxygen concentration, pressure and flow rate of delivered gasification agent are key factors to be considered; the coiled tube with different pressure, material and diameter can be selected to reduce the composite cost.
[0021] The pore channels within the coal seam is formed by artificial drilling or fracturing process, or formed by coal seam under thermal effect of burning.
[0022] The third goal of the present invention is to provide two controlled gas injection point gasification method utilizing the above-mentioned gas injection process.
[0023] The first controlled gas injection point gasification method conducts reverse burning, gasification channel processing and gasification production by segmentally moving the coiled tubing to make the gas injection point segmentally move to the predetermined gasification position, and then adjusting the gas injection technology parameters.
[0024] The gasification method comprises the following steps:
[0025] 1) according to the parameters such as thickness and reserves of gasifiable coal seam in gasification area, segmentally moving coiled tubing according to the gas injection process to make the gas injection point position segmentally move to the predetermined gasification position;
[0026] 2) adjusting the pressure and flow rate of a single gas and controlling the parameters such as flow rate, pressure and oxygen concentration of the injected gasification agent; segmentally moving the flame working face to the predetermined gasification position in the manner of reverse burning and making gasification channel process at the same time;
[0027] 3) after completing the ignition and process of the gasification channel, improving intensity of the gasification agent injection, enhancing the gasification of underground coal and conducting gas production of underground gasification on a large scale;
[0028] 4) when the coal seam gasification of the predetermined gasification position is done, determining stopping or reducing gasification agent injection according to the consumed amount of the gasification coal, and heat value and composition of coal gas, and starting the injector head to move the oxygen/oxygen-enriched gas injection point to the next predetermined gasification position;
[0029] 5) conducting the next segment gasification channel process according to step 2), and completing the underground gasification of the predetermined coal seam area according to step 3) and 4); repeating those steps until the coal resource around the directional well channel is gasified completely.
[0030] The gas injection point segmental movement distance in the step 1) is 10˜150 m.
[0031] Preferably, the gasification flow rate during the gasification channel ignition and processing is limited within 300˜3000 m 3 /h.
[0032] Preferably, the oxygen concentration by volume in the gasification agent is 21˜55%.
[0033] In the present invention, the gas injection movement is estimated according to the parameters such as the amount of coal has gasified, the heat value and composition of coal gas. The movement standard determined by general process operation is as follows: the amount of coal has gasified is more than 50% of the total gasifiable coal in the section of directional well channel; and the heat value and composition of the production gas reduce by more than 20% compared with normal value.
[0034] Another controllable gas injection point gasification method provided by the present invention conducted reverse burning, gasification channel processing and gasification production by continuously or intermittently lifting the coiled tubing to make the gas injection point continuously move to the predetermined gasification position, and then adjusting the gas injection technology parameters.
[0035] The gasification method comprises the following steps:
[0036] 1) according to the parameters such as thickness and reserves of gasifiable coal seam in gasification area, and continuously or intermittently lifting coiled tubing to make the gas injection point continuously move to the predetermined gasification position;
[0037] 2) adjusting the pressure and flow rate of a single gas and controlling the parameters such as flow rate, pressure and oxygen concentration of the injected gasification agent; achieving continuously processing gasification channel and underground gasification production on a large scale in a manner of reverse burning;
[0038] 3) adjusting the gasification agent injection parameters whenever necessary, to guarantee relative stable status of coal gas composition and heat value;
[0039] 4) when coal seam gasification of the predetermined gasification position is done, controlling reverse movement speed of coiled tubing according to burning speed of the coal gasification, heat value and composition of coal gas, and the gasifiable coal reserves, until the coal resource around the directional well channel is gasified completely.
[0040] The flow rate of the gasification agent in the step 2) is larger than 2000 m 3 /h; preferably, the oxygen concentration by volume of gasification agent is 21˜95%.
[0041] Preferably, when the oxygen concentration by volume is larger than 60%, water steam or water can be injected to adjust the temperature and gas quality in the cavity.
[0042] The movement speed of the gas injection point is determined according to the amount of coal burned per unit of time (m), heat value and composition fluctuation of coal gas. In the practical operation of underground gasification, the movement standard determined by process operation is as follows: the gas injection point can begin to continuously move till the gasification rate (η) is larger than 50%, which is the ratio of coal burned to the gasifiable coal (T) per unit length of the directional well channel. and the reduction of heat value and composition is more than 20% of normal value, wherein the gas injection point movement rate (V) control satisfies the following equation: V=T*η/m.
[0043] The controllable gas injection point gasification method of the present invention includes the following steps:
[0044] 1) employing directional drilling technology to build up a directional well channel connecting to the existing burn zone in the predetermined gasification coal seam;
[0045] 2) delivering the coiled tubing and the nozzle to the predetermined gasification position along the directional well through the gas injection well using the injector head;
[0046] 3) injecting the auxiliary gasification agent into the annular space between the coiled tubing and the directional well wall to conduct replacement protection of the channel, and then injecting oxygen/oxygen-enriched gas into the coiled tubing;
[0047] 4) delivering the oxygen/oxygen-enriched gas through the coiled tubing to output at the nozzle, allowing its uniform mixture with the auxiliary gasification agent delivered through the annular space at the predetermined gasification position; mixed gasification agent enters the predetermined ignition position through the directional well channel or the pore channel within the coal seam;
[0048] 5) adjusting pressure and flow rate of a single gas and controlling the parameters such as pressure, flow rate and oxygen concentration of the mixed gasification agent injected into the gasifier by the ground control system; segmentally guiding the flame working face move to the predetermined gasification position in the manner of reverse burning; at the same time, processing the gasification channel and making underground gasifier to produce syngas;
[0049] 6) determining the condition of coal seam burning and gasification at the predetermined gasification position according to the coal burned, the heat value and composition of coal gas; when the stability of the heat value and composition decrease, starting the injector head to make the oxygen injection point move to the next predetermined gasification position;
[0050] 7) accomplishing the coal underground gasification in the predetermined area according to the steps 5) and 6); repeating those steps until the coal resource around the directional well channel is gasified completely; and
[0051] 8) stopping oxygen/oxygen-enriched gas input of the coiled tubing, then stopping auxiliary gasification agent input of the annular space of sieve-tube; taking out the gasification agent injection apparatus from the directional well channel and moving it to the next gasification area.
[0052] Compared with the existing technical solutions, the gas injection apparatus of the present invention employs directional drilling and coil tubing technologies so that it can control the movement of the gas injection position and can stably adjust the gasification agent injection parameters.
[0053] In the gas injection process of the present invention, the gas injection point being able to move in any distance within the directional well channel according to requirement, and effectively improve gasification recycling rate of the coal along the directional well channel. Besides, employing annular space between the coiled tubing and the directional well wall to deliver auxiliary gasification agent can effectively prevent channel coal self-burning and gas injection tube backfire, can form mixed gasification agent at the gas injection point (nozzle position), and can continuously controlling various gas injection parameters.
[0054] In the implementation process of the present invention, there is no need igniter at gas injection point to ignite, whereas it controls gasification agent injection parameters including oxygen concentration, flow rate, pressure, to make gasification channel reverse burning, quick ignition and processing, thus the gas injection point movement is continuous and the gasification process is highly stable.
DESCRIPTION OF FIGURES
[0055] FIG. 1 shows the schematic diagram of the present shaftless CRIP technology.
[0056] FIG. 2 shows the schematic diagram of gasification furnace employing controllable gas injection gasification.
[0057] FIG. 3 shows the underground gasification furnace with supported structure at horizontal segment of directional well channel as described in Embodiment 1.
[0058] FIG. 4 shows the schematic diagram of controllable gas injection point movement gasification process of Embodiment 1 (plane sectional view).
[0059] FIG. 5 shows the underground gasification furnace with bare hole structure (no support structure) at horizontal segment of the directional well channel as described in Embodiment 2.
[0060] In the figures: 1 -coiled tubing reel ; 2 -gas injection well head; 3 -coiled tubing; 4 -nozzle; 5 - glass fiber reinforced plastics sieve-tube; 6 -directional well channel; 7 -cavity; 8 -the roof of coal seam; 9 -the floor of coal seam; 10 - production well; 11 -bare hole segment of horizontal well.
[0061] Hereinafter, the present invention is described in further details. However, the following embodiments are merely simple examples of the present invention and do not represent or limit the protection scope of the present invention. The scope of protection of the invention is prescribed by the attached claims.
DETAILED DESCRIPTION
[0062] For better illustrating the present invention and helping to understand the technical solution of the present invention, the typical but non-limiting embodiments of the present invention are described in the following:
Embodiment 1
[0063] Gas injection apparatus with controllable gas injection point comprises directional well channel 6 , the directional well channel 6 is disposed with coiled tubing 3 . The coiled tubing 3 is connected with oxygen/oxygen-enriched gas line. The annular space between the coiled tubing 3 and the directional well 6 has connection to the auxiliary gasification agent line and steam line. The start end of the coiled tubing 3 is disposed with gas injection well head 2 and the terminal end is disposed with nozzle 4 .
[0064] Coiled tubing reel 1 is used for carrying the coiled tubing 3 .
Embodiment 2
[0065] A gas injection technology with controllable gas injection point, wherein oxygen/oxygen-enriched gas is delivered by the coiled tubing deposited within the directional well channel; the oxgen/oxygen-enriched gas and the auxiliary gasification agent delivered through the annular space between the coiled tubing and the directional well wall are uniformly mixed at the nozzle at the terminal end of coiled tubing; the mixed gasification agent enters the predetermined gasification position of the coal seam through the directional well channel or the pore channel within the coal seam.
[0066] The directional well channel is formed by the directional drilling method. The directional drilling method preferably employ any of directional well drilling technology, horizontal well drilling technology, lateral drilling technology, radial horizontal well technology, multilateral well technology, cluster wells technology and extended reach well technology in petroleum or coal seam gas drilling technologies. The directional well channel is longer than 10 meters.
[0067] The pore channel within the coal seam is formed by artificial drilling or fracturing process, or formed by coal seam under thermal effect of burning.
[0068] The directional well channels are unsupported channel or supported channel. The supported channels employ sieve-tube and/or casing-tube, preferably sieve-tube or the combination of sieve-tube and casing-tube for support. The support tube materials are combustible materials, more preferably organic materials, most preferably glass fiber reinforced plastics or PE pipe materials.
[0069] The oxygen/oxygen-enriched gas is provided by the gasification agent production system. The oxygen-enriched gas is a mixed gas composed of oxygen and one or both of nitrogen and carbon dioxide, wherein the concentration by volume of oxygen is larger than 21%.
[0070] The auxiliary gasification agent is one of nitrogen, carbon dioxide and water, or mixture thereof. The nitrogen is provided by a nitrogen production device. The carbon dioxide is provided by a decarbonization device.
Embodiment 3
[0071] A controllable gas injection point gasification method, wherein reverse burning, gasification channel process and gasification production is conducted by segmentally moving the coiled tubing to make the gas injection point segmentally move to the predetermined gasification position, and then adjusting the gas injection technology parameters.
[0072] The gasification method comprises the following steps:
[0073] 1) according to the parameters such as thickness and reserves of gasifiable coal seam in gasification area, segmentally moving coiled tubing according to the gas injection process to make the gas injection point position segmentally move to the predetermined gasification position;
[0074] 2) adjusting the pressure and flow rate of a single gas and controlling the parameters such as flow rate, pressure and oxygen concentration of the injected gasification agent; segmentally moving the flame working face to the predetermined gasification position in the manner of reverse burning and making gasification channel process at the same time;
[0075] 3) after completing the ignition and process of the gasification channel, improving intensity of the gasification agent injection, enhancing the gasification of underground coal and conducting gas production of underground gasification on a large scale;
[0076] 4) when the coal seam gasification of the predetermined gasification position is done, determining stopping or reducing gasification agent injection according to the amount of the coal gasified, and heat value and composition of coal gas, and starting the injector head to move the oxygen/oxygen-enriched gas injection point to the next predetermined gasification position;
[0077] 5) conducting the next segment gasification channel process according to step 2), and completing the underground gasification of the predetermined coal seam area according to step 3) and 4); repeating those steps until the coal resource around the directional well channel is gasified completely;
[0078] wherein, the gas injection point segmental movement distance in the step 1) is 10˜150 m, the gasification flow rate during the gasification channel ignition and processing is limited within 300˜3000 m 3 /h, and the oxygen concentration by volume in the gasification agent is 21˜55%.
Embodiment 4
[0079] A controllable gas injection point gasification method, wherein reverse burning, gasification channel processing and gasification production is conducted by continuously or intermittently lifting the coiled tubing to make the gas injection point continuously move to the predetermined gasification position, and then adjusting the gas injection technology parameters.
[0080] The gasification method comprises of the following steps:
[0081] 1) according to the parameters such as thickness and reserve of gasifiable coal seam in gasification area, and continuously or intermittently lifting coiled tubing according to the gas injection process to make the gas injection point continuously move to the predetermined gasification position;
[0082] 2) adjusting the pressure and flow rate of a single gas and controlling the parameters such as flow rate, pressure and oxygen concentration of the injected gasification agent; achieving continuously processing gasification channel and underground gasification production on a large scale in a manner of reverse burning;
[0083] 3) adjusting the gasification agent injection parameters whenever necessary, to guarantee relative stable status of coal gas composition and heat value;
[0084] 4) when coal seam gasification of the predetermined gasification position is done, controlling reverse movement speed of coiled tubing according to burning speed of the coal gasification, heat value and composition of coal gas, and gasifiable coal seam storage situation, until the coal resource around the directional well channel is gasified completely;
[0085] wherein, the flow rate of the gasification agent in the step 2) is set to larger than 2000 m 3 /h, and the oxygen concentration by volume of gasification agent is 21˜95%; and wherein when the oxygen volume concentration is larger than 60%, water steam or water can be injected to adjust the temperature and gas quality in the cavity.
Working Example 1
[0086] The present example is to apply the controllable gas injection point gasification method of the present invention in the brown coal seam with low metamorphic degree. As lithology intensity of coal seam is low so that the borehole is easy to collapse and shrink, the present example select the directional horizontal well structure supported with glass fiber reinforced plastics sieve-tube, which has the common advantage of the present invention and is also beneficial to improve drilling stability and reduce drilling accident rate.
[0087] FIG. 3 shows an underground gasification furnace, wherein coal seam floor 9 is at a depth of 255 meters, coal seam roof 8 is at a depth of 238 meters, and the coal is lignite. The gasification furnace comprises directional well channel 6 , production well 10 , gasification burning channels, etc. The diameter of the directional well channel 6 is 177.8 mm. The supported glass fiber reinforced plastics sieve-tube at horizontal segment of the coal seam has diameter of 139.7 mm, length of 300 meters and opening rate of 15%. The gas injection apparatus with controllable gas injection point comprises coiled tubing 3 (diameter: 66.7 mm, pressure grade: 6.0 MPa, material:316 stainless steel), gas injection well head 2 , which comprises coiled tubing operating Bop (single side door style) and coiled tubing injector head (ZRT series coiled tubing injector head); and nozzle 4 (65 mm diameter, high temperature resistance up to 1200° C.).
[0088] In the example, the gas injection apparatus is employed to make gasification for the coal seam of the directional well channel 6 of the underground gasification furnace, as shown in FIG. 4 . The gasification operating pressure of the gasification furnace is 1.5 MPa and O 2 /CO 2 is used as gasification agent for gasification production of syngas. After the gasification furnace is successfully ignited and stable gasification burning area 7 is established i at the bottom of the production well 10 , directional drilling technology is employed to build up a directional well channel 6 in predetermined gasification coal seam, then the controllable gas injection point gasification production is carried out. The detailed process and implementing steps are as follows: (1) delivering coiled tubing along directional well channel 6 to the predetermined gasification position A through gas injection well head 2 by using the injector head; avoiding to send the oxygen nozzle into the burning zone directly; (2) injecting CO 2 into the annular space between the coiled tubing and directional well wall to conduct replacement protection for the channel with initial flow rate of 300˜400 Nm 3 /h; (3) slowly injecting oxygen into the degreased coiled tubing and through oxygen nozzle to mix with CO 2 injected through the annular space; (4) controlling the total amount of injected gasification agent and oxygen concentration, segmentally moving flame working face to the predetermined gasification position in the manner of reverse burning, and making gasification channel processing at the same time; the amount of the gasification agent for reverse ignition and processing channel is 500˜3000 Nm 3 /h and the oxygen concentration is 25˜35%; (5) after the channel ignition and processing is completed, gradually improving the injection amount of the gasification agent to 4000˜6000 Nm 3 /h, and the oxygen concentration to 60˜70% and then conducting coal gas production on a large scale; (6) when the gasification at the predetermined gasification position is completed, determining stopping or reducing gasification agent injection according to the condition of gasification coal burning amount, gas production heat value and composition, and starting the injector head and continuously moving coiled tubing 3 to make the oxygen injection point move to the next predetermined gasification position B; the distance between the predetermined gasification position A and B is 0˜100 m; (7) conducting gasification channel processing according to steps (2)-(4) and accomplishing the underground gasification of the predetermined area according to steps (4) and (5); repeating those steps until the coal resource around the directional well channel 6 is gasified completely.
Working Example 2
[0089] The present example is to apply controllable gas injection point gasification method of the present invention on the lean coal seam with high metamorphic degree. As coal seam lithology is good and intensity is high, the present example selects unsupported directional horizontal well structure, which has the common advantage of the present invention and is also beneficial to reduce furnace building cost and improve coal seam ignition efficiency.
[0090] FIG. 5 shows an underground gasification furnace, wherein coal seam floor 9 is at a depth of 957 meters, coal seam roof 8 is at a depth of 950 meters, and the coal is lean coal. The gasification furnace comprises directional well channel 6 , production well 10 , gasification burning channels, etc. The diameter of the directional well channel 6 is 177.8 mm. Bare hole segment 11 in horizontal well (the horizontal well of the coal seam has unsupported bare hole) is 200 meters long. The gas injection apparatus with controllable gas injection point comprises coiled tubing 3 (diameter: 50.8 mm, pressure grade: 6.0 MPa, material: 316 stainless steel, Jiang Su Dong Tai Hua Xuan Company), gas injection well head 2 , which comprises coiled tubing operating Bop (single side door style, Ao Lan Petroleum Company) and coiled tubing injector head (ZRT series coiled tubing injector head, Yan Tai Jie Rui Company) and nozzle 4 (50 mm diameter, high temperature resistance up to 1200° C., ENN Coal Gasification mining Co., Ltd.).
[0091] In the example, gas injection apparatus is employed to conduct gasification for the coal seam of the directional well channel 6 of the underground gasification furnace, as shown in FIG. 5 . The gasification operating pressure of the gasification furnace is 2.5 MPa and O 2 /CO 2 is used as gasification agent for gasification production of syngas. After the gasification furnace is successfully ignited and stable gasification burning area 7 is established at the bottom of the production well 10 , directional drilling technology is employed to build up directional well channel 6 in predetermined gasification coal seam and then controllable gas injection point gasification production is carried out. The detailed process and implementing steps are as follows: (1) delivering coiled tubing along directional well channel 6 to the predetermined gasification position A through gas injection well head 2 by using the injector head; avoiding to send the oxygen nozzle into the burning zone directly; (2) injecting CO 2 into the annular space between the coiled tubing and directional well wall to conduct replacement protection for the channel with initial flow rate of 400˜600 Nm 3 /h; (3) slowly injecting oxygen into the degreased coiled tubing and through oxygen nozzle to mix with CO 2 injected through the annular space; (4) controlling the total amount of the injected gasification agent and oxygen concentration, segmentally moving the flame working face to the predetermined gasification position in the manner of reverse burning, and conducting gasification channel processing at the same time; the gasification agent amount for reverse ignition and processing channel is 600˜3500 Nm 3 /h and the oxygen concentration is 25˜55%; (5) after channel ignition and processing is completed, gradually improving the injection amount of the gasification agent to 4000-7500 Nm 3 /h and oxygen concentration to 60˜70% and then conducting coal gas production on a large scale; (6) when the gasification at the predetermined gasification position is completed, determining stopping or reducing gasification agent injection according to the condition of the amount of coal gasified, gas production heat value and composition, and starting the injector head and continuously moving coiled tubing 3 to make the oxygen injection point move to the next predetermined gasification position B; the distance between the predetermined gasification position A and B is 0˜40 m; (7) conducting gasification channel processing according to steps (2)-(4) and accomplishing the underground gasification of the predetermined area according to steps (4) and (5); repeating those steps until the coal resource around the directional well channel 6 is gasified completely.
[0092] When the syngas (including H 2 , CO, CH 4 , CO 2 , H 2 O, etc.) produced by the gasification method of the present invention is delivered to the ground through the production well 10 and purified, the product mainly comprising H 2 , CO, CH 4 is obtained.
[0093] The applicant stated that the present invention employ the embodiments and examples above to describe the detailed structure feature and the gas injection and gasification methods of the present invention, but the present invention is not limited to the detailed structure feature and the injection and gasification methods above, i.e. it does not mean that the present invention must rely on the detailed structure feature and the gas injection and gasification methods above to implement. Persons skilled in the art should understand, any improvement of the present invention, the equivalent replacement to the raw materials of the present invention product, adding auxiliary ingredients, specific mode selection, etc. fall within the protection scope and disclosure scope of the present invention.
|
A gas injection apparatus with a controllable gas injection point, a gas injection process, and a gasification method. The gas injection apparatus comprises a directional well channel, where a continuous oil pipe is provided in the directional well channel. The continuous oil pipe is connected to an oxygen/oxygen-rich gas pipeline. An annular gap between the continuous oil pipe and the directional well channel is connected to an auxiliary gasification agent pipeline and a vapor pipeline. A gas injection wellhead is provided at the start end of the continuous oil pipe, and a nozzle is provided at the tail end. In the present invention, based on directional drilling and continuous oil pipe technologies, the movement of a gas injection point is implemented by using a manner of combining directional drilling and a continuous oil pipe; meanwhile, by using a principle of controlling reverse combustion by adjusting a gasification agent injection parameter, the movement of a working surface position and a combustion speed of a flame are regulated, so as to achieve the objective of ignition and gasification for reverse combustion of an underground coal layer.
| 4
|
This is a continuation of application Ser. No. 07/685,356 filed Apr. 15, 1992.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a superconducting conductor employing an oxide superconducting material.
2. Description of the Background Art
In recent years, superconductors of ceramics, i.e., oxide superconductors, have been watched with interest as superconducting materials which exhibit higher critical temperatures. In particular, superconductors of yttrium, bismuth and thallium, which show high critical temperatures of about 90 K, 110 K and 120 K respectively, are expected as practicable materials. A wire of such an oxide superconductor, which is covered with a metal sheath, is particularly suitable for long wire fabrication. Thus, study has been made as to application of such an oxide superconductor to a cable, a bus bar, a current lead, a magnet and the like.
However, it is difficult to independently apply such a high-temperature superconducting material to a cable, a current lead or the like, since there is some problem regarding strength.
Further the superconducting material must withstand a temperature cycles between the working temperature and the room temperature. Superconducting properties, particularly the critical current density, of a conventional superconducting conductor have problem reduced due to such a temperature change.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a superconducting conductor which has an excellent repeated temperature property with no reduction of critical current density against a temperature change.
The superconducting conductor according to the present invention comprises an oxide superconductor and a support member which is composed with the oxide superconductor to integrally operate with the same in thermal expansion and thermal shrinkage.
According to the present invention, the support member can be formed of a metal or a nonmetal. The metal can be prepared from silver, copper, aluminum, nickel or stainless steel, or an alloy or a composite material thereof, for example. The nonmetal may be prepared from plastic which is reinforced by an inorganic materials such as fiber reinforced plastic ("FRP") or carbon fiber reinforced plastic ("CFRP"), or crystallized polymer. Inorganic particles of alumina etc. can be also employed as the inorganic materials. Alternatively, the support member may be formed by a composite of different materials.
The oxide superconductor employed in the present invention may be prepared from any one of yttrium, bismuth and thallium. In particular, a bismuth oxide superconductor which contains a 2223 phase i.e., a 110 K phase, having a longitudinally oriented a-b plane, is most advantageously applied. Such a bismuth oxide superconductor is also preferable due to excellence in critical temperature and critical current density, small toxicity, and no requirement for rare earth elements.
The oxide superconductor employed in the present invention preferably has metallic coating. A metal for such metallic coating is preferably not reactive with the superconductor, and has excellent workability and such small resistivity that the same serves as a stabilizer. The metal, such as silver or a silver alloy, for example, is adapted to cover the high-temperature superconductor or to provide an intermediate layer between the high-temperature superconductor and its coat. In the latter case, the intermediate layer is coated with another metal such as copper or aluminum, or an alloy thereof.
According to the present invention, the oxide superconductor and the support member can be composed with each other by a mechanical or physical method such as taping, bonding with an adhesive agent, or diffused bonding.
The adhesive agent may contain fiber and/or particles. In particular, such an adhesive agent is preferably employed for composing a nonmetal support member and a superconducting wire which is coated with a metal, in view of reliability. When taping is employed, on the other hand, it is preferable to use a tape which is provided with a resin material having a bonding function. In this case, the resin material is hardened after taping.
The oxide superconductor employed in the present invention may be in the form of a tape. In general, powder of an oxide superconducting material is filled into a metal sheath, which in turn is drawn and compressed and/or rolled, to be shaped into a tape. It is known that such a tape-type wire generally exhibits a high critical current density.
Such a tape-type oxide superconductor is now described with reference to a bismuth oxide superconducting material, for example.
Powder, which is based on such a 2223 composition that 20% of bismuth is substituted by lead, is so treated that the superconducting phase is mainly composed of a 2212 phase. This powder is filled into a metal pipe, preferably a silver pipe, and subjected to deformation processing and heat treatment, in order to obtain a superconductor having a high target critical current density. When the powder is filled into the metal sheath in a submicron state, it is possible to obtain a superconducting conductor having a high uniformity.
The heat treatment temperature is properly selected depending on the heat treatment atmosphere. When the oxygen partial pressure is reduced, for example, the heat treatment temperature is set at a relatively low level.
The metal sheath is preferably formed of a material which is not reactive with the superconducting material and has excellent workability. For example, the metal sheath may be prepared from silver, a silver alloy, gold or a gold alloy, or provided with an intermediate layer of such a material. Further, the metal sheath preferably serves as a stabilizer under working conditions.
The oxide superconductor covered with such a metal sheath is preferably drawn at a draft of at least 80%. The draft for rolling is also preferably at least 80%. When the rolling is performed a plurality of times, the draft for a single pass is preferably at least 40%. When the rolling or drawing is again performed after the heat treatment, the draft may be 10 to 30%. The rolling may be performed with a roll or a press.
According to the present invention, the support member preferably has a linear expansion coefficient which is as close to that of the oxide superconductor as possible. Therefore, the linear expansion coefficient of the support member is preferably not more than 20×10 -6 /°C., more preferably, not more than 10×10 -6 /°C. The linear expansion coefficient of the composite superconducting conductor, which is varied with the sectional ratios of the superconductor, the metal sheath and the support member, is preferably not more than 10×10 -6 /°C., more preferably, not more than 10×10 -6 /°C.
According to a preferred mode of the present invention, the support member has a polygonal outer periphery. The oxide superconductor is composed with each outer peripheral plane.
According to another preferred mode of the present invention, the support member has an I-shaped α H-shaped section. The oxide superconductor is composed with at least one surface of the support member.
According to still another preferred mode of the present invention, the support member has a recess portion. The oxide superconductor is arranged in and composed with the recess portion. In this mode, a plurality of tape-type oxide superconductors may be superimposed and arranged in the recess portion.
According to a further preferred mode of the present invention, the support member is provided with a spiral groove on its outer peripheral surface. The oxide superconductor is arranged in the spiral groove. According to this mode, the superconducting conductor is advantageously applied to a coil due to the spirally arranged oxide superconductor.
In the superconducting conductor according to the present invention, the support member and the oxide superconductor are so composed with each other as to integrally move against thermal expansion and thermal shrinkage. Therefore, the superconducting conductor is improved in repeated temperature property, and can regularly effectuate stable superconducting properties against stress. Thus, it is possible to suppress reduction of the critical current density.
The superconducting conductor according to the present invention having such stable superconducting properties can be advantageously applied to a cable, a bus bar, a current lead, a magnet or the like.
These and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing Example 1 of the present invention;
FIG. 2 is a sectional view showing Example 2 of the present invention;
FIG. 3 is a perspective view showing Example 4 of the present invention;
FIG. 4 is a perspective view showing Example 5 of the present invention;
FIG. 5 is a perspective view showing a superconducting conductor according to Example 6 of the present invention;
FIG. 6 is a sectional view showing a superconducting conductor according to Example 7 of the present invention; and
FIG. 7 is a front elevational view showing a coil according to Example 8 of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
Powder materials of Bi 2 O 3 , PbO, SrCO 3 , CaCo 3 and CuO were blended so that Bi, Pb, Sr, Ca and Cu were in composition ratios of 1.80:0.40:2.01:2.21:3.02. The mixed powder was heat treated at 700° C. for 12 hours and 800° C. for 8 hours. Then the powder was heat treated at 760° C. for 8 hours in a decompressed atmosphere of 1 Torr. The powder was pulverized after each heat treatment.
This powder was pulverized with a ball mill, to obtain submicron powder. The submicron powder was degassed at 800° C. for 10 minutes in a decompressed atmosphere.
This powder was filled into a silver pipe of 12 mm in outer diameter, which in turn was drawn into 1.0 mm in wire diameter. The as-formed wire was rolled into 0.18 mm in thickness, to obtain a tape-type wire. This wire was heat treated at 850° C. for 50 hours, and rolled into 0.14 mm in thickness. Thereafter the wire was further heat treated at 840° C. for 50 hours.
The tape-type wire obtained in the aforementioned manner exhibited a critical current density of 1800 A/cm 2 at the liquid nitrogen temperature. This wire was cut into pieces of 50 cm in length, and bonded to outer peripheral surfaces of an FRP pipe having a decagonal outer periphery with an adhesive agent, to be composed with the FRP pipe.
FIG. 1 is a sectional view showing a superconducting conductor composed in the above manner. Referring to FIG. 1, 10 oxide superconductors 2 are mounted on outer peripheral surfaces of a decagonal FRP pipe 1 through bonding layers 4, to be integrally composed therewith. Each oxide superconductor 2 has an Ag sheath as a coating layer.
EXAMPLE 2
A tape-type wire of an oxide superconductor was prepared similarly to Example 1. This wire was composed with a decagonal FRP pipe also similarly to Example 1, but not with an adhesive agent. Pieces of the oxide superconductor were arranged around the FRP pipe, and bound with a Teflon tape.
FIG. 2 is a sectional view showing a superconducting conductor obtained in the above manner. Referring to FIG. 2, 10 oxide superconductors 6 are arranged around a decagonal FRP pipe 5, and bound with a Teflon tape 8. The oxide superconductors 6 are integrally composed with the FRP pipe 5 by the Teflon tape 8. The oxide superconductors 6 have Ag sheaths, 7 serving as coating layers.
COMPARATIVE EXAMPLE 1
A tape-type wire of an oxide superconductor was prepared similarly to Example 1. This wire was composed with a decagonal FRP pipe. Only both ends of the oxide superconductors were fixed to the FRP pipe with soldering themselves.
All composite superconducting conductors obtained according to Examples 1 and 2 and comparative example 1 showed linear expansion coefficients of 7×10 -6 /°C.
Critical current densities of these composite superconducting conductors were repeatedly measured at the liquid nitrogen temperature and the ordinary room temperature, to evaluate deterioration of the critical current densities after 10 cycles. As the result, the critical current densities of Example 1, Example 2 and comparative example 1 were reduced by 3%, 4% and 80% respectively.
EXAMPLE 3
The tape-type wire of the oxide superconductor prepared in Example 1 was composed with a decagonal silver pipe. The Ag sheath covering the oxide superconductor was brought into diffusion bonding with each outer surface of the silver pipe to be composed therewith in second heat treatment.
COMPARATIVE EXAMPLE 2
A tape-type wire was prepared similarly to Example 1. This wire was arranged around a silver pipe having a circular outer periphery. Dissimilarly to Example 3, it was impossible to join the surface of the oxide superconductor with the outer peripheral surface of the silver pipe since the peripheral surface of the silver pipe was in a circular configuration.
The as-formed composite superconducting conductor showed a linear expansion coefficient of 12×10 -6 /°C.
Critical current densities of the composite superconducting conductors according to Example 3 and comparative example 2 were also repeatedly measured at the liquid nitrogen temperature and the ordinary room temperature, to evaluate reduction of the critical current densities after 10 cycles. As the result, the critical current density of the superconducting conductor according to Example 3 was reduced by 8%, while that of the superconducting conductor according to comparative example 2 was reduced by 85%.
As clearly understood from the above, the critical current densities were not much reduced by temperature changes in the superconducting conductors according to Examples of the present invention, which were composed for integral movement.
EXAMPLE 4
Oxides or carbonates of Bi, Pb, Sr, Ca and Cu were mixed so that these metals were in composition ratios of 1.80:0.46:2.00:2.22:3.04, to prepare powder which was formed of a 2212 phase and non-superconducting phases by heat treatment.
This powder was degassed at 700° C. for 3 hours in a decompressed atmosphere of 8 Torr. This powder was filled into a silver pipe of 12 mm in outer diameter and 8 mm in inner diameter to be coated with silver, drawn into 1 mm in diameter, and then rolled into 0.2 mm in thickness, to prepare a wire.
This wire was heat treated at 845° C. for 50 hours, then rolled at a draft of 15%, and heat treated at 840° C. for 50 hours, to obtain a tape-type wire.
Superconducting properties of this tape-type wire were evaluated in a length of 20 m. As the result, the tape-type wire exhibited excellent properties of a critical current density of 24000 A/cm 2 and a critical current of 29 A in liquid nitrogen.
As shown in FIG. 3, a pair of such tape-type wires 11 of 50 cm in length were arranged on both sides of an FRP support member 12, and bonded thereto with an epoxy adhesive agent. The as-formed superconducting conductor showed stable superconducting properties, with no changes against 40 repeated temperature cycles between the room temperature and 77 K.
EXAMPLE 5
A wire similar to that of Example 4 was rolled at a draft of 15%. Five such wires were superimposed and heat treated at 840° C. for 50 hours.
As shown in FIG. 4, a pair of such tape-type wires 14 of 50 cm in length were bonded onto both sides of an FRP support member 13 with an epoxy adhesive agent, which contained cut pieces of glass fiber. This superconducting conductor exhibited a critical current of 320 A at the liquid nitrogen temperature, and showed stable superconducting properties against 100 temperature cycles between the room temperature and 77 K.
As described above, the superconducting conductors according to Examples 4 and 5 showed stable superconducting properties against repeated temperature cycles.
EXAMPLE 6
Oxides or carbonates containing Bi, Pb, Sr, Ca and Cu were mixed with each other so that these elements were in composition ratios of 1.77:0.46:2.01:2.20:3.01. The mixed powder was heat treated to prepare powder which was formed of a 2212 phase, containing Bi+Pb, Sr, Ca and Cu in composition ratios of about 2:2:1:2, and non-superconducting phase.
This powder was degassed at 700° C. for 3 hours in a decompressed atmosphere of 12 Torr.
The as-formed powder was covered with a silver pipe of 12 mm in outer diameter and 8 mm in inner diameter, drawn into 1 mm in outer diameter, and then rolled into 0.2 mm in thickness. This wire was heat treated at 840° C. for 50 hours, and then rolled at a draft of 15%.
The as-formed tape-type wire was cut into pieces of 50 cm in length. 10 such pieces were superimposed and heat treated at 840° C. for 50 hours.
As shown in FIG. 5, a pair of such decadal tape-type wires 23 were arranged in concave portions 22 provided on both sides of a support member 21, and bonded thereto with an epoxy adhesive agent.
The as-formed superconducting conductor exhibited a critical current of 250 A at the liquid nitrogen temperature. Further, this superconducting conductor showed stable superconducting properties, with no changes against 110 repeated temperature cycles between the room temperature and 77 K.
EXAMPLE 7
Oxides or carbonates containing Bi, Pb, Sr, Ca and Cu were mixed so that these elements were in composition ratios of 1.79:0.41:1.97:2.26:2.95. This mixed powder was heat treated to prepare powder which was formed of a 2212 phase and non-superconducting phases.
Then the powder was degassed at 720° C. for 5 hours in a decompressed atmosphere of 9 Torr.
The as-formed powder was covered with a silver pipe of 9 mm in outer diameter and 6 mm in inner diameter, drawn into 1 mm in outer diameter, and then rolled into 0.2 mm in thickness.
Eight such wires were superimposed and brought into diffusion bonding with each other, heat treated at 840° C. for 50 hours, and thereafter rolled at a draft of 15%.
The as-formed wire was cut into a length of 50 cm, and heat treated at 840° C. for 50 hours.
As shown in FIG. 6, such octal tape-type wires 24 were bonded to recess portions 26 of an octagonal FRP support member 25 with an epoxy adhesive agent, similarly to Example 6. The epoxy adhesive agent contained cut pieces of glass fiber.
The as-formed superconducting conductor exhibited a critical current of 770 A at the liquid nitrogen temperature. Further, this superconducting conductor showed stable properties against 100 temperature cycles between the room temperature and 77 K.
EXAMPLE 8
Oxides or carbonates containing Bi, Pb, Sr, Ca and Cu were mixed with each other so that these elements were in composition ratios of 1.78:0.44:1.99:2.23:2.98. This mixed powder was heat treated to prepare powder which was formed of a 2212 phase and non-superconducting phases.
This powder was degassed at 710° C. for 8 hours in a decompressed atmosphere of 4 Torr.
The as-formed powder was covered with a silver pipe of 12 mm in outer diameter and 8 mm in inner diameter, drawn into 1 mm in outer diameter, and then inserted in a silver pipe having a larger diameter, to prepare a multicore wire having 1296 cores. The multicore wire was drawn into 1 mm in outer diameter, and then rolled into 0.17 mm in thickness.
Five such tape-type wires were superimposed and brought into contact with each other, heat treated at 840° C. for 50 hours, rolled at a draft of 12%, and further heat treated at 840° C. for 50 hours.
As shown in FIG. 7, such a tape-type wire 27 was wound on an FRP bobbin 29, which was provided with a spirally extending groove 28 on its outer peripheral surface. The wire 7 was bonded to the bobbin 29 with epoxy resin. Thus, a coil of 15 mm in inner diameter and 60 mm in height was prepared as shown in FIG. 7.
This coil exhibited a critical current of 60 A at the liquid nitrogen temperature. Further, this coil showed stable properties against 100 temperature cycles between the room temperature and 77 K. Also when an external magnetic field was applied, this coil showed stable properties with no movement of the wire 27.
Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims.
|
A superconducting conductor, having an excellent repeated temperature property with no reduction of critical current density against a temperature cycle, comprises an oxide superconductor and an fiber reinforced plastic ("FRP"), serving as a support member, which is composed with the oxide superconductor for integrally moving with the oxide superconductor in thermal expansion and thermal shrinkage. The oxide superconductor is bonded to the FRP with an adhesive agent, or wound on and fixed to the same with a Teflon tape or the like.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates in general to the field of information handling system cooling, and more particularly to dual mode portable information handling system cooling.
2. Description of the Related Art
As the value and use of information continues to increase, individuals and businesses seek additional ways to process and store information. One option available to users is information handling systems. An information handling system generally processes, compiles, stores, and/or communicates information or data for business, personal, or other purposes thereby allowing users to take advantage of the value of the information. Because technology and information handling needs and requirements vary between different users or applications, information handling systems may also vary regarding what information is handled, how the information is handled, how much information is processed, stored, or communicated, and how quickly and efficiently the information may be processed, stored, or communicated. The variations in information handling systems allow for information handling systems to be general or configured for a specific user or specific use such as financial transaction processing, airline reservations, enterprise data storage, or global communications. In addition, information handling systems may include a variety of hardware and software components that may be configured to process, store, and communicate information and may include one or more computer systems, data storage systems, and networking systems.
Information handling systems provide a wide range of performance capabilities based upon the type of components included in the system. For example, processing capability depends upon the number of instructions that a processor can execute in a given time period. To make effective use of a powerful processor, the system typically needs a sufficient quantity of RAM for storing instructions and high capacity links to communicate information between the processor and desired components. In some instances, processor performance is enhanced by moving processing functions from a central processor unit (CPU) to supporting processors. For example, a graphics processor unit (GPU) executes instructions under the direction of a CPU to generate images for presentation at a display. In general, more powerful information handling systems have a larger housing to hold components. A larger-sized housing typically allows more room for the components and for supporting equipment, such as cooling fans. Typically, more powerful processing components tend to have greater amounts of heat generated as a by-product of processing instructions. The heat is removed by heat sinks and cooling fans that blow air over the components and out of the housing. A larger-sized housing provides more room for heat transfer devices and cooling airflow. In some instances, cooling is accomplished by passing a contained liquid flow proximate the heat-generating component since liquid typically provides a more efficient heat transfer medium than air.
Difficulties with heat transfer tend to increase as the size of an information handling system housing decreases. Portable information handling systems generally have relatively small housings so that an end user can hold the system during use. Portable information handling systems typically incorporate an integrated display and battery power source so that an end user can operate the system free from any external interfaces. In order to reduce system size and weight, components are often selected to build portable information handling systems so that heat generation and power consumption by the components fall within tight constraints. As a result, portable information handling systems typically have reduced processing capabilities relative to desktop or tower systems. Further, portable information handling systems often include power and cooling system logic that attempts to alter system operations to extend battery life and avoid overheating. One example of a way to avoid excessive power consumption and heat generation is to run a processor at a reduced speed, however, running a processor at reduced speed also reduces system performance. An end user may find reduced performance acceptable for some functions, such as word processing, however other functions often need full system performance to provide meaningful use to an end user, such as for gaming. In any event, the capability of a processor included with a portable information handling system is limited by the ability of the system to remove excess heat generated by the processor, which in turn is for practical purposes generally limited by the size of the housing.
SUMMARY OF THE INVENTION
Therefore a need has arisen for a system and method which supports dual mode portable information handling system cooling.
In accordance with the present invention, a system and method are provided which substantially reduce the disadvantages and problems associated with previous methods and systems for cooling a portable information handling system. Liquid cooling is selectively applied at a heat transfer device within an information handling system to supplement cooling otherwise available, such as passive cooling or cooling provided by airflow from a fan. When liquid cooling is available, processing components having the supplement cooling can operate at greater speeds since excess heat created by the greater operating speeds is removed by the liquid cooling. When liquid cooling is not available, processing components operate in a throttled condition as needed to maintain thermal constraints.
More specifically, a portable information handling system housing contains processing components that cooperate to process information, a display to present information and a battery to power the processing components and display. A cooling fan generates cooling airflow across a thermal transfer device, such as heat sink or heat pipe, to remove thermal energy generated as a by-product of the operation of one or more processing components. A cold plate disposed in the housing proximate the thermal transfer device accepts thermal energy from the thermal transfer device to liquid of a liquid cooling device. The liquid cooling device liquid removes thermal energy to the environment external to the housing with a pump and radiator disposed external to the housing. The liquid cooling device is selectively removable from information handling system 10 , such as by disconnecting tubes of the liquid cooling system from the housing or removing the cold plate from the housing. When liquid cooling is available, processing components can operate at greater speeds that generate excess heat with the liquid cooling supplementing other cooling available at the information handling system. When liquid cooling is not available, processing components within the information handling system operate at throttled speeds to prevent overheating.
The present invention provides a number of important technical advantages. One example of an important technical advantage is that a portable information handling system includes selectively-activated processor liquid cooling that will allow powerful processors to operate at high speeds with minimal impact on housing size. An external liquid pump conveniently adds system cooling when desired in both a portable and fixed configuration. For example, including a liquid pump with an AC-DC adapter provides ready availability when operating on external power while a USB interface provides power for liquid pumping when operating on internal power. Alternatively, including liquid cooling with a housing cradle supports full system capabilities when in a fixed configuration that are not otherwise available in portable systems due to limitations of air cooling. A removable cooling plate that couples and decouples proximate to a heat sink or heat pipe maintains liquid cooling fluids in a separate integrated system for ready use with limited risk of spilling the fluid. When liquid cooling is unavailable, the processor or other heat-generating device continues to operate at a lower capability within the limits of air cooling.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood, and its numerous objects, features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. The use of the same reference number throughout the several figures designates a like or similar element.
FIG. 1 depicts an information handling system in a portable housing having a selectively removable liquid cooling system interfaced with a processor heat transfer device;
FIG. 2 depicts a liquid cooling system cold plate affixed to a heat pipe;
FIG. 3 depicts a portable information handling system aligned to receive liquid cooling from a docking station cradle; and
FIG. 4 depicts an external liquid cooling pump powered by an external information handling system AC/DC adapter or a USB connection with the information handling system.
DETAILED DESCRIPTION
Selective configuration of liquid cooling at a portable information handling system supports enhanced processing capability when liquid cooling is available and light weight portability when liquid cooling is removed. For purposes of this disclosure, an information handling system may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, an information handling system may be a personal computer, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The information handling system may include random access memory (RAM), one or more processing resources such as a central processing unit (CPU) or hardware or software control logic, ROM, and/or other types of nonvolatile memory. Additional components of the information handling system may include one or more disk drives, one or more network ports for communicating with external devices as well as various input and output (I/O) devices, such as a keyboard, a mouse, and a video display. The information handling system may also include one or more buses operable to transmit communications between the various hardware components.
Referring now to FIG. 1 , an information handling system 10 in a portable housing 12 has a selectively removable liquid cooling system 14 interfaced with a processor heat transfer device 16 . Information handling system 10 includes plural processing components that cooperate to process information, such as a central processing unit (CPU) 18 , RAM 20 , hard disk drive 22 , chipset 24 and graphics processing unit (GPU) 26 . Information handling system 10 has a portable configuration that allows operation without external devices, such as with an integrated display 28 for presenting information as visual images and a battery 30 for powering the processing components. During portable operations, a power manager 32 directs battery 30 to power components. If external power is available, an external AC/DC adapter 34 provides power to the components and to charge battery 30 . A fan 36 disposed within housing 12 generates a cooling airflow past the processing components and heat transfer device 16 to carry heat through a vent 38 and out of housing 12 .
Removable liquid cooling system 14 selectively interfaces cooling liquid with heat transfer device 16 to provide additional cooling for the processing components, such as CPU 18 . For example, a pump 40 draws a water glycol mixture from information handling system 10 through an exhaust tube 42 to a radiator 44 , which transfers heat from the liquid to the atmosphere external to information handling system 10 , such as with a fan in radiator 44 that blows cooling past heat transfer portions in radiator 44 . Pump 40 then draws cooled liquid from radiator 44 through a transfer tube 46 and provides the cooled liquid through an intake tube 48 back to information handling system 10 . Intake tube 48 and exhaust tube 42 selectively interface through connectors 50 to a cold plate 52 disposed within housing 12 . When connectors 50 couple to cold plate 52 , liquid from pump 40 is in fluid communication with cold plate 52 to aid in cooling heat transfer device 16 . When connectors 50 decouple from cold plate 52 , liquid is not available for cooling heat transfer device 16 so that cooling is accomplished by fan 36 without the aid of liquid cooling. A thermal manager 54 monitors temperatures within housing 12 and at the processing components to ensure that thermal constraints are not exceeded. For example, without the availability of liquid cooling, thermal manager 54 constrains the operating speed of CPU 18 to prevent the generation of excess thermal energy and run fan 36 at higher speeds; with the availability of liquid cooling thermal manager 54 allows operation of CPU 18 at full speed and minimizes the speed of fan 36 to reduce power consumption and noise. In alternative embodiments, other processing components, such as GPU 26 , are cooled with liquid cooling or throttled in the absence of liquid cooling. In one embodiment, CPU 18 is designed to require liquid cooling in order to operate at full speed, such as to support gaming applications, with a throttled state to provide minimal functionality without liquid cooling, such as to support word processing or web browsing activities.
In the example embodiment depicted by FIG. 1 , pump 40 and a fan in radiator 44 obtain power from a selected of plural power sources. Power may come from an external power source 56 , such as an AC outlet. Alternatively, AC/DC adapter 34 that provides power to information handling system 10 can also provide power to pump 40 . As a third alternative, power is provided from battery 30 of information handling system 10 through an external interface, such as a USB ports 58 located at housing 12 and pump 40 and a USB cable 60 . In most circumstances, a constant speed pump 40 provides adequate liquid flow for cooling across the operational thermal range of information handling system 10 . In an alternative embodiment, the speed or operation of pump 40 is managed through communication across USB cable 60 . For example, pump 40 is operated at a slow speed or intermittently to maintain a desired thermal condition at heat transfer device 16 while reducing noise and power consumption.
Referring now to FIG. 2 , a liquid cooling system cold plate 52 is affixed to a heat pipe 62 . Heat pipe 62 provides a thermal conduction path from processor 18 to a radiator 19 disposed in a cooling airflow generated by fan disposed beneath radiator 19 . Processor 18 is disposed beneath a heat sink 64 that spreads heat generated by processor 18 to the heat pipes 62 . Cooling plate 52 is affixed to heat pipe 62 in a permanent fashion, such as with solder or screws, so that high thermal conduction is available from heat pipe 62 to liquid disposed in cold plate 52 . Liquid cooling is applied to cold plate 52 by selectively engaging liquid or disengaging liquid with a sealed connection accessible at the housing of information handling system 12 . In alternative embodiments, cold plate 52 may include an attachment device that selective attaches and detaches with a thermally-conductive material that is in thermal connection with a cooling liquid. Affixing cold plate 52 in a permanent manner provides optimal thermal conduction, however, removable coupling and de-coupling of cold plate 52 or a portion of cold plate 52 to heat pipe 62 provides adequate thermal conduction with the advantage of keeping cooling liquid within a contained environment without having to rely on sealed connectors.
Referring now to FIG. 3 , a portable information handling system is aligned to receive liquid cooling from a docking station cradle 66 . Docking station cradle 66 has a connector 68 to support power and peripheral interactions with information handling system 10 as with a conventional cradle, however, includes a cold plate 52 aligned to insert into an opening 70 formed in the bottom surface of information handling system 10 . Cold plate 52 is in liquid communication with pump 40 and radiator 44 of cradle 66 so that liquid cooling is available through cold plate 52 to a heat sink 16 or other heat transfer device within the housing 12 of information handling system 10 . Opening 70 is selectively closed when information handling system 10 is removed from cradle 66 to prevent end user interaction with heated internal components of information handling system 10 . When docked at cradle 66 with liquid cooling provided by cold plate 52 to heat sink 16 , information handling system can operate with increased processing speeds because excess thermal energy is removed from housing 12 with liquid cooling. When undocked so that liquid cooling is not available, a fan 36 provides cooling adequate to support operations with lower processor speeds.
Referring now to FIG. 4 , an external liquid cooling pump 40 is powered by an external information handling system AC/DC adapter 34 or a USB connection 58 with the information handling system 10 . AC/DC adapter 34 , pump 40 and radiator 44 are coupled together in a contiguous piece for ease of operation. In an alternative embodiment, AC/DC adapter 34 selectively separates from pump 40 to provide power without liquid cooling. Cold plate 52 inserts into a side opening 72 of housing 12 to a position proximate a heat transfer device within housing 12 . Although a removable cold plate may not provide as much thermal conduction as a cold plate that is affixed within housing 12 , a biasing mechanism within housing 12 provides adequate physical contact between removable cold plate 52 and the internal heat transfer device so that thermal conduction between the internal heat transfer device and liquid associated with cold plate 52 takes place. Having cold plate 52 as a removable component allows liquid to remain in a contained environment to help reduce the risk of inadvertent leaks that might damage electronic components.
Although the present invention has been described in detail, it should be understood that various changes, substitutions and alterations can be made hereto without departing from the spirit and scope of the invention as defined by the appended claims.
|
Liquid cooling is selectively enabled at a portable information handling system to provide enhanced processing capabilities when needed or desired. A liquid cooling cold plate conducts thermal energy from a processing component heat pipe or heat sink to a liquid pumped from external to the information handling system housing. The pump operates with power provided from an AC/DC adapter of the information handling system or power provided from an interface with the information handling system, such as a USB port and cable. Alternatively, liquid cooling is included in a cradle to automatically engage with the information handling system is coupled to the cradle.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 10/514,817, filed on Nov. 12, 2004, which is a U.S. national phase of International Application No. PCT/EP03/01847 filed Feb. 24, 2003, which claims priority to German Application No. 102 23 560.0, filed May 27, 2002. The entire disclosure of each of the above-identified applications is incorporated herein by reference.
BACKGROUND
[0002] The disclosure relates to a connector for packaging containing medical fluids, in particular infusion or transfusion bags, which serves to extract a fluid from the bag. Moreover, the disclosure relates to packaging for medical fluids, in particular an infusion or transfusion bag, with such a connector.
RELATED TECHNOLOGY
[0003] WO 96/23545 describes an infusion bag with an injection part and an extraction part. The injection part serves to feed a drug by means of an injection syringe. It comprises a tubular connection part, which is sealed by a protective cap designed as a break-off part. A self-sealing septum sits in the opening area of the connection part, whilst a membrane capable of being pierced is arranged in the connection part, so that the septum does not come into contact with the solution before the use of the infusion bag. The extraction part serves to extract the solution by means of a spike. The extraction part does not have a self-sealing septum, otherwise the structure is similar to that of the injection part.
[0004] A connector for the extraction of an infusion solution is also described in DE 197 28 775 C2. The tubular connection part of the known extraction part is sealed by a flat membrane, which is in one piece with the connection part.
[0005] The known extraction parts have been tried and tested in practice. A drawback, however, consists in the fact that the infusion bag is not sealed again after the spike has been withdrawn. There is therefore the risk of the infusion solution running out. This is particularly critical after the addition of cytostatic drugs.
[0006] A further drawback is that the connection between the spike and the extraction part is not secured against slipping out. When the bag is hanging on the stand, there is the risk of the connection of the spike arid the extraction part being separated due to unintentional tugging on the flexible-tube line.
[0007] There is also the drawback that the injected membrane, which seals the connection part of the extraction part, does not always withstand greater mechanical loads. Thus, it has been shown in drop tests that the membrane of individual extraction parts ruptured.
SUMMARY
[0008] The problem underlying the disclosure is to provide a connector for packages containing medical fluid, in particular infusion or transfusion bags, which reliably seals the packaging after the withdrawal of the spike.
[0009] Accordingly, the disclosure provides a connector for packages containing medical fluids, including a tubular connection part for receiving a spike for the extraction of the fluid, the connection part having upper and lower openings, a break-off sealing part, a self-sealing membrane that can be pierced by the spike for the extraction of the fluid and having a circular upper portion, which transforms into a dish-shaped lower portion to form a trough-shaped recess, wherein a portion of the membrane sealing surrounds the spike when the spike pierces the dish-shaped portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The figures show the following:
[0011] FIG. 1 illustrates a connector designed as an extraction part for packages containing medical fluids in sectional representation,
[0012] FIG. 2 illustrates an infusion bag with the extraction part of FIG. 1 and an injection part and
[0013] FIG. 3 illustrates the injection part of the infusion bag of FIG. 2 in sectional representation.
DETAILED DESCRIPTION
[0014] The connector according to the disclosure has a self-sealing membrane, which is arranged in the connection part for accommodating the spike for the extraction of the fluid. The self-sealing membrane prevents the fluid from running out of the packaging after withdrawal of the spike.
[0015] It is advantageous that the self-sealing membrane has a circular portion, which transforms into a dish-shaped portion, whereby the circular portion of the membrane surrounds the spike in a sealed manner when it pierces the dish-shaped portion.
[0016] The special formation of the membrane with the circular and dish-shaped portion on the one hand ensures that the spike is guided reliably when it pricks the membrane and on the other hand guarantees that the membrane is again reliably sealed after withdrawal of the spike even in the presence of relatively high internal pressure in the packaging. It has been shown in tests that the special formation of the membrane is decisive for immediate re-sealing, whereby the sealing of the membrane is further enhanced with increasing pressure in the packaging. The reliable sealing can be traced back not to the volume of material, but to the special geometry of the membrane.
[0017] In a preferred form of embodiment of the connector, the material of the dish-shaped portion of the membrane is weakened, so that the membrane can be particularly easily pierced by the spike. The membrane is preferably pre-slit in the form of a cross. It can also be pre-slit in the form of a star or only be provided with a simple slit.
[0018] In a particularly preferred form of embodiment, the tubular connection part of the connector consists of a lower and an upper section, whereby the sections are fixed in a snap-in manner. The self-sealing membrane is preferably held clamped with elastic deformation of the same between the lower and upper section. Consequently, the fitting of the connector can be carried out in a straightforward manner by pressing of the individual parts. It is however also possible for the individual parts to be welded and/or glued together.
[0019] A further particularly preferred form of embodiment makes provision such that an outer portion, which is clamped between the two sections, follows on from the circular portion of the membrane.
[0020] In order to prevent the self-sealing membrane in the tubular connection piece from coming into contact with the solution contained in the infusion and transfusion bag prior to the use of the latter, a second membrane capable of being pierced is preferably arranged beneath the self-sealing membrane thereby forming an intermediate space. The second membrane is expediently a one-piece component of the tubular connection piece.
[0021] It has been shown in tests that the use of a membrane curved upwards or downwards instead of a flat membrane leads to an increase in drop strength. Since the second membrane is designed curved upwards or downwards, the connector according to the invention withstands relatively great mechanical loads. Apart from the increase in drop strength, there is also the advantage that the spike in the pierced position is held clamped by the curved membrane. The retention force of the spike in the withdrawal position is thus increased, as a result of which unintentional slipping out is prevented.
[0022] In order to secure the upper and lower part of the connection piece against radial torsion, both parts can have toothing or the like, which also ensures precise alignment of the parts during pressing together. Furthermore, the risk of damage to the two membranes is especially low during the pressing together of the individual parts.
[0023] The break-off sealing part of the connector, which serves as an originality seal, is preferably connected to the connection part via a circular rupture zone.
[0024] Since the break-off sealing part preferably has a grip part, which is designed in the manner of an arrow pointing upwards, it can immediately be recognized that the connector is an extraction part, but not an injection part. Preferably, the arrow is a recess in the grip part, which is immediately recognizable without lettering or the like being necessary. Confusion between the extraction and injection part of a package containing medical fluids can thus be avoided.
[0025] The lower part of the connection piece also preferably has an arrow pointing upwards, which is designed as a raised structure, preferably in a recessed grip. The upward-pointing arrow of the lower connection-piece part also permits the connector to be unequivocally assigned as the extraction part after breaking-off of the sealing part.
[0026] An example of an embodiment is explained in greater detail below by reference to the drawings.
[0027] Connector 20 designed as an extraction part for packages containing medical fluids, in particular infusion or transfusion bags, has a tubular connection part 1 , which includes a package-side lower section 2 and a connection-side upper section 3 . Tubular connection part 1 therefore has an upper and a lower opening 1 a, 1 b. Connector 20 is an injection-moulded part made of polypropylene.
[0028] Lower section 2 of tubular connection part 1 has a lower cylindrical portion 4 , which transforms into an upper sleeve-shaped portion 5 . Cylindrical portion 4 of lower section 2 can be inserted into a connection socket of a film bag and can be welded or glued to the socket or be directly welded into the film bag without a socket. Cylindrical portion 4 is sealed at its upper end with a membrane 6 capable of being pierced, said membrane being a single-piece component of lower section 2 . The injected membrane is curved downwards. Alternatively, however, the membrane can also be curved upwards.
[0029] Upper section 3 of tubular connection part 1 is fixed in a snap-in manner on lower section 2 , whereby upper section 3 has a cylindrical portion 7 which surrounds lower section 2 . The internal wall of cylindrical portion 7 of upper section 3 has a peripheral groove 8 , into which a peripheral projection 9 on the outer wall of sleeve-shaped portion 5 of lower section 2 snaps when the two sections 2 , 3 are pressed together.
[0030] A self-sealing membrane 10 made of an elastic material, which is also referred to as a septum, is held clamped with elastic deformation of the same between the lower and upper section 2 , 3 of tubular connection part 1 . Self-sealing membrane 10 has an outer portion 11 , which is clamped between lower and upper sections 2 , 3 of circular connection part 1 . Outer portion 11 is followed by an upper circular portion 12 , which transforms into a lower dish-shaped portion 14 thereby forming a trough-shaped recess 13 at the upper side of membrane 10 . Dish-shaped portion 14 is pre-slit in the form of a cross or a star in centre 15 , so that the elastic material is weakened, but is not severed.
[0031] Upper section 3 of tubular connection part 1 is followed, via a circular rupture zone 31 , by a cap-shaped sealing part 16 , which seals upper opening 1 a of connection part 1 . Sealing part 16 transforms into a flat grip part 17 , which is provided with a recess 18 in the shape of an arrow 19 pointing upwards. It can immediately be recognized from the direction of arrow 19 that connector 20 is not injection part 40 , but rather the extraction part.
[0032] The side view of connector 20 of FIG. 1 is shown in FIG. 2 . FIG. 2 shows an infusion bag 21 filled with infusion solution, which has connector 24 for the extraction of the infusion solution and a further connector 40 for the injection of a solution into infusion bag 21 .
[0033] On the outer wall of cylindrical portion 7 of upper section 3 , tubular connection part 1 of connector 20 has two recessed grips 21 lying opposite one another, which are each formed by projecting webs 22 which are arranged at a distance from one another. A further arrow 23 , which also points upwards in order to identify connector 20 as the extraction part, is formed as a raised structure on the outer wall of cylindrical portion 7 between webs 22 .
[0034] Infusion bag 21 comprises two film layers 24 , which are welded together at lower and upper edge 25 , 26 and also at longitudinal edges 27 , 28 . Two connections sockets 29 , 30 are welded into upper edge 25 of the infusion bag. The tubular connection pieces of injection and extraction part 40 , 20 are inserted into connection sockets 29 , 30 and connected with the sockets during sterilization. The tubular connection pieces of the originality seals can however also be molded onto an insert that is round or designed in the manner of a boat, said insert being welded in between the two film layers.
[0035] FIG. 3 shows injection part 40 of film bag 21 in a sectional representation. Injection part 40 has a similar structure to extraction part 20 . The parts corresponding to one another are therefore provided with the same reference numbers. Injection part 40 has a tubular connection part 1 ′, which consists of a lower and an upper section 2 ′, 3 ′. The two sections 2 ′, 3 ′ are fixed in a snap-in manner with the interposition of a self-sealing membrane 10 ′, whereby a projecting shoulder 8 ′ of lower section 2 ′ engages in a groove 9 ′ of upper section 3 ′. Flat membrane 6 ′, which however can also be curved, is injected into lower section 2 ′.
[0036] Upper section 3 ′ of tubular connection part 1 ′ is again followed, via a circular rupture zone 31 ′, by a cap-shaped break-off part 16 ′, which transforms into a flat grip part 17 ′. An arrow 19 ′ pointing downwards is designed as a recess in grip part 17 ′. Arrows 23 ′ pointing downwards to indicate the flow direction are located on the outer wall of upper section 3 ′ again inside recessed grips 21 ′.
[0037] For the extraction of infusion solution, break-off part 16 of extraction part 20 is broken off by turning or breaking the same, so that self-sealing membrane 2 is laid bare. The spike of a known transfer system is pushed into tubular connection part 1 of extraction part 20 , as a result of which pre-slit membrane 10 is pierced and membrane 6 curved downwards is penetrated. Trough-shaped recess 13 serves as a guide for the spike. The spike is sealed by circular portion 12 of membrane 10 . On account of the special formation of injected membrane 6 , the spike is held firmly in tubular connection part 1 .
[0038] The infusion solution can then be extracted. When the spike is again withdrawn, self-sealing membrane 10 reliably seals extraction part 20 even in the presence of a relatively high internal pressure. Moreover, the mechanical strength of extraction part 20 is increased by the special formation of injected membrane 6 .
[0039] Injection part 40 serves to inject an active substance into the infusion solution. For this purpose, self-sealing membrane 10 ′ and injected membrane 6 ′ are again pierced with the injection needle of a syringe after removal of break-off part 16 ′. The injection part is again sealed after withdrawal of the needle.
[0040] It is to be understood that the foregoing description is intended to illustrate and not to limit the scope of the invention, which is defined by the scope of the appended claims. Other embodiments are within the scope of the following claims.
|
The disclosure relates to a connector for packaging containing medical fluids, in particular infusion or transfusion bags, including a tubular connection part for receiving a spike for the withdrawal of fluid, and having a lower opening on the packaging side and an upper opening on the connection side. A self-sealing membrane, which is pierced by the spike, is located in the connection part. The membrane has an upper, annular section leading into a lower, plate-shaped section, said annular section of the membrane surrounding the spike in a sealing manner, when the latter pierces the plate-shaped section. The membrane acts as a guide for the spike and also reseals the connector, once the spike has been removed.
| 0
|
FIELD OF THE INVENTION
This invention relates to programming memory controllers for computer systems.
BACKGROUND OF THE INVENTION
In computer system operations, a memory controller (MC) driven by a Central Processing Unit (CPU) interacts with an outside memory. A CPU in a single integrated circuit chip is often referred to as a microprocessor. A memory controller may be outside of the microprocessor chip or it may reside inside. An MC resident inside the microprocessor chip can operate at the speed of the processor clock, which indicates the computer speed. In modern, high performance computer systems, synchronous dynamic random access memory (SDRAM) is typically used as the outside memory. The clock for the SDRAM operates at a speed many times lower than the processor clock.
Signals passing between the MC and the SDRAM take a finite time to travel, and both the MC and the SDRAM take a finite time to respond. Thus, time delays are associated with the finite speed of signal travel and the finite response time of a device or a system. These time delays have their origins in the physical processes involved in the construction and operation of electronic devices that make up the computer system. Therefore, various time delays encountered in computer operations can be minimized or optimized, but cannot be eliminated. Reliable computer design must take into account all significant time delays affecting computer operation.
Certain time delays are always significant, and thus must be taken into account in the design of the MC for input/output operations. Significance of some other time delays is measured with respect to the time period of the processor clock. Therefore, as the computer speed increases, various additional time delays have to be taken into account to ensure reliable operation of the MC. In computer input/output operations involving an MC and a SDRAM, signals originating in the MC do not appear instantaneously at the SDRAM, and vice-versa, due to propagation delays. Further, various time delays associated with a SDRAM depend on that specific SDRAM and its actual physical layout in the computer circuit board. Thus, the signaling delays between an MC and a SDRAM vary from system to system due to different types of system configurations and memory performance specifications.
Computer operations such as the input/output (I/O) operations are synchronized with the processor clock. The I/O operations take place around precise digital transitions in logic gates and flip flops constituting digital devices and systems. In order to make computer operations reliable, (e.g., a data read from a memory) it is necessary to hold a participating signal (e.g., a command signal) stable for a short time before and after the precise transition moment. Such time considerations, together with the various time delays mentioned earlier, constitute a significant fraction of the clock time period.
A memory controller in a digital computer typically will have the capability of generating a replica of the processor clock signal delayed by half a time period. This creates a digital time delay unit of half a processor clock period. This digital time delay unit along with the aforementioned analog time delays inherently present in the computer system dictates the programmed design of the MC for reliable input/output operations with the SDRAMs.
Digital signals for communications between the MC and the SDRAM fall into three categories: clock signals; command signals; and data signals. In a computer system, multiple signal lines constitute both the command and data paths. All communicating I/O signals must be designed to flow in concert in order to produce the right digital transitions at the right time. Precise timing designs of all these signals may be done, for example, by “Firmwire”, which is an embedded software contained in an erasable Programmable Read Only Memory (EPROM) or a flash memory. The present technique of MC programming design has been to use a spreadsheet to store all possible timing combinations and to manually design suitable solutions. Such exercises are specific for a particular system configuration. This becomes more difficult as the number of time delay elements to be considered increases with the increase in processor clock speed, and design may not be optimized for highest achievable performance. It has become necessary, therefore, to define the design problem with mathematical precision and create a general algorithm to solve it.
SUMMARY OF THE INVENTION
In one aspect, the invention relates to a method for programming a controller of a memory unit comprising: inputting a plurality of initialization parameters of the memory unit; calculating a clock delay and a command delay for each initialization parameter; calculating a set of read command delays for each pair of clock delays and command delays; calculating a set of write command delays for each pair of clock delays and command delays; calculating a system performance for each pair of clock delays and command delays; selecting the initialization parameter that offers the optimum system performance.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a schematic diagram of a computer system showing a processor interconnected with an external memory controller and a memory (SDRAM).
FIG. 1 b is a schematic diagram of a computer system showing a processor with an internal memory controller connected to a memory (SDRAM).
FIG. 2 is a block diagram describing SDRAM access by a memory controller.
FIG. 3 is a timing diagram describing SDRAM read and write operations.
FIG. 4 is a timing diagram depicting analog delays of various computer signals.
FIG. 5 is a timing diagram showing clock and command signal programming.
FIG. 6 is a timing diagram describing SDRAM read operation.
FIG. 7 is a timing diagram describing SDRAM write operation.
FIG. 8 is an algorithmic flowchart describing timing parameter calculations for programming a memory controller in accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to methods for programming memory controllers to correctly and optimally perform input/output operations with outside memory like a SDRAM. The method of the invention provides systematic analysis of various time delays and time constraints inherently present in the operation of devices and systems like a SDRAM. Deliberate programmable time delays may be introduced at the MC to serve as design elements. One such time delay element is the processor clock time period, which is the smaller digital time unit. The other is the SDRAM clock time period, the larger digital time unit. With these two digital time delay input parameters, along with an analog delay element (SDRAM device parameters and system input parameters involving propagation delays), correct and optimal timings in communications between an MC and a SDRAM are then systematically designed. Exemplary embodiments of this systematic method for programming an MC to provide high speed and efficient input/output operations with an external memory are described below with reference to the attached Figures.
FIG. 1 a is a schematic diagram of a computer system showing a processor 11 connected ( 13 ) with an external Memory Controller (MC) 15 . The MC 15 is connected ( 17 ) to an external memory 19 for input/output operations.
FIG. 1 b is a schematic diagram of a computer system showing a processor 21 with a memory controller 23 resident in the processor. The MC communicates ( 25 ) with the external memory 27 . By having the MC inside the microprocessor chip allows the MC to operate at the processor clock speed. The MC then could be designed to have faster external memory (SDRAM) access for input/output (I/O) operations.
FIG. 2 depicts a typical SDRAM controller hookup 30 . Communicating signals between the MC 31 and the SDRAM 33 are physically arranged in three groups: the clock signal 35 ; the unidirectional (from MC to SDRAM) command bus 37 ; and the bi-directional data bus 39 . The command and data signals are sampled synchronously. The clock signal makes that synchronous computer operation possible.
FIG. 3 shows basic SDRAM read and write accesses 40 . There are three signals shown in the plot: a clock signal 41 ; a command signal 43 and a data signal 45 . They represent the signals at SDRAM I/O pins. The three signals correspond to the signal groups discussed in FIG. 2 . Since SDRAMs operate synchronously with the clock, the commands must be sampled at a clock edge, e.g., a rising edge, shown in the figure as A 47 ; B 49 , D 53 ; and E 55 . For an SDRAM read or an SDRAM write, SDRAM receives a RAS (row address strobe) 57 and a CAS (column address strobe) 59 commands. Similarly for a SDRAM read or a SDRAM write, SDRAM receives a RAS 61 and a CAS 63 commands. The delay from a RAS to a CAS is defined as the RAS-CAS delay, which is an SDRAM parameter given by the SDRAM manufacturer. Systems use the smallest given RAS-CAS delay to achieve the best performance. To sample the commands correctly, the clock and the commands must satisfy the minimum setup time F 65 and minimum hold time G 67 given by the manufacturer. For a read operation, the data appears on the data bus at a clock rising edge C 51 (only cache latency 2 is shown). For a write operation, written data must be driven at the same time as the CAS command 63 so write data 71 is sampled the same time as the CAS command.
For the design of an algorithm to correctly program the MC, various time delays and time constraints (analog type time elements) associated with the physical operation of a memory device like a SDRAM need to be specified. Table 1 is an exemplary specification for a SDRAM. Not all listed parameters are needed for this algorithm development.
TABLE 1
Parameter
Typical Time (ns)
Comment
tRCD
26
RAS to CAS delay
tRP
26
Row pre-charge
time
tRC
78
Row cycle time
tSAC2max
7
CLK to valid data
out conflict
tOH2
2.5
Output data hold CL = 2
tSS
2
Input setup time
tSH
1
Input hold time
tSLZ
0
CLK to output
active
tSHZ2min
2
CLK to hi-Z min,
CL = 2
tSHZ2max
6
CLK to hi-Z max,
CL = 2
The programmable parameters for the MC required for correct and optimum I/O operation with the MC and SDRAM need to be specified. Table 2 lists and describes seventeen related programmable parameters in the MC. Other programmable parameters, such as refresh control and SDRAM initialization parameters are not listed. These timing parameters are necessary for I/O operations such as memory read, memory write, same bank access, different bank access, etc.
TABLE 2
Parameter
Description
Clkr
SDRAM to processor clock ratio
Clk_dly
SDRAM clock delay with respect to MCU base clock
(processor clock unit)
Cmd_dly
SDRAM command delay (SDRAM cycle unit)
Act_rd_dly
Read command RAS to CAS delay (SDRAM cycle
unit)
Act_wr_dly
Write command RAS to CAS delay (SDRAM cycle
unit)
Rd_cycl_dly
Wait tRP after a read command is issued
(SDRAM cycle unit)
wr_cycl_dly
Wait tRP after a write command is issued
(SDRAM cycle unit)
Rd_smp_dly
Wait to sample a read data after a read
command is issued (processor clock unit)
wr_Psh_dly
Wait to push the write data out after a write
command is issued (processor clock unit)
Rd_wait
Read data valid extension (SDRAM cycle unit)
wr_thld
Write data valid extension (processor cycle unit)
Auto_rfr_cycle
wait for auto refresh finishes (SDRAM cycle unit)
Rd_rd_dly
delay for a read allowed to other banks after
current read (SDRAM cycle unit)
Rd_wr_dly
delay for a write allowed to other banks after
current read (SDRAM cycle unit)
wr_rd_dly
delay for a read allowed to other banks after
current write (SDRAM cycle unit)
wr_wr_dly
delay for a write allowed to other banks after
current write (SDRAM cycle unit)
Rrd
RAS to RAS delay of SDRAM internal banks
(SDRAM cycle unit)
Table 3 lists required system input parameters for calculating MC programming parameters. Ten important parameters are listed and described. These system parameters are needed as inputs to the design method. This table describes an exemplary development process.
TABLE 3
Parameter
Description
cmd_delay_min
Command delay minimum
cmd_delay_max
Command delay maximum
clock_delay_min
Clock delay minimum
clock_delay_max
Clock delay maximum
sdram_mc_data delay_min
data SDRAM to MC delay
minimum
sdram_mc_data delay_max
data SDRAM to MC delay
maximum
mc_sdram_data delay_min
data MC to SDRAM delay
minimum
mc sdram_delay_max
data MC to SDRAM delay
maximum
mc_data_setup
MC read data setup time
mc_data hold
MC read data hold time
In estimating the design parameters described in Table 2 for design development, it is necessary to characterize and to estimate various design input parameters. Some time delay elements arise from signal propagation delays. Electrical signals take a finite amount of time to travel a finite distance in an integrated circuit. As the processor clock speed increases, these time delay elements become more significant. When a propagation delay becomes a significant fraction of the processor clock period, it needs to be accounted through correct and reliable I/O timing designs, involving an MC and a SDRAM. These time delay elements are analog types dependent on the physical layout of the computer hardware.
FIG. 4 shows the analog delays between an MC and a SDRAM. Six signal waveforms are shown in plot 80 , representing the signals at both MC and SDRAM I/O pins. The upper three signals 81 , 85 , and 89 correspond to the signal groups in FIG. 2 for the MC I/O pins. The lower three signals 83 , 87 , and 91 correspond to the signal groups in FIG. 2 at SDRAM I/O pins. Clock signals 81 and 83 are unidirectional from the MC to the SDRAM. Command bus signals 85 and 87 are unidirectional from the MC to the SDRAM. The data bus signals 89 and 91 are bi-directional between the MC and the SDRAM.
Analog clock_delay 93 is the clock signal's delay from the MC to the SDRAM. Clock_delay varies within the range of clock_delay_min and clock_delay_max provided as system input parameters (Table 3). The following relation holds:
clock_delay_min<clock_delay<clock_delay_max (EQ 1)
The analog cmd_delay 103 is the command bus signal's delay from the MC to the SDRAM. The cmd_delay varies within the range of cmd_delay_min and cmd_delay_max as system input parameters (Table 3). The following relation holds:
cmd_delay_min<cmd_delay<cmd_delay_max (EQ 2)
The analog sdram_mc_data_delay 109 is the data delay from the SDRAM to the MC for a read operation. The sdram_mc_data_delay varies within the range of sdram mc_data_delay_min and sdram_mc_data_delay_max provided as system input parameters (Table 3). For this delay the following relation holds:
sdram_mc_data_delay_min<sdram_mc_data_delay<sdram_mc_data_delay<_max (EQ 3)
The analog mc_sdram_data_delay 113 is the data delay from the MC to the SDRAM for a write operation. The mc_sdram_data_delay varies within the range of mc_sdram_data_delay_min and mc_sdram_data_delay_max provided as system input parameters (Table 3). For this delay the following relation holds:
mc_sdram_data_delay_min<mc_sdram_data_delay<mc_sdram_data_delay_max (EQ 4)
The MC must guarantee the commands and data are correctly sampled at the MC and/or the SDRAM. The commands must satisfy setup time 119 and hold time 121 given by the SDRAM specifications. As shown in FIG. 4, for a read operation, the MC must be programmed internally to sample with delay 108 , to get data with setup time 104 and hold time 106 , to satisfy MC I/O specifications. As noted earlier, data 107 at the MC is the same data 105 at the SDRAM, which arrived with time delay 109 . For a write operation, the MC must control data 111 to be sampled at the SDRAM with setup time 112 and hold time 114 to satisfy the SDRAM specification.
To satisfy the above setup time and hold time at the right time for variant system designs, the MC must be programmable. The programmable parameters, described in Table 2, compensate for the appropriate time delays by the correct amount to achieve the best timing and performance in the MC to SDRAM I/O operations.
FIG. 5 depicts MC clock and command programming 200 . It does not include analog delays due to propagation path delays as discussed in FIG. 4 . The MC, resident in a microprocessor, is able to generate a delayed version 203 of clock 201 with delay (clk_dly) 205 in CPU clock resolution. The programmable digital delay 205 in the CPU clock resolution produces a corresponding programmed delay 213 in command signal 206 at the MC output.
Internally, the MC has a base signal that is always synchronous with the clock and which has SDRAM clock resolution. The SDRAM clock rate is slower, (typically 4-15 times), than the CPU (microprocesor) clock rate. Additionally, the MC is able to generate the commands with programmable delay (cmd_dly) 209 in the SDRAM input clock 207 in SDRAM clock resolution resulting in a corresponding, programmed delay 217 in the command signal 215 input at SDRAM. Therefore, by programming the clk_dly 205 in CPU clock resolution and cmd_dly 209 in SDRAM clock resolution, and taking into account the analog delays clk_delay and cmd_delay, shown in FIG. 4, (not included in FIG. 5 ), the command to SDRAM is sampled at a rising edge 219 of SDRAM clock 207 . Let tSS be the set up time and tSH be the hold time specified by the SDRAM specification, and let clkr be the clock frequency ratio of the processor and SDRAM which is the same as the SDRM to processor clock period ratio. For the setup time, the following relation holds:
clk_dly+clock_delay_min+N clkr−tSS>cmd_dly+cmd_delay_max (EQ 5)
In addition, for the hold time, the following relation holds:
clk_dly+clock_delay_max+N clkr+tSH<cmd_dly+cmd_delay_min (EQ 6)
where N is an integer number satisfying both inequalities. The programmable delays clk_dly and cmd_dly need to be produced in discrete units in the range {0, 1, . . . clkr−1}. To obtain the legal settings for clk_dly and cmd_dly the following steps need to be executed:
(i). Set cmd_dly={0, 1, . . . clkr−1}
(ii). Vary clock_dly from 0 to clkr−1;
(iii). Substitute the above values into the relation involving wr_psh_dly (wait time to push the write data out in processor clock unit) in (EQ 19) derived below for write setup time to obtain best possible performance in terms of idle latency. Check the validity of the current cmd_dly and sdram_clk-dly values chosen. The valid settings can be obtained based on the iterations of the above three steps.
A read operation will now be considered to generate correct MC programmable parameters, which pertain to the read operation. Toward this end, the SDRAM read timing diagram 300 in FIG. 6 will be considered. This diagram is a simplified version of a SDRAM read timing of a recent actual CPU: UltraSPARC-III.
The first signal 301 is the processor internal clock. The second signal 303 is the MC internal base SDRAM clock. The SDRAM clock period is always a multiple of the processor clock period. The third signal line 305 represents the SDRAM clock at the MC I/O pin. It has a programmable delay (clk_dly) 307 with respect to the internal SDRAM clock base. The fourth signal 309 is the SDRAM command sync signal. All SDRAM commands must be synchronized to this signal. It has a programmable delay (cmd_dly) 311 with respect to the internal SDRAM clock base. The fifth signal 315 represents the MCU command output at MC I/O pins. The three commands on the command bus are the RAS command, 317 , the CAS command, 319 and the CKE DIS deassertion command, 321 . When CKE is deasserted, the data valid will be extended by one SDRAM cycle. The sixth signal 327 is the data sampling signal. The memory read data will be sampled into MC with the rd_smp_dly 329 with respect to the SDRAM internal base clock, 303 . The seventh signal 333 is the SDRAM data 339 reaching the MC I/O pins after a time delay (sdram_mc_data_dly) 341 . The hollow part of the data signal represents the valid portion. It consists of MC read data setup time 335 and MC read data hold time 337 . The eighth signal 339 is the SDRAM data driven out from the SDRAM I/O pins. The ninth signal 347 is the SDRAM command signal reaching SDRAM I/O pins after a time delay (cmd_dly) 355 . The tenth signal 367 is the SDRAM clock reaching the SDRAM pins after a time delay (clk_dly) 351 . There will be no new read CAS during the period of time (clkr x rd_rd_dly) 369 and there will be no new write CAS during the period of time (clkr x rd_wr_dly) 371 . The delays, set time and hold time, marked in FIG. 6, have been described in Tables 2 and 3.
For the read operation, the following parameters are to be calculated:
act_rd_dly (read command RAS to CAS delay);
rd-wait (read data valid extension);
rd_smp_dly (wait to sample a read data).
For the read command operations, the following relation must be satisfied:
clkr(1+act_rd_dly)>tRCD (EQ 7)
Therefore, set
act_rd_dly=Ceil(tRCD)/(clkr))−1 (EQ 8)
Because act_rd_dly is the minimum possible legal setting, act_rd_dly in (EQ 8) gives the best possible performance in terms of read idle latency.
For read setup time, the following relation must be satisfied:
1+rd_smp_dly>clkr(1+act_rd_dly)+cmd_
delay_max+Remainder(clk_dly+clk_delay_max−cmd_dly−cmd_delay_max, clkr)+tSAC2−tSLZ+sdram_mc_data_dly_max+mc_data_setup (EQ 9)
In addition, for read hold time, the following relation must be satisfied:
1+rd_smp_dly<clkr(1+act_rd_dly)+cmd_
delay_min+Remainder(clk_dly+clk_delay_min−cmd_dly−cmd_delay_min, clkr)+tOH2−tSLZ+sdram_mc_data_dly_min+(1+RD_WAIT)clkr−mc_data_hold (EQ 10)
Given positive numbers X and Y, the Remainder function is defined such that R is a positive number that satisfies:
X=P×Y+R (EQ 11)
where P is an integer and 0<R<Y. R is denoted as:
R =Remainder( X, Y ) (EQ 12)
Therefore, let
rd_smp_dly=Ceil(clkr(1+act_rd_dly)+cmd_
delay_max+remainder(clk_dly+clk_delay_max−cmd_dly−cmd_delay_max, clkr)+tSAC2−tSLZ+sdram_mc_data_dly+mc_data_setup−1); (EQ 13)
this results in,
RD_WAIT=Ceil((1+rd_smp_dly−cmd_delay_min−Remainder(clk_
delay_min+clk_dly−ctl_dly−cmd_delay_min, clkr)−tOH2+tSLZ−dram_mc_data_dly_min+mc_data_hold)/clkr−1−act_rd_dly). (EQ 14)
RD_WAIT must be maintained as a positive number because no logic circuit can control past performance. Therefore,
rd_wait=RD_WAIT−1, if RD_WAIT>0; (EQ 15)
rd_wait=0, if RD_WAIT=0; (EQ 16)
The setting of write parameters can be obtained in a similar fashion.
FIG. 7 is a simplified version of the SDRAM write timing diagram 400 (used in an actual CPU, the UltraSPARC-III). The first signal 401 is the processor internal clock. The second signal 403 is the MC internal base SDRAM clock. The SDRAM clock period is always a multiple of the processor clock period. The third signal line 405 represents the SDRAM clock at the MC I/O pin. It has a programmable delay 407 with respect to the internal SDRAM clock base. The fourth signal 409 is the SDRAM command sync signal. All SDRAM commands must be synchronous to this signal. It has a programmable delay (cmd_dly) 411 with respect to the internal SDRAM clock base. The fifth signal 415 represents the MCU command output at MC I/O pins. There are two commands on the command bus. They are RAS command 417 and CAS command 419 . The sixth signal 425 is the data driving signal. The memory read data would be driven out from MC with the wr_psh_dly 427 with respect to SDRAM internal base clock. The seventh signal 429 is the SDRAM data out at the MC I/O pins. The eighth signal 433 is the SDRAM data reaching SDRAM I/O pins after a time delay (mc_sdram_data_dly) 437 . The ninth signal 439 is the SDRAM clock reach the SDRAM pins after a propagation path time delay (clock_delay) 443 . The tenth signal 445 is the SDRAM command signal reaching the SDRAM I/O pins after a propagation path time delay (cmd_delay) 451 . The delays, set time and hold time marked in the figure, have been described in the Tables 2 and 3.
A memory WRITE operation is controlled by the following parameters:
act —wr _dly (write command RAS to CAS delay);
wr psh dly;
wrdata_thld (write data valid extension).
clkr(1+act_wr_dly)>tRCD (EQ 17)
Therefore,
act_wr_dly=Ceil((tRCD−clkr)/clkr) (EQ 18)
Because act_wr_dly is the minimum possible legal setting, act_wr_dly in EQ 18 gives the best possible performance in terms of idle latency.
For write setup time, it must satisfy
1+wr_psh_dly+mc_dram_dly_max+tSS<clkr(1+act_wr_dly)+cmd_delay_min+Remainder(clk_dly+clk_delay_min−cmd_delay−cmd_delay_min, clkr); (EQ 19)
Hold time:
1+wr_psh_dly+mc_dram_dly_min+wrdata_thld−tSH>clkr(1+act_wr_dly)+cmd_delay_max+Remainder(clk_dly+clk_delay_max−cmd_dly−cmd_delay_max, clkr); (EQ 20)
Therefore, let
wr_psh_dly=Floor(clkr(1+act_wr_dly)+cmd_delay_min+Remainder(clk_dly+clk_delay_min−cmd_dly−cmd_delay_min, clkr)−1−mc_dram_dly_max); (EQ 21)
this results in,
wrdata_thold=Ceil(clkr(1+act_wr_dly)+cmd_delay_max+Remainder(clk_dly+clk_delay_max−cmd_delay−cmd_delay_max, clkr)−1−wr_psh_dly−mc_dram_dly_min+tSH; (EQ 22)
Programmable parameters to avoid conflicts will now be considered.
For same bank access, the following parameters are important:
rd_cycl_dly(wait for row precharge time tRP after a read command is issued);
wr_cycl_dly (wait for row precharge time tRP after a write command is issued);
auto-rfr-cycle(wait for auto refresh to finish).
For a bank access, we have:
tRC−tRCD+RD_WAIT*clkr<clkr(1+rd_cycl_dly)+clk_delay_max−ck_delay_min; (EQ 23)
tRC'tRCD=clkr(1+wr_cycl_dly)+clk_delay_max−clk_delay_min (EQ 24)
tRC<auto_rfr_cycle clkr (EQ 25)
Therefore,
rd_cycl_dly=Ceil((tRC−tRCD−clk_delay_max+clk_dly_min+RD_WAIT*clkr)/clkr)−1 (EQ 26)
wr_cycl_dly=Ceil((tRC−tRCD−clk_dly_max+clk_dly_min)/clkr)−1 (EQ 27)
auto_rfr_cycle=Ceil((tRC/clkr)); (EQ 28)
For different bank accesses:
rd_rd_dly (delay for a read allowed to other banks after current read);
rd_wr_dly (delay for a write allowed to other banks after current read);
wr_rd_dly (delay for a read allowed to other banks after current write);
wr_wr dly (delay for a write allowed to other banks after current write).
The following formulas compute starting and ending points for the use of the data bus during read and write operations:
Read_Data_Start=clkr+cmd_delay_min+Remainder(clk_dly+clk_delay_min−ctl_dly−clk_min, clkr)+clkr+tSLZ; (EQ 29)
Read_Data_End=clkr+cmd_delay_max+Remainder(clk_dly+clk_delay_max−ctl_dly−cmd_delay_max, clkr)+RD_WAIT*clkr+clkr+tSHZ2+sdram_mc_dly_max; (EQ 30)
Write_Data_Start=1+wr_psh_dly+mc_sdram_dly_min; (EQ 31)
Write_Data_End=1+wr_psh_dly +mc_sdram_dly_max+wrdata_thld; (EQ 32)
Therefore,
rd_rd_dly=Ceil((Read_Data_End−Read_Data_Start)/clkr)−1; (EQ 33)
rd_wr_dly=Ceil((Read_Data_End−Write_Data_Start)/clkr)−1; (EQ 34)
wr_rd_dly=Ceil((Write_Data_End−Read_Data_Start)/clkr)−1; (EQ 35)
wr_wr_dly=Ceil((Write_Data_End−Write_Data_Start)/clkr)−1; (EQ 36)
rrd[1:0]=Ceil((tRRD/(clkr)). (EQ 37)
In the above derivation, legal settings are mathematically obtained to achieve the best idle latency for the MC. All legal settings are then checked for peak bandwidth performance. The memory system performance is measured in terms of read bandwidth and write bandwidth, expressed in bytes/sec. The bandwidth represents the rate of data transfer out of memory (read) or into it (write). The peak bandwidth performance will ultimately decide the best setting among all the legal settings obtained by the above equations.
For single bank:
Read Bandwidth=1/Ceil(clkr(1+act_rd_dly)+rd_cycle_dly)/clkr)clkr; (EQ 38)
Write Bandwidth=1/Ceil(clkr(1+act_wr_dly)+wr_cycle_dly)/clkr )clkr; (EQ 39)
Two Banks on One DIMM Set:
Read Bandwidth=1/Max(Ceil(clkr(1+act_rd_dly)+rd_cycle_dly)/clkr)clkr*2, rd_rd_delay*clkr); (EQ 40)
Write Bandwidth=1/Max (Ceil(clkr(1+act_wr_dly)+wr_cycle_dly)/clkr)clkr*2, wr_wr_delay*clkr); (EQ 41)
Two Banks on Two DIMM Sets:
Read Bandwidth=1/Max(Ceil(clkr(1+act_rd_dly)+rd_cycle_dly)/clkr)*clkr, rd_rd_dly*clkr)2*clkr); (EQ 42)
Write Bandwidth=1/Max(Ceil(clkr(1+act_wr_dly)+wr_cycle_dly)/clkr)*clkr, wr_wr_dly*clkr)2*clkr); (EQ 43)
Four Banks on Two DIMM Sets:
Read Bandwidth=1/Max(Ceil(clkr*(1+act_rd_dly)+rd_cycle_dly)/clkr)*clkr, rd_rd_dly*clkr); (EQ 44)
Write Bandwidth=1/Max(Ceil(clkr*(1+act_wr_dly)+wr_cycle_dly)/clkr)*clkr, wr_wr_dly*clkr). (EQ 45)
From the three pairs of the inequalities, the following margins can be calculated:
Command setup margin:
cmd_setup_margin=clk_dly+clock_delay_min+N clkr−tSS−cmd_dly −cmd_delay_max; (EQ 46)
For the hold time:
cmd_hold_margin=cmd_dly+cmd_delay_min−clk_dly−clock_delay_max−N clkr−tSH; (EQ 47)
MC data setup margin:
mc_data_setup_margin=1+rd_smp_dly−(clkr(1+
act_rd_dly)+cmd_delay_max+Remainder(clk_dly+clk_delay_max−cmd_dly−cmd_delay_max, clkr)+tSAC2−tSLZ+sdram_mc_data_dly_max+mc_data_setup); (EQ 48)
MC data hold margin:
mc_data_hold_margin=clkr(1+
act_rd_dly)+cmd_delay_min+Remainder(clk_dly+clk_delay_min−cmd_dly−cmd_delay_min, clkr)+tSAC2−tSLZ+sdram_mc_data_dly_max+mc_data_setup); (EQ 49)
SDRAM setup margin:
sdram_data_setup_margin=clkr(1+act_wr_dly)+cmd_delay_min+Remainder(clk_dly+clk_delay_min−cmd_delay−cmd_delay_min, clkr)−(1+wr_psh_dly+mc_dram_dly_max+tSS); (EQ 50)
SDRAM hold margin:
sdram_data_hold_margin=1+wr_psh_dly+mc_dram_dly_min+wrdata_thld−tSH−(clkr(1+act_wr_dly)+cmd_delay_max+Remainder(clk_dly+clk_delay_max cmd_dly−cmd_delay_max, clkr)); (EQ 51)
With these margin performance numbers, the best legal setting can be obtained easily.
The MC programming method is now ready for implementation. The flow chart 500 for the MC programmable parameter calculation is described in FIG. 8 . The first step 501 is initialization of all inputs, including the SDRAM parameters in Table 1, system parameters in Table 3 and the time period ratio parameter clkr. The next step 503 includes storing all the legal settings described in Table 3 and the computation of programmable time delays clk_dly and cmd_dly. In the third step 505 , for each pair of clk_dly and cmd_dly, the parameters rd_smp_dly, rd_act_dly, rd_wait, wr_psh_dly, wr_act_dly and wr_thld are calculated. Based on these calculated parameters, the parameters rd_cycle_dly, wr_cycle_dly, auto_rfr_cycle, rd_rd_dly, wr_wr_dly, rd_wr_dly and wr_rd_dly are calculated. All the calculated parameters are stored.
In the last step 507 , for each pair of clk_dly and cmd_dly, memory bandwidth performance and margins are calculated from the above mentioned equations. Then, a set of parameters is chosen that give the best performance and the best margins.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
|
A method for programming a controller of a memory unit has been developed. The method includes inputting variable initialization parameters of the memory unit and a clock delay and a command delay for each parameter. Based on each pair of clock delays and command delays, calculate a set of delays for a read command and a write command. Calculate the system performance for each pair of clock and command delays bases on the read and write delays and select the initial parameters that offer optimum system performance.
| 6
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an optical amplifier for use in optical fiber communication systems and optical signal processing systems.
[0003] This application is based on patent application No. Hei 11-197126, the content of which is incorporated herein by reference.
[0004] 2. Description of the Related Art
[0005] The basic configuration of a conventional optical amplifier is shown in FIG. 22. This optical amplifier is comprised by two amplifying sections having different gain band regions (L-amplifying section and S-amplifying section), a divider, and a combiner, and attempts to broaden the operational bandwidths by coupling the two gain band regions in the wavelength domain. (refer to “Broadband and gain-flattened amplifier composed of a 1.55 μm-band and a 1.58 μm-band Er 3+ -doped fiber amplifier in a parallel configuration”, M. Yamada et. al., EE Electronics Letters, Vol. 33, No. 8, 1977, pp710-711) (Reference 1).
[0006] Various types of dividers and combiners are utilized in constructing such optical amplifiers, and they can be classified as a dielectric multi-layer filter or a combination of fiber grating in association with circulator. Those based on dielectric multi-layer filter are reported in the following references.
[0007] “Broadband and gain-flattened amplifier composed of a 1.55 μM-band and a 1.58 μm-band Er 3+ -doped fiber amplifier in a parallel configuration”, M. Yamada et. al., EE Electronics Letters, vol. 33, no. 8, 1977, pp710-711. (Reference 1)
[0008] Japanese Unexamined Patent Application, First Publication, No. Hei 10-229238, Publication Date, Aug. 25, 1998. (Reference 2)
[0009] Japanese Unexamined Patent Application, First Publication, No. Hei 11-204859, Publication Date, Jul. 30, 1999. (Reference 3)
[0010] International Application Published under the Patent Cooperation Treaty, PCT/US98/16558, “Optical amplifier apparatus”, International publication date, Apr. 8, 1999, International Publication Number WO 99/17410. (Reference 4)
[0011] Those based on a combination of circulator and fiber grating are reported in the following references.
[0012] European Patent Application, EP 0 883 218 A1, “Wide band optical amplifier”, Publication date Sep. 12, 1998. (Reference 5)
[0013] “A gain-flattened ultra wide band EDFA for high capacity WDM optical communication systems”, Y. Sun et. al., Technical Digest of ECOC'98, pp.53-54, 1998. (Reference 6)
[0014] The following reference does not specify what type of device is used.
[0015] Japanese Unexamined Patent Application, First Publication, No. Hei 4-101124, Publication Date, Apr. 2, 1992. (Reference 7)
[0016] All of the above references assume that the wavelength division properties are either perfect or present no particular problems.
[0017] However, as will be shown with specific examples in the following, wavelength division properties of these devices are not perfect, and problems are encountered depending on the manner and conditions of applying the amplifiers.
[0018] First, the most common problem of such amplifiers is encountered when the dividers and combiners are made of dielectric multi-layer filters. FIGS. 1A and 1B show the configuration of a conventional optical amplifier, where FIG. 1A shows a design based on dielectric multi-layer filters of the long wavelength transmission type (L-type) for the divider and combiner, represented by L-divider ( 3 ) and L-combiner ( 4 ), and FIG. 1B shows a design based on dielectric multi-layer filters of the short wavelength transmission type (S-type) for the divider and combiner, represented by S-divider ( 5 ) and S-combiner ( 6 ).
[0019] The amplifying section has a gain medium and a pumping section for excitation, and examples of such optical amplifiers are rare-earth doped fiber amplifier, fiber Raman amplifier and semiconductor laser amplifier. The rare-earth doped fiber amplifiers include erbium-doped fiber amplifier and the like, and according to “Wideband erbium-doped fibre amplifiers with three-stage amplification”, H. Masuda et. al., IEE Electronics Letters, vol. 34, no. 6, 1998, pp567-568 (Reference 8), it is advantageous when such an amplifier has a gain equalizer to broaden the region of flat gain because such an amplifier can produce a large total gain bandwidth.
[0020] In optical communication systems, optical amplifiers are generally designed to receive wavelength-multiplexed light signals, and in optical signal processing systems for instruments and the like, optical amplifiers are generally designed to receive wavelength- multiplexed light signals or single wavelength light signals.
[0021] [0021]FIGS. 2A and 2B show configurations of the divider, where FIG. 2A represents an L-type dielectric multi-layer filter (L-divider), and FIG. 2B represents an S-type dielectric multi-layer filter (S-divider). The L-divider receives input light containing a short-wavelength λs and a long wavelength λl in the common port (c), and transmits a long wavelength λl from the transmission port (l) and reflects a short wavelength λs from the reflection port (s). On the other hand, the S-divider receives input light containing a short-wavelength λs and a long wavelength λl in the common port (c), and reflects a long wavelength light λl from the reflection port (l) and transmits a short wavelength light λs from the transmission port (s).
[0022] [0022]FIGS. 3A and 3B show configurations of the combiner, where FIG. 3A represents an L-type dielectric multi-layer filter (L-combiner), and FIG. 3B represents an S-type dielectric multi-layer filter (S-combiner). The L-combiner receives input light containing a short-wavelength λs from the reflection port (s) and a long wavelength λl from the transmission port (l), and outputs light containing a long wavelength λl and a short wavelength λs from the common port (c). On the other hand, the S-combiner receives input light containing a short-wavelength λs from the transmission port (s) and a long wavelength λl from the reflection port (l), and outputs light containing a long wavelength λl and a short wavelength λs from the common port (c).
[0023] Referring to FIGS. 1A and 1B, the dividers (L- and S-dividers) 3 ,. 5 , perform the steps described above, and divide the multiplexed signal light containing a long wavelength λl and a short wavelength λs into a long wavelength signal light λl and a short wavelength signal light λs, which are input into the respective amplifying sections (L-a and S-amplifying sections) 1 , 2 , and are combined in the combiners 4 , 6 and multiplexed light signals are thus output.
[0024] However, there are problems in the performance of the light amplifiers described above, which will be explained in the following.
[0025] [0025]FIGS. 4A and 4B show gain spectra obtained in the amplifying sections (L-, S-amplifying sections) 1 , 2 , where FIG. 4A shows an overall view of the gain region while FIG. 4B shows details of gains in the vicinities of the wave boundaries (wavelengths λtr-s to λtr-l) of the L- and S-amplifying sections. In FIG. 4B, wavelengths in the L-amplifying section are denoted by λl* and those in the S-amplifying section are denoted by λs*, and the peak gains in the L-, S-amplifying sections are denoted by G while the wavelength-specific gains for λl*, λs* are denoted by G*.
[0026] [0026]FIGS. 5A and 5B show loss spectra in the L-divider, and show the losses relating to a transmission loss between ports c and s, and the same between ports c and l (refer to FIGS. 2A and 2B), which are denoted respectively by Lcs1 and Lcl1 where 1 indicates that the losses are related to long wavelengths. FIG. 5A shows the loss in the overall view of the gain region and FIG. 5B shows the details of the loss in the wave boundary. For both Lcs1 and Lcl1, the loss becomes larger as the wavelength of the signal waves moves away from the respective boundary wavelengths (wavelengths λtr-s to λtr-l) into fringes of the respective gain regions.
[0027] However, in the long wavelength side of the loss spectrum (i.e., at the λtr-l end), the loss Lcs1 between the port s (for reflected light) and the common port c is limited to a certain constant value, because of the contribution from residual reflection components in the dielectric multi-layer filter.
[0028] The difference in the wavelengths λtr-s to λtr-l (referred to as the boundary bandwidth) is typically 5˜10 nm at a 15 μm wavelength, and the limiting value and the loss at the wavelength λs* are typically about 10 dB and 20 dB, respectively. The boundary bandwidth and the slope of the curve of loss spectrum in the vicinity of the wave boundary are dependent on the parameters (composition and the number of layers of lamination) of the dielectric multi-layer filter.
[0029] [0029]FIGS. 6A and 6B show the loss spectra of the S-type divider, where FIG. 6A, 6B relate, respectively, to the transmission losses between ports s and l, and between ports c and l shown in FIGS. 2A and 2B (referred to as Lcs2, Lcl2, where 2 indicates that the losses are related to short wavelengths). FIG. 6A refers to the overall view of the loss region and FIG. 6B shows details of losses in the wave boundary. Both Lcs2, Lcl2 show a tendency to increase as the wavelengths of the signal waves move away from the respective boundary wavelengths (wavelengths λtr-s to λtr-l) into fringes of the gain regions.
[0030] However, in the short wavelength side of the loss spectrum (i.e., at the λtr-s end), the loss Lcs2 between the port l (for reflected light) and the common port c is limited to a certain constant value, which is caused by the contribution from residual reflection components in the dielectric multi-layer filter.
[0031] The difference in the wavelengths λtr-s to λtr-l (referred to as the boundary bandwidth) is typically 5˜10 nm at a 15 μm wavelength, and the limiting value and the loss at the wavelength λs* are typically about 10 dB and 20 dB, respectively. The boundary bandwidth and the slope of the curve of loss spectrum in the vicinity of the wave boundary are dependent on the parameters (composition and the number of layers of lamination) of the dielectric multi-layer filter.
[0032] The loss spectra of the L- and S-type combiners are the same as the loss spectra of the L- and S-type dividers shown in FIGS. 5 and 6, because of the reciprocality of light propagation. That is, if the transmission ports are the same, the loss values are the same.
[0033] [0033]FIGS. 7A and 7B show loss spectra in the optical circuits of a conventional optical amplifier. The losses are incurred in the L- and S-amplifying sections, and the circuit loss is represented by a sum of the losses in the dividers and combiners, and are expressed in the units of dB. FIG. 7A shows the losses in the L-type divider and combiner shown in FIG. 1A, and FIG. 7B shows the losses in the S-type divider and combiner shown in FIG. 1B.
[0034] In the case of the L-type amplifier, the loss value (denoted by U) in the S-amplifying section at a wavelength λl* is limited to 20 dB, which is twice the limit value (about 10 dB). These values, 20 dB and 10 dB, correspond to non-dimensional numbers, 100 and 10 , respectively, so that the former is ten times the latter. On the other hand, the case of the S-type amplifier, the loss value (denoted by Ls) in the L-amplifying section at a wavelength λs* is limited to 20 dB, which is twice the limit value (about 10 dB). In other words, the loss of signal light at the wavelength λs* is limited to ten times the limit value.
[0035] As explained above, in the vicinity of the wave boundaries, because the wave separation properties in the dividers and combiners are not perfect, the output light, for example wavelength λl*, from its primary circuit (through the L-amplifying section) is affected by the contribution from the residual light in the reflection circuit (through the S-amplifying section).
[0036] For the purpose of providing a quantitative explanation, the optical powers of the primary output light and the residual light are designated, respectively, by P and P*. If the value of P* is not sufficiently small compared with P, coherent interference is generated and interference noise will be superimposed on the signal light to cause operational problems. For example, in an optical communication system, an increase in bit error rate will lead to degradation of the system performance.
[0037] In the L-type divider and combiner (refer to FIG. 1A), P and P* are related to the input power Pin (in units of dBm) according to the following expressions.
P=Pin+G and P*=Pin+G*−Ll (1)
P−P*=G−G*+Ll (2)
[0038] where G* is the gain in the residual circuit and Ll represents the circuit loss described in FIGS. 7A and 7B, and wavelength-dependent losses in the dividers and combiners are neglected for simplicity. If it is assumed that the difference between G and G* is smaller than Ll and can be neglected, the difference between P and P* is equal to Ll from equation (2). In the example given in FIGS. 7A and 7B, Ll is about 20 dB, but this value is not sufficiently large, so that interference noise is generated.
[0039] Similarly, in the configuration based on S-type dividers and combiners (refer to FIG. 1B), P and P* are related to the input power Pin (in units of dBm) according to the following expressions.
P=Pin+G and P*=Pin+G*−Ls (3)
P−P*=G−G*+Ls (4)
[0040] where Ls represents the circuit loss described in FIGS. 7A and 7B. If it is assumed, for simplicity, that the difference between G and G* is smaller than Ls and can be neglected, the difference between P and P* is equal to Ls from equation (4). In the example given in FIGS. 7A and 7B, Ls is about 20 dB, but this value is not sufficiently large, so that interference noise is generated.
[0041] If it is assumed that 30 dB is a sufficiently high value of the difference P−P* to prevent the interference noise from being generated, in the wavelength regions where the gain difference, G−G*, is less than 10 dB, it is obvious that interference noise cannot be neglected.
[0042] In the amplifier based on L-type dividers and combiners, the signal wavelength in the long wavelength region to produce a gain difference G−G* of less than 10 dB is designated by λl** as indicated in FIGS. 4A and 4B, and the gain value at this wavelength is designated by G**. Then, as shown in FIG. 7A, in the region from the vicinity of the signal wavelength λs** (where the power difference P−P* in the short wavelength region becomes less than 30 dB) to the vicinity the signal wavelength λl**, the optical power difference P−P* is less than 30 dB. Therefore, because of such double adverse effects, i.e., insufficient differences in gain as well as output power levels caused by residual reflection components in both L- and S-devices, interference noise generated in the boundary bandwidth causes degradation in the amplifier performance. Similar results occur in the amplifier based on S-type dividers and combiners, and therefore, it creates a difficulty that the useable wavelengths are restricted in the conventional design of amplifiers regardless of the wavelengths of dividers and combiners.
[0043] As discussed above, in the conventional technologies based on dielectric multi-layer filters, interference noises are unavoidable in the signal waves in the vicinity of the wave boundaries, and therefore, it creates a problem that the useable wavelengths are restricted. Even in those systems using dividers and combiners not based on dielectric multi-layer filters, the same problems are experienced because the wavelength division properties of the dividers and combiners are not perfect.
SUMMARY OF THE INVENTION
[0044] It is an object of the present invention to resolve the problems outlined above, and provide an optical amplifier having a broad bandwidth of useable wavelength for processing input signal light.
[0045] According to the present invention, the object has been achieved in an optical amplifier comprising: an optical divider for dividing input signal light according to wavelengths; two amplifying sections disposed in parallel and having different wavelength amplification regions for amplifying respective light signals emitted from the optical divider; an optical combiner for combining the light signals output from the respective amplifying sections; and an optical filter disposed in series with at least one of the two amplifying sections for generating a loss in a specific wavelength region.
[0046] The optical amplifier of such a design enables to narrow the latent noise region by the action of the filter in generating a loss in residual reflection components created by the wave division effect in the optical divider so as to increase the gain performance of the signal processing circuit associated with the optical filter.
[0047] Also, the object has also been achieved in another design of the optical amplifier comprising: an optical divider using a dielectric multi-layer filter for dividing input signal light according to wavelengths; two amplifying sections disposed in parallel and having different wavelength amplification regions for amplifying respective light signals emitted from the optical divider; and an optical combiner for combining light signals output from respective amplifying sections using a filter having a blocking wavelength region different than the dielectric multi-layer filter provided in the optical divider.
[0048] The optical amplifier of such a design enable to narrow the latent noise region as a result of improved gain in the signal processing circuits because the transmission region of the dielectric multi-layer filter used in the optical divider is different than the dielectric multi-layer filter used in the optical combiner.
[0049] Accordingly, the present optical amplifier provides benefits that the wavelength bandwidth of the latent noise region has been narrowed and, consequently, the bandwidth of useable wavelengths of signal light that can be used for optical processing purposes has been broadened.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] [0050]FIGS. 1A, 1B are schematic diagrams of the configurations of an optical amplifier according to the conventional technology.
[0051] [0051]FIGS. 2A, 2B are schematic diagrams of conventional L-type and S-type dividers.
[0052] [0052]FIGS. 3A, 3B are schematic diagrams of conventional L-type and S-type combiners.
[0053] [0053]FIGS. 4A, 4B are graphs showing the gain spectra in the conventional amplifying section.
[0054] [0054]FIGS. 5A, 5B are graphs showing the loss spectra in a conventional L-type divider (and an L-type combiner).
[0055] [0055]FIGS. 6A, 6B are graphs showing the loss spectra in a conventional S-type divider (and an S-type combiner).
[0056] [0056]FIGS. 7A, 7B are graphs showing the circuit loss spectra in the conventional optical amplifier.
[0057] [0057]FIGS. 8A, 8B are schematic diagrams of the first configuration of the optical amplifier of the present invention.
[0058] [0058]FIG. 9 is a graph showing the circuit loss spectrum in the first configuration.
[0059] [0059]FIGS. 10A, 10B are schematic diagrams of the second configuration of the optical amplifier of the present invention.
[0060] [0060]FIG. 11 is a graph showing a circuit loss spectrum in the second configuration of the optical amplifier of the present invention.
[0061] [0061]FIG. 12 is a schematic diagram of the configuration of Embodiment 1 of the optical amplifier of the present invention.
[0062] [0062]FIG. 13A, 13B are graphs showing the gain spectra of the optical amplifier in the first embodiment.
[0063] [0063]FIG. 14 is a graph showing the circuit loss spectrum in Embodiment 1.
[0064] [0064]FIG. 15 is a schematic diagram of the configuration of the optical amplifier in Embodiment 2 of the present invention.
[0065] [0065]FIGS. 16A, 16B are graphs showing the gain spectra in the amplifying section in Embodiment 2.
[0066] [0066]FIG. 17 is a graph showing the circuit loss in Embodiment 2.
[0067] [0067]FIG. 18 is a schematic diagram of the configuration of the optical amplifier in Embodiment 3.
[0068] [0068]FIG. 19 is a graph showing the circuit loss spectrum in Embodiment 3.
[0069] [0069]FIG. 20 a schematic diagram of the configuration of the optical amplifier in Embodiment 4.
[0070] [0070]FIG. 21 is a graph showing the circuit loss spectrum in Embodiment 4.
[0071] [0071]FIG. 22 is a schematic diagram of the basic configuration of the conventional optical amplifier.
[0072] [0072]FIG. 23 is a schematic diagram of the third configuration of the optical amplifier of the present invention.
[0073] [0073]FIG. 24 is a schematic diagram of the configuration of the optical amplifier in Embodiment 5 of the present invention.
[0074] [0074]FIG. 25 is a schematic diagram of the configuration of the optical amplifier in Embodiment 6 of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0075] The following embodiments do not restrict the interpretation of the claims relating to the present invention, and the combination of all the features explained in the embodiments are not always indispensable means of solving the problem.
[0076] The first configuration of the present optical amplifier is shown in FIGS. 8A and 8B. FIG. 8A shows a configuration based on an L-type divider and an S-type combiner (referred to as L-divider and S-combiner hereinafter), and FIG. 8B shows a configuration based on an S-divider and an L-combiner. FIG. 9 shows the circuit loss spectra of the amplifier in the first configuration, relating the circuit losses through the L- and S-amplifying sections, representing a sum of the losses in the divider and combiner in units of decibels (dB). This loss spectra are obtained from the loss spectra shown in FIGS. 5 and 6 which were explained in the section on the related art. The loss values are typical values as described in the section concerned with the related art.
[0077] The wavelength region that shows less than 30 dB power difference, P−P*, in FIG. 9 occurs from the vicinity of λs* to the vicinity of λl*. This difference in the wavelengths (difference between the wavelengths in the vicinities of λs* and λl*) is considerably smaller than the difference in the corresponding wavelengths (difference between the wavelengths in the vicinities of λs** and λl**) described in the section concerned with the related art. That is, according to the first configuration, bandwidth of the signal waves affected by the interference noise is narrower compared with that of conventional amplifiers, because the residual reflection components have been reduced, thus enabling to expand the useable bandwidth of signal waves.
[0078] The second configuration of the optical amplifier is shown in FIGS. 10A and 10B. FIG. 10A shows a configuration based on an L-divider and an L-combiner, and FIG. 10B shows a configuration based on an S-divider and an S-combiner.
[0079] According to the second configuration, an extra optical filter is added to the conventional technology. The optical filter 7 in FIG. 10A is a short wavelength transmission type and the optical filter 8 in FIG. 10B is a long wavelength transmission type. The filters 7 , 8 include 2 -port optical filters having dielectric multi-layer filters or fiber gratings that reflect those signal waves having wavelengths in the vicinities of boundary wavelengths.
[0080] However, when optical amplifiers based on such filters 7 and 8 , utilizing 2 -port optical filter are made of dielectric multi-layer filters, amplifiers can be produced at lower cost compared with amplifiers based on other types of optical filters, because of the low cost of making dielectric multi-layer filters. When the filters 7 and 8 are made of fiber gratings, optical amplifiers utilizing such filters are advantageous because the insertion losses due to insertion of signal waves are smaller compared with the insertion losses experienced by other types of filters so that higher gain and output power as well as lower interference noise can be obtained from such optical amplifiers.
[0081] In FIGS. 10A and 10B, although the optical filters 7 , 8 are placed in the aft-stage of the L- and S-amplifying sections, they may be placed in series in the fore-stage. However, considering the insertion loss of the optical filters, the aft-stage placement is more advantageous than the fore-stage placement, because the interference noise is lower in such an arrangement.
[0082] [0082]FIG. 11 shows a circuit loss spectrum of the optical amplifier based on the second configuration, especially the use of an L-divider and an L-combiner, shown in FIG. 10A. The optical filter 7 in this case is based on a 2-port optical filter having dielectric multi-layer filters, relating the circuit losses through the L- and S-amplifying sections, and representing a sum of the losses in the divider and combiner in units of decibels (dB). These loss spectra are obtained from the loss spectra shown in FIGS. 5 and 6 relating to the section on the related art. The loss values are typical values as described in the section concerned with the related art.
[0083] The wavelength region that shows less than 30 dB power difference, P−P*, in FIG. 11 occurs from the vicinity of λs** to the vicinity of λtr-l. This difference in the wavelengths (difference between the wavelengths in the vicinities of λs** and λtr-l) is considerably small than the difference in the corresponding wavelengths described in the section concerned with the related art. That is, according to the second configuration, bandwidth of the signal waves affected by the interference noise is narrower compared with that of conventional amplifiers, thus enabling to expand the bandwidth of useable signal wavelengths.
[0084] The foregoing embodiments were all based on dielectric multi-layer filters, but the following optical amplifiers are based on other types of filters.
[0085] [0085]FIG. 23 shows a third configuration of the optical amplifier. The divider (1:1 division) and combiner are either fiber couplers (combiners), whose performance properties do not vary with wavelengths, or a combination of a fiber coupler and either a divider or a combiner made of dielectric multi-layer filters.
[0086] Because the signal wavelength λs in the short wavelength band is close to the wavelengths in the wave boundary between the long and short wavelength bands, such signal waves tend to mix with the long wavelengths in the long wavelength L-amplifying section, and therefore, such mixed wave components are eliminated by placing an optical filter in the aft-stage of the L-amplifying section. The loss value in the optical filter for the mixed waves should be higher than 30 dB for the same reasons as explained earlier.
[0087] Although a combination of a circulator (as a divider) and a fiber grating (as a combiner) is used in References 5 and 6, the fiber grating clearly serves a different purpose than the optical filter provided in the present invention as a constituting element for the purpose of eliminating residual reflection components.
[0088] In the three configurations presented above (first to third configurations), there are two amplifying sections, however, when there are three amplifying sections, it is clear that the same configuration and results can be derived by re-configuring the amplifying circuit in such a way that two adjacent long wavelength bands are grouped to be processed in one amplifying section using a pair of divider and combiner, as explained above, so that the operation is the same as the amplifier having two amplifying sections. Even if the number of amplifiers exceeds four, other alternative arrangements may similarly be provided. Therefore, the present invention is valid in any amplifier having more than two amplifying sections.
[0089] In the following, various embodiments of the optical amplifier based on the present configuration designs will be explained with reference to the drawings.
[0090] Embodiment 1
[0091] [0091]FIG. 12 shows an optical amplifier in Embodiment 1. This is an example of using an erbium doped fiber amplifier (EDFA) in the amplifying section. A regular EDFA for short wavelength band (S-type EDFA) 11 is used for processing short wavelength signals, and a long wavelength band (L-type EDFA) 12 , having the bandwidth enlarged by a gain equalizer, described in the section concerned with the related art, was used for processing long wavelength signals.
[0092] [0092]FIGS. 13A and 13B show schematic diagrams of the gain spectra of the amplifying sections (S-type EDFA and L-type EDFA) in Embodiment 1, where FIG. 13A relates to the overall view of the spectrum and FIG. 13B relates to the details of the spectrum near the wave boundary. The wave boundary extends from 1562 to 1566 nm. The number of layers of the dielectric multi-layer filter is approximately 100. The peak gain of the amplifying section is 20 dB, and the gains for S-type EDFA and L-type EDFA at 1570 nm are 10 dB for each. FIG. 14 shows the circuit loss spectrum of the amplifier in Embodiment 1.
[0093] The boundary bandwidth in which the differential power P−P* of the signal waves is less than 30 dB is approximately 1560˜1568 nm according to the results shown in FIGS. 13, 14. It means that the bandwidth of the “latent noise region” is 8 nm. On the other hand, in the conventional optical amplifiers based on L-type divider and S-type combiner, the corresponding boundary bandwidth is approximately 1561˜1574, resulting in the bandwidth of the latent noise region of 13 nm.
[0094] As explained above, compared with the conventional technologies, the bandwidth of the latent noise region (wavelength region that cannot be used for signal waves because of interference noise effects) in the present optical amplifier is about a half of the conventional width ({fraction (8/13)} to be exact).
[0095] Embodiment 2
[0096] [0096]FIG. 15 shows a configuration of the optical amplifier in Embodiment 2. This is an example of using a semiconductor laser amplifier (SLA) in the amplifying section. The wavelength gain region of SLA can be changed by varying the semiconductor composition ratio. In this embodiment, although short wavelength band SLA (S-type SLA) 13 and long wavelength band SLA (L-type SLA) 14 are being used, and they have primarily different composition ratios of semiconductors.
[0097] [0097]FIGS. 16A and 16B show schematic diagrams of the gain spectra of the amplifying sections (S-type and L-type SLA) in this embodiment, where FIG. 16A relates to the overall spectrum and FIG. 16B relates to the spectrum near the wave boundary. The wave boundary extends from 1560 to 1570 nm. The number of layers of the dielectric multi-layer filter is approximately 50. The peak gain of the amplifying section is 20 dB, and the gains for S-type SLA 13 and L-type SLA 14 at 1585 nm are 10 dB for each. FIG. 17 shows the circuit loss spectrum of the amplifier in this embodiment.
[0098] The boundary bandwidth in which the differential power P−P* of the signal waves is less than 30 dB is approximately 1554˜1576 nm according to the results shown in FIGS. 16 , 17 . It means that the width of the latent noise region is 22 nm. On the other hand, in the conventional optical amplifiers based on L-divider and S-combiner, the corresponding boundary bandwidth is approximately 1557˜1595, resulting in the width of the latent noise region of 38 nm.
[0099] As explained above, compared with the conventional technology, the width of the latent noise region (wavelength region that cannot be used for signal waves because of interference noise effects) in the present optical amplifier is about a half of the conventional width ({fraction (22/38)} to be exact).
[0100] Embodiment 3
[0101] [0101]FIG. 18 shows a configuration of the optical amplifier in Embodiment 3. This is an example of using a semiconductor laser amplifier (SLA) and an optical filter in the amplifying section. The wavelength gain region of SLA can be changed by varying the semiconductor composition ratio. In this embodiment, although short wavelength band SLA (S-type SLA) 13 and long wavelength band SLA (L-type SLA) 14 are being used, they are primarily different in the semiconductor composition ratios.
[0102] The structure of the amplifying section in this embodiment is the same as that in FIGS. 16A and 16B. The number of layers in the dielectric multi-layer filter, L-divider, L-combiner and the optical filter 15 used in the amplifier shown in FIG. 18 is approximately 50. FIG. 19 shows circuit loss spectrum for the amplifier in this embodiment.
[0103] The boundary bandwidth in which the differential power P−P* of the signal waves is less than 30 dB is approximately 1556˜1570 nm according to the results shown in FIGS. 16, 19. It means that the bandwidth of the latent noise region is 14 nm. On the other hand, in the conventional optical amplifiers based on L-divider and L-combiner, the corresponding boundary bandwidth is approximately 1557˜1595, giving the width of the latent noise region as 38 nm.
[0104] As explained above, compared with the conventional technology, the width of the latent noise region (wavelength region that cannot be used for signal waves because of interference noise effects) in the present optical amplifier is about a third of the conventional width ({fraction (14/38)} to be exact).
[0105] Embodiment 4
[0106] [0106]FIG. 20 shows a configuration of the optical amplifier in Embodiment 4. This is an example of using a fiber Raman amplifier (FRA) in the amplifying section. The wavelength gain region of FRA can be changed by varying the pumping wavelength. The amplifier in this embodiment is a 3-wavelength band amplifier, based on the concept outlined earlier to regard an amplifier for two wavelength bands as one amplifying section. A short wavelength band FRA (S-type FRA) 16 and a long wavelength band FRA (L-type FRA) 17 are used to construct a 2-wavelength band optical amplifier, which is designated as the new long wavelength band FRA (L*-type FRA), and a short wavelength band FRA (S*-type FRA) 18 is used at the short wavelength end of the new L*-type FRA, as a third amplifying section, in association with an L-divider ( 3 ′) and an S-combiner ( 6 ′). The outlines of the gain spectra of the amplifying sections (S-type FRA, L-type FRA, and S*-type FRA) are shown in FIG. 21.
[0107] The number of layers of the dielectric multi-layer filters used in the L-divider and S-combiner used in this embodiment is approximately 50. Similar to Embodiment 3, the width of the latent noise region relates, in this case, to the widths of the two wave boundaries in the 3-wavelength bands, and both are 14 nm. On the other hand, in the conventional optical amplifier, the corresponding boundary bandwidth is 38 nm.
[0108] As explained above, compared with the conventional technology, the width of the latent noise region (wavelength region that cannot be used for signal waves because of interference noise effects) in the present optical amplifier is about a third of the conventional width ({fraction (14/38)} to be exact).
[0109] Embodiment 5
[0110] [0110]FIG. 24 shows a configuration of the optical amplifier in Embodiment 5. This configuration appears similar to the one for Embodiment 1, but Embodiment 1 is based on the first amplifier configuration, and Embodiment 5 is based on the third amplifier configuration of the present invention. The amplifying section is comprised by an S-type EDFA for short wavelengths, an L-type EDFA for long wavelengths, and the divider and combiner are made of fiber couplers that are not dependent on wavelength and having a 1:1 split ratio. A fiber grating is placed in each aft-stages of the S-EDFA and L-EDFA for eliminating long wavelength signal waves and short wavelength signal waves, respectively, to serve as optical filters, and are respectively referred to as L-fiber-grating and S-fiber-grating. The S- and L-EDFA respectively amplify signal waves having wavelengths in a range of 1530˜1560 nm and wavelengths in a range of 1570˜1600 nm.
[0111] The S-fiber-grating filters only those signal waves having wavelengths in a range of 1550˜1560 nm to generate a loss value of more than 20 dB. However, the L-EDFA generates a gain of more than 20 dB for wavelengths of signal waves in a range of 1570˜1600 nm, at the same time, a gain of less than 10 dB for wavelengths of signal waves in a range of 1550˜1560 nm, and a loss of more than 10 dB for wavelengths of signal waves in a range of 1530˜1550 nm. Also, the L-fiber-grating filters only those waves having wavelengths in a range of 1570˜1600 nm to generate a loss value of more than 20 dB. However, the S-EDFA generates a gain of more than 20 dB for wavelengths of signal waves in a range of 1530˜1560 nm, at the same time, a gain of less than 10 dB for wavelengths of signal waves in a range of 1570˜1600 nm. Fiber gratings having such optical properties can be produced readily at low cost.
[0112] In this embodiment, non-useable wavelength range for signal waves is 10 nm that exists between 1560˜1570 nm. This value is less than half the value generally observed in the conventional technologies and is clearly less than the conventional amplifiers that do not use L- and S-fiber-gratings.
[0113] Also, in this embodiment, because the divider and combiner used in the input section and output section of the amplifier have a split ratio of 1:1 and no wavelength dependency, compared with an amplifier based on wave-separation type divider and combiner such as dielectric multi-layer filters, an excess loss value of nearly 3 dB is generated. However, fiber couplers having a 1:1 split ratio and no wavelength dependency have an advantage that they generally cost less than other types of filters. Also, the excess loss can be compensated by providing additional means.
[0114] Embodiment 6
[0115] [0115]FIG. 25 shows a configuration of the optical amplifier in Embodiment 6. This configuration may appear similar to the one for Embodiment 1, but a significant difference is that the divider is based on a dielectric multi-layer filter and the combiner is based on a fiber coupler having a 1:1 split ratio and no wavelength dependency. Also, an S-fiber-grating is placed in the aft-stage of the L-EDFA as an optical filter for filtering signal waves in the short wavelength band.
[0116] The S-fiber-grating filters only those signal waves having wavelengths in a range of 1550˜1560 nm to generate a loss value of more than 10 dB. However, the L-EDFA generates a gain of 20 dB for wavelengths of signal waves in a range of 1570˜1600 nm, at the same time, a gain of less than 10 dB for wavelengths of signal waves in a range of 1550˜1560 nm, and a loss of more than 10 dB for wavelengths of signal waves in a range of 1530˜1550 nm. Also, the S-divider generates a loss of more than 10 dB for signal waves in a range of 1530˜1560 nm between input port (c) and port (l) connecting to the L-EDFA.
[0117] In this embodiment, the latent noise bandwidth is 10 nm that exists between 1560˜1570 nm. This value is clearly less than the conventional amplifiers that do not use S-fiber-gratings, and is less than half the value generally observed in the conventional technologies.
[0118] The present invention has been demonstrated using examples as described above, but the configurations of the amplifiers are not limited to those demonstrated in specific examples, and includes those circuit designs within the concept outlined in the present invention.
|
In the optical amplifier an optical divider based on long wavelength (or short wavelength) transmission type dielectric multi-layer filter divides input signal light according to wavelengths, and amplifying sections disposed in parallel and having different respective wavelength amplification regions respectively amplify light signals emitted from the optical divider, and an optical combiner based on long wavelength (or short wavelength) transmission type dielectric multi-layer filter combines light signals output from the respective amplifying sections. In another configuration of the optical amplifier, input signal light is divided using an optical divider based on a dielectric multi-layer filter of a long wavelength (or short wavelength) transmission type, and output signals from the divider are filtered using an optical filter connected in series to a short wavelength (or long wavelength) amplifier generating a loss in the long wavelength (or short wavelength) region of the light signals. Interference noise caused by residual reflection components in the dielectric multi-layer filter is thus suppressed, thereby increasing the bandwidth of useable wavelengths in the signal light.
| 7
|
BACKGROUND OF THE INVENTION
[0001] This invention relates to packaging of cables, electronic device chargers and other items employing connectors.
[0002] Often, in the case of purchasing accessories (e.g., chargers, connection cables, headphones, headsets, hands free devices) for electronic devices, such as cellular phones, for example, consumers are overwhelmed by the large selection of different connection plugs available. Determining which plug type and size will fit the particular phone or device can be difficult. Further, once they have what they believe to be the correct plug the consumers can be frustrated when trying to open the clamshell package in which such items are typically sold. After opening the package, the consumer may determine that in fact the connector does not fit the device, and is the incorrect connector type. This leads to frustration for the consumer, and is likely to result in the accessory item being returned to the point of purchase. Since the packaging has been opened already, the vendor will now have to repackage the item for later resale, or will have to sell the product at a discount as a returned item.
SUMMARY OF THE INVENTION
[0003] In accordance with the invention, a system and method are provided to enable access to a connector plug of an accessory or cable without having to open the packaging in which the accessory or cable are packaged for sale. A collar member and corresponding locking member interact with the package, to hold the connector plug outside of the package for access for testing the fit of the plug prior to purchase.
[0004] Accordingly, it is an object of the present invention to provide an improved point of sales packaging for enabling testing of connections with devices prior without having to open the packaging.
[0005] It is a further object of the present invention to provide an improved method of presenting electronic device accessories for sale while allowing access to connector plugs for testing the fit thereof prior to purchase.
[0006] It is yet another object of the present invention to provide an improved manner to access a connector cable of a device in a package without having to open the package.
[0007] The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation, together with further advantages and objects thereof, may best be understood by reference to the following description taken in connection with accompanying drawings wherein like reference characters refer to like elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a top view of a clamshell package employing the invention;
[0009] FIG. 2 is a sectional view taken along line 2 - 2 of FIG. 1 ;
[0010] FIG. 3 is a perspective view of a lock collar portion of the device according to the invention;
[0011] FIG. 4 is a perspective view of an end cover portion of the device;
[0012] FIG. 5 is a perspective view of a cotter pin portion of the device;
[0013] FIG. 6 is a perspective view of the lock collar, end cover portion of FIG. 4 and cotter pin of FIG. 5 when assembled; and
[0014] FIG. 7 is a perspective view of an alternative end cover portion.
DETAILED DESCRIPTION
[0015] The system according to a preferred embodiment of the present invention comprises a base member and locking portion that interact with the wall of a point of sale clamshell package to securely hold a connector plug externally of the clamshell package, to enable access to the plug for testing of fit before purchase of the package.
[0016] A clamshell package is typically two parts, usually a front and a back molded alongside each other connected (all as one piece) that can be closed together in the manner of an actual clam shell.
[0017] A blister package is a molded plastic container that can be affixed to a cardboard backing, the blister package can also be made to fit around the cardboard backing, so you can simply slip the cardboard into the plastic package.
[0018] Referring to FIG. 1 , a top view of a clamshell package employing the invention therewith, the package 10 typically includes a base flange or backing card 12 , which may comprise cardboard or the like, and a top member 14 , typically made of some type of plastic, and together, items 12 and 14 define a package with an interior space to receive an item for point of sale presentation. Top member 14 will typically be transparent (at least partially) to enable consumers to view the item held therein. An opening 16 is defined at a top of the package to enable the package to hang at a point of sale location.
[0019] Inside the package, an accessory (not visible in FIG. 1 ) is placed, and may comprise, for example, a cellular telephone charging cord, which may carry a cigarette lighter plug for insertion to a cigarette lighter socket in an automobile. Also, the accessory might be a charger or other item adapted to connect to an electronic device (such as a computer, PDA, phone, game, etc.). In the illustrated example, the accessory has a cable 18 which carries an interface plug 20 at the end of the cable distal from the accessory, to enable the accessory and electronic device (e.g., cellular phone) to be interconnected.
[0020] Referring to FIGS. 1, 2 , 3 , 4 and 5 , in accordance with the invention, a base lock collar 22 and an end cover 24 are provided, wherein the base collar 22 is positioned outside the clamshell package, and includes an extending neck portion extending into the package, the neck portion has a wider distal end 26 , and a narrower central portion 28 . The base collar is suitably provided with a disk-like flange portion 30 . The portions 26 , 28 and 30 are substantially cylindrical in configuration, with a central through bore 32 that defines a substantially cylindrical opening. The lock collar 22 has a cut-out portion 34 extending radially from the center to the distal edge of the portion 30 .
[0021] FIG. 4 illustrates the details of the cover portion 24 , which is disk-like in appearance, having a central opening 36 sized to have the opening diameter correspond to the outer diameter of portion 28 of the lock collar 22 . Cover portion 24 has a cut out portion 38 extending radially from the center to the distal edge of the portion 24 .
[0022] FIG. 5 illustrates a cotter pin 25 , which suitably has a bias to return to a set configuration when bent, so as to allow expanding to fit over the lock collar, but returning to its original shape to assist in keeping the lock collar, cover and package/cable in engagement with one another.
[0023] In operation, the clam shell package has an opening therein adapted to receive portions 26 and 28 of lock collar 22 therethrough and also cable 18 and plug 20 therethrough. The cable 18 is passed through the opening 34 in lock collar 22 so that the cable 18 is now positioned in opening 32 , the plug portion of cable 18 is passed through the opening of the clamshell so that the plug 20 is now outside of the clamshell package. Portions 26 and 28 are passed through the opening of the clamshell so as to extend to the inside thereof. Flange portion 30 interacts with the outside face of the clamshell package top member 14 to prevent movement of the lock collar beyond the inside face of the clamshell. Lock end cover 24 is then fit over the extended portion of lock collar 22 , to fit around the portion 28 thereof. Cotter pin 25 then fits around the portion 28 , to further secure the cover portion 24 relative to the lock portion 22 . The interaction of the various noted components thus enable the plug 20 to be displayed externally of the clamshell, allowing access to the plug for testing the fit thereof prior to purchase, while keeping the cable substantially secured inside the package. The cable may suitably be looped or knotted inside the package to further prevent it from being pulled beyond the lock collar portion 26 . FIG. 6 illustrates the interaction of lock collar 22 , lock end cover 24 and cotter pin 25 when joined together (with the cord 18 and clamshell 14 removed, to show the interaction of these components). It will be noted that the space 40 between the flange 30 and cover 24 is the region where the clamshell 14 wall is received.
[0024] It will be understood that the configurations shown thereby enable access to the plug portion 20 , for testing the fit thereof. Also, the diameter of the openings 32 and 36 may be made such that the cable can be pulled out of or pushed back into the clamshell interior, to allow reaching further from the package with the plug, if desired. In such a case, if the cable is knotted to prevent removal from the package, a sufficient distance from the plug to the knotted portion is provided to allow some movement of the cable out of the package. Alternatively, the diameters can be such that the cable does not readily move, in the case where it is not desired that the cable be so extended or retracted.
[0025] While the noted examples of use are for testing fit of a plug, alternatively the plug (or, alternatively, a socket) could also be used to provide power or communications to/from a device inside the packaging, for programming of the device in the package (or an external device), for providing power to a device to test/demonstrate the functions thereof, to recharge a device, or the like.
[0026] A further alternative embodiment, rather than have the lock collar be formed as a separate member as in the preferred embodiment, is to have the clamshell package be pre-formed in the configuration of a lock collar. Then, the lock end cover operates to with the pre-formed section of the clamshell to hold the plug and cable in place. A post is molded into the inside of the cavity in the clamshell/blister package, with an open end in the clamshell, to display the plug/connector and fit a number of plugs. The plugs can be secured (e.g. by tying) around the post inside of the cavity to secure the cord inside of the package.
[0027] Still further, the clamshell portion can be formed to sufficiently engage the cable and plug so as to hold the plug outside of the clamshell, without needing the lock end cover. This may be accomplished, for example, by the clamshell cover portion around the cable/plug shrinking (such as by application of heat) to fit tightly with the cable/plug.
[0028] The clamshell/blister package can be molded around a plug/connector/cord, secured inside of the package by a wire or string, or nylon fastener, or flexible securement device. The securing material can be positioned through holes trough the back of the package and around the plug/connector/cord, or the plug/connector/cord can be attached by two posts molded inside of the clamshell/blister package.
[0029] The plug/connector could be displayed outside the molded clamshell/blister package trough the front or back of the package as well as trough the walls of the cavity. The plug/connector/adapter can also be connected to an open front package of varied materials by securing the device to the package trough various means with various materials.
[0030] A still further embodiment of the lock collar and lock end covers do not employ the openings 34 or 38 , and instead, member 22 and 24 are formed of material with sufficient stretching properties to allow them to stretch to fit over the plug and cable portions for installation, but having sufficient rebound properties to return to original shape and size, so as to maintain the plug in engagement.
[0031] Another embodiment involves forming the lock collar on the cable at manufacture time of the cable (or after manufacture). Then after purchase, the consumer can break or tear or cut off the lock collar.
[0032] While the embodiments illustrated show electrical connectors and cables, the packaging concept is also applicable to optical cables, tubing connectors and the like.
[0033] In accordance with the invention, therefore, a package with a plug or connector extending therefrom is provided to allow access to the plug/connector for testing fit, testing operation of a device, powering, programming or otherwise accessing a device or accessory without having to open the package. This enables a consumer to ensure that the connector plug fits the consumer's device, which may be cellular phone, a PDA, a game console or the like.
[0034] In the preferred embodiment, the lock collar 22 and lock cover member are suitable formed by molding a pliable yet firm rubber or plastic material. Also, injection molding may be employed. In a particular embodiment, the diameter of the flange portion 30 is 2.25 cm. Cover 24 is suitably of similar diameter. The overall height 42 ( FIG. 3 ) is 1.25 cm. The outer diameter 44 of portion 26 is approximately 2.5 mm, while the outer diameter of portion 28 is approximately 1.5 mm. The inner diameter of portion 32 is suitably 0.75 mm. These dimensions will vary, of course, depending on the particular size and configuration of the plug/connector 20 and cable 18 with which the device is used. Also, these diameters are employed with a stiff plastic clamshell package. Other package materials may warrant changes in the diameters to accomplish the desired engagement between the package, lock member and plug.
[0035] An alternative embodiment of the end cover is shown in FIG. 7 . This end cover 24 ′, includes a flap portion 46 and corresponding depression 48 , whereby the flap portion folds down to cover the opening 38 , to provide a cover for the opening 38 . A protrusion 50 and corresponding depression 52 may be provided to engage or align the flap and depression.
[0036] Advantages thereby provided include enabling a consumer with little or no knowledge of the variety of plug/socket combinations to test and ensure that the correct fit is made. Also, the consumer can choose a plug in accessory without having to seek the assistance of a sales clerk to determine which plug style is correct. Retailers are thereby assisted in knowing that the consumers can select the correct accessory plug style with little or no assistance from the retailer. Still further, the retailer can display items for sale knowing the items will likely remain in the package until the time of sale, reducing the likelihood that consumers will open the packages and take the items out to test the fit before purchase, reducing the likelihood of damage to the package or item, and removing the need to reunite opened items with their packages and repackage them.
[0037] While plural embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. The appended claims are therefore intended to cover all such changes and modifications as fall within the true spirit and scope of the invention.
|
A packaging configuration of a device inside a package maintains a plug or connector of the device accessible externally of the package, without having to open the package. The plug or connector is accessible to test the connectivity or to power or communicate with the device.
| 1
|
BACKGROUND OF THE INVENTION
[0001] This invention relates to concrete formed structures and methods for making concrete formed structures.
[0002] Many homeowners are using concrete incorporated in functional features of a home such as integral sinks, drainboards, and butcher blocks. Typically, concrete structures such as tables and countertops are either pre-cast in a shop or built on site. Contractors who use pre-cast concrete typically pour the concrete in the shop where conditions are controlled, using special casting tables, and they have the countertop in their possession while it is curing and until it can be adequately sealed.
[0003] Concrete structures are made of cement, lightweight aggregates, and a combination of additives. Additives such as fiber reinforcement, silica fume pozzolan, and acrylic are often used.
[0004] Some type of reinforcement is used such as structural steel, wire mesh, fiberglass, and/or fibers. Sometimes more than one type of reinforcement is used.
[0005] After pouring the concrete and adding the structural support, the concrete structures are cured. Next, countertops are ground, grinding off the surface with progressively finer diamond polishing stones. This achieves two important objectives, durability and beauty.
[0006] Next, the concrete structures are sealed. The type of seal, method and number of coats of sealer is unique to each concrete installer. Some installers prefer epoxy sealers, which are preferable harder than the concrete.
SUMMARY OF THE INVENTION
[0007] This invention relates to concrete formed tables and methods for making concrete formed tables. Particularly, utilizing the methods of the present invention, ornamental tables can be produced with intricate inlaid and/or engraved insignia, such as letters, designs, advertising, or other suitably attractive material. Furthermore, utilizing the methods of the present invention, ornamental tables can be produced with highly detailed features on the side surfaces of the tables.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a mold used in the present invention, the mold bearing an insignia.
[0009] FIG. 2 is a top view of the mold, including a design and a jig.
[0010] FIG. 3 is a perspective view of a finished structure, incorporating the insignia, the design, a base coupler, and a base.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
[0012] Referring now to FIG. 1 , a perspective view of a mold 10 used to produce a table or other structure 60 (shown on FIG. 3 ) in the present invention is shown, the mold bearing an insignia 30 on an inside wall of the mold 10 . The insignia 30 is a mirror image of the desired end product insignia, because the insignia will then be legible outside the mold. It is noted that the insignia 30 is preferably positively formed (i.e., not an indentation in the mold) in order that the insignia in the structure 60 will ultimately appear engraved. However, it is understood that the insignia 30 could also be an indentation in the mold 10 , to produce a positive emblem on the structure 60 .
[0013] Because the insignia 30 can be as detailed as a user desires, it is preferable that a relatively soft molded rubbery material is used to form the mold 10 to both ease eventual withdrawal of the mold 10 , yet provide enough rigidity to sustain the detail level of the insignia during curing.
[0014] One preferred material for the mold 10 that the inventor has found advantageous is a liquid mold rubber composition, such as polyurethane RTV (or “Room Temperature Vulcanizing”) mold rubber, manufactured by PolyTek Development Corporation of Easton, Pa., who provide flexible high strength rubber for making tough durable molds.
[0015] Referring now to FIG. 2 , a top view of the mold 10 , including a design 40 and a jig 50 is shown.
[0016] To manufacture a structure, first the mold 10 is provided. Next, the manufacturer places a design 40 , if desired, into the bottom of the mold 10 , the bottom filled portion of the mold 10 ultimately becoming the top of the structure 60 .
[0017] A lightning bolt is shown as a design 40 , although the shape, size, color, and composition of the design 40 can vary widely in accordance with user preference. For instance, any type of design, such as a trademark for marketing purposes, can be employed as a design 40 , creating an effective marketing tool.
[0018] Preferred materials to create the design 40 include, but are not limited to, acrylic, stainless steel, aluminum, brass or the like.
[0019] A weighted jig 50 is placed on top of the design 40 , such that the design 40 remains on the bottom of the mold 10 when the concretious material is poured into the mold 10 . The shape of the jig 50 may vary from that shown. It is preferable that the jig 50 is taller than the mold 10 so that the jig 50 can be removed later in the process, although the jig 50 could remain embedded within the structure 60 if desired. The jig 50 is provided so that the concrete material does not travel under the design 40 , so that the design 40 remains apparent to viewers after the mold 10 has been removed (described later).
[0020] Next, the manufacturer fills the mold 10 with suitable material (not shown), such as cement, lightweight aggregates, and/or any combination of additives, as fiber reinforcement, silica fume pozzolan, acrylic, coloring materials in accordance with manufacturer preference.
[0021] Next, the manufacturer preferably gently vibrates the filled mold 10 (not shown), allowing air bubbles to escape the concretious matrix contained in the mold 10 .
[0022] Next, the manufacturer can remove the jig 50 from the mold 10 (not shown), and the fill material, because at this point the design 40 will have remained at the bottom of the mold 10 .
[0023] Next, the manufacturer strikes off, or levels, extra concrete material from the top of the mold 10 (not shown), creating a relatively even surface that will eventually become the bottom of the structure.
[0024] Next, the manufacturer can place reinforcement, such as steel, within the concrete matrix (not shown).
[0025] Next, the manufacturer again trowels or strikes off, or levels, extra concrete material from the top of the mold 10 (not shown), creating a relatively even surface that will eventually become the bottom of the structure.
[0026] Next, the manufacturer inserts a suitable base 70 (shown on FIG. 3 ), into top of the concrete matrix (that will eventually become the bottom of the structure). The base 70 can vary widely, but one preferable base is a metal structure that is coupled to the concrete matrix by an anchor/bolt system coupled to the base and the matrix. Also preferably, the base 70 will have a threaded coupler for coupling remaining base support, such as support 80 shown on FIG. 3 .
[0027] Next, the manufacturer allows the concrete matrix to cure, preferably overnight. At this point, the concrete matrix has dried from a wet condition to a “green” condition. At this point, the manufacture can remove the mold 10 from the structure 60 .
[0028] The structure 60 is then allowed to “rack” or dry for preferably a period of two days, dependent on the type of concrete matrix employed.
[0029] At this point in the process, the structure 60 is in a dry condition. Preferably, a slurry is used to fill in any void space that the manufacturer wishes to cover (not shown), and again allowed to sit to allow the slurry to dry.
[0030] Preferably, the structure is then polished, such as with a circular sanding device, to remove any of the matrix that may have concealed portions of the design 40 .
[0031] Next, a coating is applied to the structure 60 , and any excess coating is then removed if desired.
[0032] As shown in FIG. 3 , a finished structure 60 is then produced, with a design 40 , an insignia 30 , a base 70 and a support structure 80 .
[0033] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
|
An ornamental table is disclosing having structure such a concrete matrix, an exposed design on a top surface of the matrix, and an insignia on a side surface of the matrix. A method of producing the table is also disclosed.
| 0
|
CROSS REFERNCE TO RELATED APPLICATION
[0001] This is a continuation of U.S. application Ser. No. 10/161,635, filed Jun. 5, 2002, the subject matter of which is incorporated by reference herein. This application also relates to U.S. application Ser. No. 11/126,160, filed on May 11, 2005, the subject matter of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a display apparatus having a display panel in which display pixels are arranged in a matrix and a driving device for supplying to the display panel a gray scale voltage corresponding to display data. More specifically, the invention relates to a display apparatus that uses a liquid crystal material, organic EL, and plasma and its driving device for displaying.
[0003] JP-A-2001-13478 discloses a liquid crystal display apparatus source driver that constitutes a reference voltage generating circuit for generating a gamma correction reference voltage by resistive voltage division, and a resistance setting circuit for selecting a resistance to be used for the resistive voltage division from among a plurality of resistances. The reference further discloses that a gamma correction setting register receives data for setting the value of resistance, appeared on a display data line, in response to a clock signal CK when an enable signal E goes to “H”, and then switching on or off respective switches for resistances and other switches that comprise the reference voltage generating circuit according to the bit value of the received data for setting the value of resistance, thereby determining the reference voltage.
[0004] JP-A-6-348235 discloses a liquid crystal display apparatus that constitutes a liquid crystal display panel having a X signal line and a Y signal line, a horizontal driver for selecting a gray scale signal from among a plurality of gray scale signals supplied from a gray scale voltage generating circuit, on the basis of a data signal of an image to be displayed, for supply onto the X signal line of the liquid crystal display panel, and a vertical driver for supplying a liquid panel scanning signal onto the Y signal line of the liquid crystal display panel. The reference further discloses that the gray scale voltage generating circuit constitutes a plurality of fixed resistances interposed in series between the sides of the reference voltage of a high potential and the reference voltage of a low potential, and voltage varying unit for varying a voltage at a connection point between the fixed resistances to a voltage between the high potential reference voltage and the low potential reference voltage, thereby supplying the voltage at the connection point between the fixed resistances as a gray scale signal. The reference furthermore discloses that by adjusting the resistance value of a variable resistance in the above-mentioned manner, the voltage level of the gray scale signal or a gray scale voltage can be arbitrarily adjusted, so that gray scale characteristics can be freely modified.
[0005] JP-A-11-24037 discloses a gray scale voltage generating circuit that constitutes amplification unit for generating a variable intermediate-level gray scale voltage from an intermediate-level reference voltage and amplification unit for supplying gray scale voltages of negative polarity. The former amplification unit divides a reference supply voltage with the resistance divided for amplification, thereby generating a higher gray scale voltage of positive polarity and a lower gray scale voltage of positive polarity. Then, the amplification unit further divides these voltages with the resistance divided, thereby generating the intermediate-level reference voltage. Finally, the amplification unit generates the variable intermediate level-gray scale voltage from the intermediate-level reference voltage, using a variable resistance as a feedback resistance. The latter amplification unit inverse-amplifies all the gray scale voltages of positive polarity, obtained by dividing the resistive voltage and then amplifying the reference supply voltage, at the same amplification factor with respect to a liquid crystal GND potential, for supply as the gray scale voltages of negative polarity. The reference further discloses that the gray scale characteristics can be adjusted just by adjusting a single variable resistance.
[0006] In the above-mentioned art, however, among 64 gray scale levels of voltages, the voltages at the two ends are fixed as a GND voltage or the reference voltage externally supplied. Accordingly, adjustment to the gray scale voltage fixed as the GND voltage is impossible. Further, for adjustment to the gray scale voltage fixed as the reference voltage, an additional adjustment circuit becomes necessary outside the gray scale voltage generating circuit, thus leading to an increase in the number of components. Though there are some cases where adjustment to the voltages of the gray scale levels at the two ends becomes necessary due to the characteristic differences of liquid crystal display panels, the above-mentioned techniques did not take such cases into consideration.
[0007] JP-A-11-175027 discloses a liquid crystal driving circuit that constitutes a latch address control circuit, a first holding circuit, a second holding circuit, setting registers, a gray scale voltage generating circuit, a gray scale voltage selector circuit, and an amplifier circuit. The latch address control circuit sequentially generates latch signals that receive display data. The first holding circuit holds the number of display data equivalent to the number of output data lines in response to a latch signal, and the second holding circuit receives and then holds the number of display data held in the first holding circuit, equivalent to the number of the output data lines in response to a horizontal synchronization signal. The setting registers control the value of a gray scale voltage. The gray scale voltage generating circuit receives a plurality of different reference voltages to generate a gray scale voltage specified by one of the setting registers. The gray scale voltage selector circuit selects a gray scale voltage according to the display data held in the second holding circuit, and the amplifier circuit shifts the gray scale voltage selected by the selector circuit so as to be more closer to an offset voltage, and amplifies the gray scale voltage by an amplitude factor specified by one of the setting registers, for supply. The reference further discloses that the setting registers for setting the amplification factor of respective operational amplifiers in the amplifier circuit are provided for respective R, G, and B display colors, and that a voltage setting can be changed according to each of the colors. The reference further discloses that an offset voltage setting can be changed, because the offset voltage of the amplifier circuit is generated by dividing an offset reference voltage with the resistance divided and a common voltage, using a plurality of variable resistances, the resistance value of which can be set. In the above-mentioned art, however, an offset adjustment circuit becomes necessary in the amplified circuit. Thus the size of the driving circuit becomes large, so that the cost of the circuit increases. Further, in this art, a gamma correction control register sets the resistance values of all the variable resistances in a resistance ladder for adjustment so as to obtain a desired gamma characteristic. Accordingly, if the resistance value of a single variable resistance is adjusted, the overall resistive voltage division ratio would be changed. This leads to a change in all the gray scale voltages. Thus, in order to adjust gray scale voltages according to the respective characteristics completely, it would take much time. Further, The reference does not disclose adjustment to the gray scale voltage amplitude.
[0008] JP-A-2001-22325 discloses a liquid crystal display apparatus that constitutes a pair of amplifiers, a voltage dividing circuit for generating a plurality of a pair of symmetrical reference voltages of positive and negative polarities from standard voltages of positive and negative polarities, and a variable voltage generating circuit for supplying a pair of symmetrical reference voltages of positive and negative polarities for gray scale adjustment to a pair of voltage dividing points in the voltage dividing circuit, associated with specific intermediate gray scale levels. The reference further discloses that by increasing a positive reference voltage V x−2 from a positive reference voltage V x−1 by a desired value and decreasing a negative V x+1 from V x by the desired value simultaneously in the variable voltage generating circuit in a normally white mode, the voltage values of reference voltages V 0 to V x−2 , V x+1 to V 2x−1 can be changed smoothly. The reference discloses that, with this arrangement, adjustment to and modification of a gray scale level-brightness characteristic can be easily performed by a single variable voltage generating circuit.
[0009] However, the above-mentioned art does not display insertion of a variable resistance into the reference voltage generating circuit, and does not disclose adjustment to the amplitude of a gray scale voltage.
SUMMARY OF THE INVENTION
[0010] An object of the present invention is to provide a display apparatus and a display driving device in which, by adjusting both of the gradient and the amplitude of a gray scale number-gray scale voltage characteristic, adjusting accuracy is improved, and image quality is thereby improved.
[0011] Therefore, a display apparatus and a display driving device according to the present invention comprise a gray scale voltage generating circuit for generating a plurality of levels of a gray scale voltage from a reference voltage, an amplitude adjustment register capable of setting the amplitude of a characteristic curve of a plurality of levels of the gray scale voltage with respect to gray scale numbers, and a gradient adjustment register capable of setting the gradient of the characteristic curve.
[0012] Then, preferably, the display apparatus and the display driving device according to the present invention further comprise resistive voltage dividing circuits for dividing the reference voltage with resistance divided, an amplitude adjustment variable resister connected in series with the side of the reference voltage closer to the side of the reference voltage than the resistive voltage dividing circuits, the resistance setting of which is adjustable according to a setting in the amplitude adjustment register, and a gradient adjustment variable resister connected in series with the resistive voltage display circuits, the resistance setting of which is adjustable according to a setting in the gradient adjustment register.
[0013] Alternatively, preferably, the display apparatus and the display driving device according to the present invention further comprise resistive voltage dividing circuits for dividing the reference voltage with the resistance divided, an amplitude adjustment variable resister connected in series with ground, closer to the ground than the resistive voltage dividing circuits, the resistance setting of which is adjustable according to a setting in the amplitude adjustment register, and a gradient adjustment variable resister connected in series with the resistive voltage dividing circuits, the resistance setting of which is adjustable according to a setting in the gradient adjustment register.
[0014] According to the present invention, both of the gradient and the amplitude of the gray scale number-gray scale voltage characteristic can be adjusted. Thus, adjusting accuracy is improved, and image quality is thereby improved.
[0015] Other objects, features and advantages of the invention will become apparent from the following description of the embodiments of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIGS. 1A, 1B , and 1 C are characteristic curves showing a gamma characteristic of a typical liquid crystal display panel;
[0017] FIGS. 2A, 2B , 2 C and 2 D are characteristic curves showing adjustments to the gamma characteristic according to the present invention;
[0018] FIG. 3 is a block diagram showing a configuration of a gray scale voltage generating circuit according to a first embodiment of the present invention;
[0019] FIGS. 4A and 4B are a block diagram showing configurations of a variable resister according to the first embodiment of the present invention;
[0020] FIG. 4C is a table showing a relationship between a register setting and the resistance value of the variable resister according to the first embodiment of the present invention, respectively;
[0021] FIGS. 5A, 5B , and 5 C are characteristic curves showing adjustment operations of the gamma characteristic using settings of an amplitude adjustment register according to the present invention;
[0022] FIGS. 6A, 6B , and 6 C are characteristic curves showing adjustment operations of the gamma characteristic using settings of a gradient adjustment register according to the present invention;
[0023] FIGS. 7A and 7B are a block diagram showing a configuration of a selector circuit, showing a relationship between a register setting value and a resistance divided voltage according to the first embodiment of the present invention, respectively;
[0024] FIG. 8 is a characteristic curve showing an adjustment operation of the gamma characteristic using settings of a micro adjustment register according to the present invention;
[0025] FIG. 9 is a block diagram showing a configuration of a liquid crystal display apparatus system according to a first embodiment of the present invention;
[0026] FIGS. 10A and 10B are timing diagrams showing a flow for a register setting according to the present invention;
[0027] FIG. 11 are characteristic curves showing asymmetrical gamma characteristics of a liquid crystal display panel;
[0028] FIG. 12 is a block diagram showing a configuration of a gray scale voltage generating circuit according to a second embodiment of the present invention;
[0029] FIG. 13 is a block diagram showing a configuration of a gray scale voltage generating circuit according to a third embodiment of the present invention;
[0030] FIG. 14 is a block diagram showing a configuration of a liquid crystal display apparatus system according to a second embodiment of the present invention;
[0031] FIG. 15 is a block diagram showing a configuration of a liquid crystal display apparatus system according to a third embodiment of the present invention; and
[0032] FIG. 16 is a block diagram showing a configuration of a liquid crystal display apparatus system according to a fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0033] A typical gamma characteristic will be described with reference to FIGS. 1A, 1B , and 1 C. FIG. 1A shows an applied voltage-brightness characteristic when a liquid crystal display panel is in a normally black mode. The smaller the applied voltage is, the lower the brightness becomes, and the larger the applied voltage is, the higher the brightness becomes. It can be seen from this characteristic curve that a change in the brightness with respect to the applied voltage is slow or becomes saturated in a low applied voltage region and a high applied voltage region.
[0034] In addition to liquid crystal display panels in the normally black mode, there are also liquid crystal display panels in a normally white mode. However, a description herein will be directed to the case where the liquid crystal display panel is in the normally black mode. Incidentally, the present invention can be practiced irrespective of the mode of the liquid crystal display panel.
[0035] Next, FIG. 1B shows gray scale number-brightness characteristics. This characteristic is commonly referred to as the gamma characteristic. A solid line indicated by reference numeral 101 shows the characteristic that the brightness linearly increases as the gray scale number increases, and this characteristic is defined as the characteristic when y=1.0. The value of y is obtained from the following expression (1):
(gray scale number) γ =brightness [ cd/m 2 ] (1)
[0036] From the above expression (1), it can be seen that curves indicated by reference numerals 102 and 103 show the characteristics when γ=2.2 and γ=3.0, respectively. Traditionally, when display data is displayed on the liquid crystal display panel, the gamma characteristic a person perceives has the highest image quality is generally the characteristic indicated by the curve 102 when γ=2.2.
[0037] Thus, in a liquid crystal display apparatus, by adjusting an applied voltage for each gray scale number, adjustment to the gamma characteristic is made.
[0038] FIG. 1C is a characteristic curve showing the relationship between gray scale number and applied voltage when the number of gray scale levels is set to 64. The applied voltage-brightness characteristic shown in FIGS. 1A, 1B , and 1 C varies from one liquid crystal display panel to another liquid crystal display panel. When an applied voltage is adjusted such that y becomes equal to 2.2, for example, an adjusted value of the applied voltage becomes different according to each of the liquid crystal display panels. A curve indicated by reference numeral 104 in FIG. 1C shows the relationship between gray scale number and applied voltage when γ=2.2. Curves indicated by reference numerals 105 and 106 show relationships between gray scale number and applied voltage when γ=2.2 in liquid crystal display panels different from the one for the curve 104 . As described above, in a liquid crystal display apparatus, a gray scale voltage generating circuit becomes necessary that can adjust an applied voltage, which will be referred to as a gray scale voltage, according to the characteristic of each liquid crystal display panel so as to obtain a desired gamma characteristic.
[0039] In order to allow adjustment to voltages of the gray scale levels at the two ends, the present invention is configured to have a resistance ladder. In this configuration, variable resistances are disposed at both ends of the resistance ladder. A reference voltage is externally supplied to one of the ends and the other end is coupled to ground. Voltages of the gray scale levels at the two ends such as the ones indicated by reference numerals 107 and 108 in FIG. 1C are generated by resistive voltage division using the variable resisters. Further, it is arranged such that a register, which will be referred to as an amplitude adjustment register, can set the resistance values of the variable resisters, and that offset adjustment which was conventionally made by an amplifier circuit was also made possible by the resistance ladder.
[0040] The present invention is not limited to this arrangement, and is configured to have the resistance ladder by which other voltages of gray scale levels than the ones of gray scale levels at the two ends can also be adjusted by register settings. The contents of the adjustments will be explained with reference to FIGS. 2A, 2B , and 2 C.
[0041] FIG. 2A shows gray scale number-vs.-gray scale voltage characteristics in the cases where the resistance values of the variable resistances at both ends of the resistance ladder have been set by the amplitude adjustment register. Dotted lines indicated by reference numeral 201 show the characteristics where an amplitude voltage adjustment to gray scale voltages is made such that the gray scale voltage of the highest scale level is changed without changing the gray scale voltage of the lowest gray scale level. Solid lines indicated by reference numeral 202 show the characteristics where the amplitude voltage adjustment to the gray scale voltages is made such that the gray scale voltage of the lowest scale level is changed without changing the gray scale voltage of the highest gray scale level. Both of the characteristic lines 201 and 202 show the cases where one of the variable resisters at both ends of the resistance ladder or the variable resisters on both of the reference voltage side and the ground side of the resistance ladder has been set by the amplitude adjustment register. Solid lines indicated by reference numeral 203 on FIG. 2B show characteristics where the variable voltages at both ends of the resistance ladder have been simultaneously set by the amplitude adjustment register. In this case, the same effect as in the case of offset adjustment that was made by the amplifier circuit can be obtained.
[0042] Next, solid lines indicated by reference numeral 204 in FIG. 2C show gray scale number-gray scale voltage characteristics where the gradient characteristic of voltages of intermediate gray scale levels is adjusted. This adjustment can be made by the gradient adjustment register. This register allows setting of the resistance values of the variable resisters that generate gray scale voltages 205 and 206 that determine the gradient characteristic in the resistance ladder.
[0043] As described above, gray scale voltages indicated by the curves 104 to 106 in FIG. 1D in accordance with the characteristics of respective liquid crystal display panels can be roughly set by the amplitude adjustment register and the gradient adjustment register. Adjustment to obtain a desired gamma characteristic according to the characteristics of respective liquid crystal display panels can be thereby facilitated, so that an adjustment time can be shortened.
[0044] Next, solid lines indicated by reference numeral 207 in FIG. 2D show gray scale number-gray scale voltage characteristics where respective gray scale voltages are micro adjusted. This micro adjustment becomes possible by providing resistive voltage dividing circuits for further dividing the respective voltages of gray scale levels resistive-voltage-divided by one or a plurality of the variable resisters and then allowing a desired gray scale voltage to be selected from among the voltages generated by the resistive voltage division according to a setting in a micro adjustment register. With this arrangement, even if a single variable resistance value is changed, which is the case where the problem described above would occur, respective gray scale voltages resistive-voltage-divided by this variable resister are further resistive-voltage-divided to select a desired voltage. Only the desired gray scale voltage can be thereby adjusted with no other gray scale voltages changed so much.
[0045] Further, by allowing the micro adjustment of respective gray scale voltages, adjustment to the gamma characteristic can be made with higher accuracy, so that higher image quality can be effected. As described above, the present invention is configured to have a resistance ladder. With this configuration, when adjustment to the gamma characteristic is made, rough gray scale adjustment such as amplitude voltage adjustment to the gray scale voltages and the gradient characteristic adjustment to the voltages of intermediate gray scale levels according to the characteristics of respective liquid crystal display panels can be made by using settings of the amplitude register and the gradient register. Adjustment to the gamma characteristic can be thereby facilitated, so that an adjustment time can be shortened. Further, by providing the micro adjustment register, micro adjustment to the gray scale voltages which have been adjusted by the amplitude adjustment register and the gradient adjustment register can be further made. Adjusting accuracy can be thereby improved, so that high image quality can be effected. Still further, a degree of freedom in an adjustment range is increased. Thus, versatility of adjustment is obtained.
[0046] A configuration of a liquid crystal display apparatus according to a first embodiment of the present invention will be described with reference to FIGS. 3 to 10 .
[0047] FIG. 3 is a block diagram showing a configuration of a gray scale voltage generating circuit according to the present invention. Reference numeral 301 denotes a control register for holing settings for adjusting the gamma characteristic, reference numeral 302 denotes the gray scale voltage generating circuit, and reference numeral 303 denotes a decoder circuit for decoding a gray scale voltage corresponding to display data. The control register 301 constitutes an amplitude adjustment register 304 , a gradient adjustment register 305 , and a micro adjustment register 306 , described above. Incidentally, the values in the control register 301 may also be stored in a non-volatile memory in a CPU to which the liquid crystal display apparatus is connected.
[0048] The gray scale voltage generating circuit 302 constitutes a resistance ladder 307 disposed between the sides of a reference voltage 316 externally supplied and GND, for generating voltages of gray scale levels, variable resisters 321 to 324 and resistive voltage division circuits 326 to 331 for further dividing voltages with resistance divided by the variable resisters, all of which constitutes the resistance ladder 307 , selector circuits 308 to 313 for selecting a gray scale voltage generated by the resistive voltage dividing circuits 326 to 331 according to a setting in the micro adjustment register 306 , an amplifier circuit 314 for buffering the output voltage of the respective selector circuits, and an output unit resistance ladder 315 for dividing the output voltage with resistance divided of the amplifier circuit 314 into a desired number of gray scale levels (herein 64) of voltages.
[0049] The lower variable resistance 321 disposed at the bottom of the resistance ladder 307 is configured to allow setting of its resistance value according to a lower variable resistance setting 317 set in the amplitude adjustment register 304 . The upper variable resister 322 disposed on the top of the resistance ladder 307 is configured to allow setting of its resistance value according to an upper variable resistance setting 318 set in the amplitude adjustment register 304 . Then, it is arranged such that the voltages divided by the variable resisters 321 and 322 are set to the voltages of the gray scale levels at the two ends, and amplitude adjustment of a gray scale voltage can be set by the amplitude adjustment register 304 . The lower variable resister 321 is connected to the GND side in series, being closer to the GND side than the resistive voltage dividing circuit 331 and the lowest level of the gray scale voltage. The upper variable resister 322 is connected to the side of the reference voltage 316 in series, being closer to the side of the reference voltage 316 than the resistive voltage dividing circuit 326 and the highest level of the gray scale voltage. That is, the lower variable resister 321 and the upper variable resister 322 are disposed outside the resistive voltage dividing circuits. When the gray scale voltage amplitude is reduced by the variable resisters 321 and 322 , power dissipation can be reduced. For this purpose, either one of the variable resisters 321 and 322 may be employed.
[0050] The lower-middle variable resister 323 disposed in the lower position from the middle of the resistance ladder 307 is configured to allow setting of its resistance value according to a lower-middle variable resistance setting set in the gradient adjustment register 305 . The upper-middle variable resister 324 disposed in the upper position from the middle of the resistance ladder 307 is configured to allow setting of its resistance value according to an upper-middle variable resistance setting set in the gradient adjustment register 305 . The voltages divided by both of the variable resisters 323 and 324 with the resistance divided are set to voltages of gray scale levels that determine the gradient characteristic of the voltages of intermediate gray scale levels, and it is arranged such that the gray scale voltage gradient characteristic can be set by the gradient adjustment register 305 . The variable resisters 319 and 320 are connected with the resistive voltage dividing circuits in series. Even if the variable resistance settings 319 of the variable resister 323 and the variable resistance setting 320 of the variable resister 324 change, the gray scale voltage amplitude is not affected so much. By adjusting both of the variable resisters 323 and 324 , the contrast of an image can be improved. For this purpose, either one of the variable resisters 323 and 324 may be employed.
[0051] By configuring the gray scale voltage generating circuit to have the resistance ladder as described above and setting variable resistance values in the resistance ladder by means of the amplitude adjustment register 304 and the gradient adjustment register 305 , a resistive voltage division ratio can be changed, so that the amplitude voltage adjustment to the gray scale voltages and the gradient characteristic adjustment to the voltages of the intermediate gray scale levels can be adjusted. Details of these operations will be described later.
[0052] Gray scale voltages generated according to the variable resistance values set in the amplitude adjustment register 304 and the gradient adjustment register 305 are further divided by the resistive voltage dividing circuits 326 to 331 with the resistance divided to generate micro-adjustment gray scale voltages to which micro adjustment is made. Next, the micro-adjustment gray scale voltages are supplied to the selector circuits 308 to 313 to select a desired gray scale voltage according to a setting 325 set in the micro adjustment register 306 . With this arrangement, micro adjustment to the respective gray scale voltages can be made, and the accuracy of adjustment to the gamma characteristic can be improved, so that the degree of freedom of adjustment is also improved. Details of this operation will be described later.
[0053] The respective gray scale voltages generated as described above are buffered at the amplifier circuit 314 in a subsequent stage. Then, in order to generate desired voltages of 64 gray scale levels, the gray scale voltages are divided by the output unit resistance ladder 315 with the resistance divided so as have a linear relationship to one another, and thereby the 64 gray scale voltages are generated. With this arrangement, among the 64 gray scale voltages generated by the gray scale voltage generating circuit 302 , a gray scale voltage corresponding to display data is decoded to become an applied voltage to the liquid crystal display panel.
[0054] The circuit as described above constitutes a resistance ladder that can make rough gray scale voltage adjustments such as the amplitude voltage adjustment to the gray scale voltages and the gradient characteristic adjustment to the voltages of intermediate gray scale levels by using settings in the amplitude adjustment register 304 and the gradient adjustment register 305 , when the gamma characteristic is adjusted. Then, it is arranged such that micro adjustment to the respective gray scale voltages generated by the resistance ladder can be further made according to a setting in the micro adjustment register 306 . Adjustment to the gamma characteristic can be thereby facilitated, so that an adjustment time can be shortened. Then, the adjusting accuracy and the degree of freedom of adjustment are improved, so that a small-sized gray scale voltage generating circuit that can effect high image quality and versatility is thereby realized at a low cost.
[0055] Next, the settings in the registers and the operations of the variable resisters 321 to 324 in FIG. 3 according to this embodiment will be described with reference to FIGS. 4A, 4B , and 4 C. Reference numeral 401 shows the internal configuration of the variable resister 321 , 322 , 323 , or 324 . The variable resisters 321 to 324 herein are configured such that for each decrease of bit in settings in the registers which are the amplitude adjustment resister 304 and the gradient adjustment register 305 , the resistance is incremented by 4 R, where R indicates a unit of resistance. If a setting in the register is “111”[BIN] as indicated by reference numeral 402 , switches 403 to 405 connected to the terminals of the resisters in the variable resister 401 are switched ON, thereby bringing the variable resister 401 into a short-circuited state. Accordingly, the total resistance of the variable resister 401 becomes OR. Incidentally, the switches 403 to 405 are controlled on a bit-to-bit basis of a setting in the register; the switch 403 is controlled to be switched ON or OFF according to the second bit of a setting in the register, the switch 404 is controlled to be switched ON or OFF according to the first bit of the setting in the register, and the switch 405 is controlled to be switched ON or OFF according to the zeroth bit of the setting of the register. Next, if a setting in the register is “000”[BIN] as indicated by reference numeral 406 , the switches 403 to 405 connected to the terminals of the resistances in the variable resister 401 are switched OFF. The total resistance of the variable resister 401 becomes the sum of the resistances inside the variable resister, or 28 R. The relationship between setting of the register and variable resister value in the above-described circuit configuration becomes the one shown in the table indicated by reference numeral 407 .
[0056] The relationship between setting in the register and variable resistance value is just an example for setting. If the respective bits of a setting in the register are inverted, the relationship between setting of the register and variable resistance value becomes inverted; if a setting in the register increases, the resistance value of the variable resister also increases. The relationship between setting in the register and variable resister may also be inverted, as described above. The change ratio of a variable resistance value with respect to a setting in the register is herein set to 4 R for each setting. The change ratio may also be smaller or larger than 4 R. If the change ratio of a variable resistance value for each setting in the register is decreased, the accuracy of adjustment is improved. However, the range of adjustment becomes smaller. Conversely, if the change ratio of a variable resistance value for each setting in the register is increased, the adjustment range becomes more extended. However, the accuracy of adjustment deteriorates. Preferably, the resistance unit R constitutes several tens of kiloohms, because current dissipation can be reduced. Though the number of bits of a setting in the register described above is set to three bits, the number of the bits of the setting may be increased. In this case, though the adjustment range increases, the size of the gray scale voltage generating circuit increases.
[0057] With the arrangement described above, the resistance values of the variable resisters can be changed according to a setting in the register.
[0058] Next, adjustment operations of the gamma characteristic by the amplitude adjustment register 304 and the variable resisters 321 and 322 in the resistance ladder 307 in FIG. 3 will be described with reference to FIGS. 5A, 5B , and 5 C.
[0059] FIG. 5A shows an adjustment operation when the resistance value of the lower variable resister 321 in the resistance ladder 307 in FIG. 3 is set by the amplitude adjustment register 304 . A solid line indicated by reference numeral 501 shows a gray scale number-gray scale voltage characteristic when the amplitude adjustment register 304 is set to a default setting. If the gray scale voltage of the lowest gray scale level is to be changed without changing the gray scale voltage of the highest gray scale level to make amplitude adjustment to the gray scale voltages to a small degree, as shown by a dotted line indicated by reference numeral 502 , a setting in the amplitude adjustment register 304 should be set such that the resistance value of the lower variable resister 321 becomes large. If the gray scale voltage of the lowest gray scale level is to be changed without changing the gray scale voltage of the highest gray scale level to make amplitude adjustment to the gray scale voltages to a great degree, as shown by a dotted line indicated by reference numeral 503 , a setting in the amplitude adjustment register 304 should be set such that the resistance value of the lower variable resister 321 becomes small.
[0060] By changing the resistance value of the lower variable resister 321 according to a setting in the amplitude adjustment register 304 in this manner, the gray scale voltage of the lowest gray scale level can be changed without changing the gray scale voltage of the highest gray scale level, thereby allowing amplitude adjustment to the gray scale voltages.
[0061] Next, FIG. 5B shows an adjustment operation when the resistance value of the upper variable resister 322 in the resistance ladder 307 in FIG. 3 is set by the amplitude adjustment register 304 . As described above, the solid line 501 in FIG. 5B shows the gray scale number-gray scale voltage characteristic when the amplitude adjustment register 304 is set to the default setting. If the gray scale voltage of the highest scale level is to be changed without changing the gray scale voltage of the lowest gray scale level as shown in a dotted line indicated by reference numeral 504 to make amplitude adjustment to the gray voltages to a small degree, a setting in the amplitude adjustment register 304 should be set such that the resistance value of the upper variable resister 322 becomes large. If the gray scale voltage of the highest gray scale level is to be changed without changing the gray scale voltage of the lowest gray scale level as shown by a dotted line indicated by reference numeral 505 to make amplitude adjustment to the gray scale voltages to a great degree, a setting in the amplitude adjustment register 304 should be set such that the resistance value of the upper variable resister 322 becomes small.
[0062] By changing the resistance value of the upper variable resister 322 according to a setting in the amplitude adjustment register 304 in this manner, the gray scale voltage of the highest gray scale level can be changed without changing the gray scale voltage of the lowest gray scale level, so that amplitude voltage adjustment to the gray scale voltages can be made.
[0063] Next, FIG. 5C shows an adjustment operation when the resister values of the lower variable resister 321 and the upper variable resister 322 are simultaneously set by the amplitude adjustment register 304 . As described above, the solid line 501 in FIG. 5C shows the gray scale number-gray scale voltage characteristic when the amplitude adjustment register 304 is set to the default setting. If the gray scale voltages of the highest and lowest gray scale levels are to be increased with the gray scale number-gray scale voltage characteristic and the amplitude voltage kept to be the same as those in the case of the solid line 501 , as shown in a dotted line indicated by reference numeral 506 , a setting in the amplitude adjustment register 304 should be set such that the resistance value of the lower variable resister 321 becomes large and the resistance value of the upper variable resister 322 becomes small. Further, if the gray scale voltages of the highest and lowest gray scale levels are to be decreased with the gray scale number-gray scale voltage characteristic and the amplitude voltage kept to be the same as the ones indicated by the solid line 501 , as shown in a dotted line indicated by reference numeral 507 , a setting in the amplitude adjustment register 304 should be set such that the resistance value of the lower variable resister 321 becomes small and the resistance value of the upper variable resister 322 becomes large.
[0064] If the resistance values of the lower and upper variable resisters 321 and 322 are simultaneously set according to a setting in the amplitude adjustment register 304 in this manner, the characteristic becomes the one obtained by making offset adjustment to the gray scale number-gray scale voltage characteristic when the amplitude adjustment register 304 is set to the default setting.
[0065] As described above, the amplitude adjustment register 304 in FIG. 3 can make amplitude voltage adjustment to the gray scale voltages according to the characteristics of respective liquid crystal display panels.
[0066] Next, adjustment operations of the gamma characteristic using the gradient adjustment register 305 and the variable resisters 323 and 324 in the resistance ladder 307 in FIG. 3 will be described with reference to FIGS. 6A, 6B , and 6 C.
[0067] FIG. 6A shows an adjustment operation when the resistance value of the lower-middle variable resister 323 in the resistance ladder 307 in FIG. 3 is set by the gradient adjustment register 305 . A solid line indicated by reference numeral 601 shows a gray scale number-gray scale voltage characteristic when the gradient adjustment register 305 is set to a default setting. As shown in a dotted line indicated by reference numeral 602 , if the gray scale voltages of low gray scale levels are to be changed without changing the gradient characteristic of the gray scale voltages of high gray scale levels to make adjustment such that the gradient of the gray scale voltages of intermediate gray scale levels is reduced, a setting in the gradient adjustment register 305 should be set such that the resistance value of the lower-middle variable resister 323 becomes large.
[0068] As shown in a dotted line indicated by reference numeral 603 , if the gray scale voltages of low gray scale levels are to be changed without changing the gradient characteristic of the gray scale voltages of high gray scale levels to make adjustment such that the gradient of the gray scale voltages of intermediate gray scale levels is increased, a setting in the gradient adjustment register 305 should be set such that the resistance value of the lower-middle variable resister 323 becomes small.
[0069] By changing the resistance value of the lower-middle variable resister 323 according to a setting in the gradient adjustment register 305 in this manner, the gray scale voltages of low gray scale levels can be changed without changing the gradient characteristic of the gray scale voltages of high gray scale levels, so that the gradient of the gray scale voltages of intermediate gray scale levels can be adjusted.
[0070] Next, FIG. 6B shows an adjustment operation when the resistance value of the upper-middle variable resister 324 in the resistance ladder 307 in FIG. 3 is set by the gradient adjustment register 305 . As described above, the line 601 shows the gray scale number-gray scale voltage characteristic when the gradient adjustment register 305 is set to the default setting. As shown in a dotted line indicated by reference numeral 604 , if the gray scale voltages of high gray scale levels are to be changed without changing the gradient characteristic of the gray scale voltages of low gray scale levels to make adjustment such that the gradient of the gray scale voltages of intermediate gray scale levels is reduced, a setting in the gradient adjustment register 305 should be set such that the resistance value of the upper-middle variable resister 324 becomes large. Further, as shown in a dotted line indicated by reference numeral 605 , if the gray scale voltages of high gray scale levels are to be changed without changing the gradient characteristic of the gray scale voltages of low gray scale levels to make adjustment such that the gradient of the gray scale voltages of intermediate gray scale levels becomes large, a setting in the gradient adjustment register 305 should be set such that the resistance value of the upper-middle variable resister 324 becomes small.
[0071] By changing the resistance value of the upper-middle variable resister 324 according to a setting in the gradient adjustment register 305 , the gray scale voltages of high gray scale levels can be changed, so that the gradient of the gray scale voltages of intermediate gray scale levels can be adjusted.
[0072] FIG. 6C shows an adjustment operation when the resistance values of the lower-middle variable resister 323 and the upper-middle variable resister 324 are simultaneously set by the gradient adjustment register 305 . As described above, the line 601 shows the gray scale number-gray scale voltage characteristic when the gradient adjustment register 305 is set to the default setting. As shown in a dotted line indicated by reference numeral 606 , if the gradient characteristic is to be the same as that of the line 601 and gray scale voltages 608 that determine the gradient characteristic are to be increased, a setting in the gradient adjustment register 305 should be set such that the resistance value of the lower-middle variable resister 323 is large and the resistance value of the upper-middle variable resister 324 is small. Further, as shown in a dotted line indicated by reference numeral 607 , if the gradient characteristic is to be the same as that of the line 601 and the gray scale voltages 608 that determine the gradient characteristic are to be reduced, a setting in the gradient adjustment register 305 should be set such that the resistance value of the lower-middle variable resister 323 is small and the resistance value of the upper-middle variable resister 324 is large.
[0073] If the resistances of the lower-middle resister 323 and the upper-middle variable resister 324 are simultaneously set according to a setting in the gradient adjustment register 305 , the gradient characteristic of the gray scale number-gray scale voltage remains the same as the characteristic when the gradient adjustment register 305 is set to the default setting. However, the voltage values of the gray scale voltages 608 that determine the gradient characteristic are adjusted.
[0074] As described above, the gradient adjustment register 305 in FIG. 3 can adjust only the gradient characteristic of the gray scale voltages of intermediate gray scale levels according to the characteristics of respective liquid crystal display panels, with no amplitude voltage change in the gray scale voltages.
[0075] Next, the relationship between setting in the micro adjustment register 306 and the selector circuits 308 to 313 in FIG. 3 according to this embodiment will be described with reference to FIGS. 7A, 7B , and 7 C.
[0076] Referring to FIG. 7A , reference numeral 701 denotes one of the selector circuits 308 to 313 , the internal configuration of which is shown. Reference numeral 702 denotes one of the resistive voltage dividing circuits 326 to 331 in the resistance ladder 307 in FIG. 3 , the internal configuration of which is shown. FIG. 7A shows a configuration in which resistive voltage division with a resistance value of 1 R is performed to generate eight micro adjustment gray scale voltages A to H. The selector circuit 701 selects one of the micro adjustment gray scale voltages A to H generated by the resistive voltage dividing circuit 702 according to a setting 703 in the micro adjustment register 306 .
[0077] The selector circuit 701 comprises two-input one-output selector circuits, and selects the output of a selector circuit in a first-stage selector circuit group 704 according to the zeroth bit of the register setting 703 , selects the output of a selector circuit in a second stage selector circuit group 705 according to the first bit of the register setting 703 , and selects an output in a third-stage selector circuit 706 according to the second bit of the register setting 703 .
[0078] If the register setting 703 is set to “000” [BIN], the selector circuit 701 supplies the micro adjustment gray scale voltage A divided by the resistive voltage dividing circuit 702 with the resistance divided. If the register setting 703 is set to “111” [BIN], the selector circuit 701 supplies the micro adjustment gray scale voltage H divided by the resistive voltage division circuit 702 with the resistance divided. In this way, for each increase of bit in the register setting 703 in the micro adjustment register 306 , the selector circuit 701 sequentially selects one of the micro adjustment gray scale voltages A to H, each divided by the resistive voltage dividing circuit 702 with the resistance divided. The relationship between the register setting 703 and the micro adjustment gray scale voltages A to H selected by the selector circuit 701 is shown in a table indicated by reference numeral 707 .
[0079] The relationship between a register setting and the selector circuit is just an example. If the respective bits of a register setting are inverted, the relationship between the register setting and the selector circuit is inverted. If the register setting increases, the selector circuit sequentially selects one of the micro adjustment gray scale voltages H to A in this stated order. As described above, the relationship between register setting and variable resistance may also be inverted.
[0080] The number of bits of a setting in the register for the selector circuit described above is three bits, and the selector circuit selects one of the eight micro adjustment gray scale voltages. The number of the bits of a setting may be increased to increase the number of selectable gray scale levels. In this case, a gray scale voltage micro adjustment range becomes more extended. However, the size of the gray scale voltage generating circuit increases. Further, although the resistance value used for resistive voltage division in the resistive voltage dividing circuit is set to 1 R, this value may be set to be smaller or larger. If the resistance value is reduced, the micro adjustment range becomes narrower. However, the adjusting accuracy is improved. If the resistance value is increased, the micro adjustment range becomes more extended, but the adjusting accuracy deteriorates. Further, like the variable resisters in FIG. 4A , preferably, the unit resistance R constitutes several tens of kiloohms, because power dissipation can be thereby reduced.
[0081] Next, adjustment to the gamma characteristic by the micro adjustment register 306 and the selector circuits 308 to 313 in FIG. 3 will be described with reference to FIG. 8 .
[0082] Referring to FIG. 8 , a solid line indicated by reference numeral 801 shows a gray scale number-gray scale voltage characteristic when the micro adjustment register 306 is set to a default setting. A dotted line indicated by reference numeral 802 shows a characteristic when a setting in the micro adjustment register 306 is set such that the voltage value selected by the selector circuits 308 to 313 is maximized. A dotted line indicated by reference numeral 803 shows a characteristic when a setting in the micro adjustment register 306 is set such that the voltage value selected by the selector circuits 308 to 313 is minimized. Accordingly, the voltages in a region from the dotted line 802 to the dotted line 803 constitute the range of gray scale voltages that can be set for micro adjustment by the micro adjustment register 306 . Reference numerals 804 to 809 denote the outputs of the selector circuits 308 to 313 or the gray scale voltages that can be micro adjusted, and they can be micro adjusted within the range of the gray scale voltages from the dotted line 802 to the dotted line 803 .
[0083] As described above, according to a setting in the micro adjustment register 306 in FIG. 3 , one gray scale voltage is selected from among the gray scale voltages generated by the voltage dividing circuits 326 to 331 in the resistance ladder 307 , respectively so as to allow micro adjustment. With this arrangement, micro adjustment to gray scale voltages according to the characteristics of respective liquid crystal display panels becomes possible. The adjusting accuracy is thereby improved, so that high image quality can be effected.
[0084] A configuration of a liquid crystal display apparatus system where the gray scale voltage generating circuit that can adjust the gamma characteristic using three types of the adjustment registers is included in a signal line driving circuit will be illustrated in FIG. 9 . The three types of the adjustment registers are the amplitude adjustment register, gradient adjustment register, and micro adjustment register described above. Reference numeral 900 denotes the liquid crystal display apparatus according to the present invention. Reference numeral 901 denotes a liquid crystal display panel, reference numeral 902 denotes the signal line driving circuit that includes the gray scale voltage generating circuit 302 in FIG. 3 for supplying a gray scale voltage corresponding to display data to the signal line of the liquid crystal display panel 901 . Reference numeral 903 denotes a scanning line driving circuit for scanning scan lines on the liquid crystal display panel 901 , reference numeral 904 denotes a system power generation circuit for supplying power for operating the signal line driving circuit 902 and the scanning line driving circuit 903 . A supply voltage 905 supplied from the system power generation circuit 904 to the signal line driving circuit 902 includes the reference voltage 316 in FIG. 3 . Next, reference numeral 906 is an MPU (micro processor unit) for performing various control and processing for displaying an image on the liquid crystal display panel 901 . The signal line driving circuit 902 constitutes a system interface 907 for exchanging display data with the MPU 906 and exchanging data with the control register, a display memory 909 for temporarily storing display data 908 supplied from the system interface 907 , and the control register 301 , gray scale voltage generating circuit 302 , and decoder circuit 303 , illustrated in FIG. 3 . The control register 301 includes the amplitude adjustment register 304 , gradient adjustment register 305 , and micro adjustment register 306 illustrated in FIG. 3 . The signal line driving circuit 902 and the scanning line driving circuit 903 may also be included in the liquid crystal display 901 .
[0085] The MPU 906 conforms to the bus interface of the 16-bit bus 68xxx general-purpose MPU family, for example. From the MPU 906 , a CS (Chip Select) signal for indicating chip selection, an RS (Register Select) signal for selecting whether an address or data in the control register 301 is specified, an E (Enable) signal for commanding the start of processing, an R/N (Read/Write) signal for selecting data writing or reading, and a Data signal indicating a 16-bit data that represents an actual address or data setting in the control register 301 . By means of these control signals, settings in the amplitude adjustment register 304 , gradient adjustment register 305 , and micro adjustment register 306 are assigned to respective addresses in the control register 301 , and data writing and reading operations are performed onto each address in the control register 301 to which setting data is assigned.
[0086] Next, the operations of the control signals supplied from the MPU 906 to the system interface 907 in the signal line driving circuit 902 will be described with reference to FIGS. 10A and 10B . First, the CS signal is set to “Low”, and the control register 301 is brought into an accessible state. During the period in which the RS signal is “Low”, address specification is performed. During the period in which the RS signal is “High”, data specification is performed. If data writing is performed into the control register 301 , the R/W signal is held “Low”. A predetermined address value is set for the Data signal during the period of address specification. During the period of data specification, data to be written into the register at this address, such as a setting in the amplitude adjustment register 304 , gradient adjustment register 305 , or micro adjustment register 306 , all described above, is set. Thereafter, the E signal is driven “high” for a given period, and data is thereby written into the control register 301 .
[0087] When reading out data that has been set in the control register 301 , the CS signal and the RS signal are set in the same manner as that described above. Then, the R/W signal is held “High”. A predetermined address is set during the period of address specification. After this setting, by holding the E signal “High” for the given period, the data written in the register during the period of data specification is read out.
[0088] By writing settings in the amplitude adjustment register 304 , gradient adjustment register 305 , micro adjustment register 306 at the respective assigned addresses in the control register 301 , when adjustment to the gamma characteristic is made, amplitude voltage adjustment to the gray scale voltages, gradient characteristic adjustment to the gray scale voltages of intermediate gray scale levels, and micro adjustment become possible. Adjustment to the gamma characteristic is thereby facilitated, and gray scale voltages in accordance with the characteristics of the respective liquid crystal display panels can be thereby set.
[0089] Next, a configuration of a liquid crystal display apparatus according to a second embodiment of the present invention will be described.
[0090] First, generally, when a gray scale voltage is applied to a liquid crystal display panel, the polarity of the gray scale voltage must be reversed by an alternating current having a given period, which is hereinafter referred to as an M signal, so as to alternating-current drive the liquid crystal display panel.
[0091] The gray scale number-gray scale voltage characteristic of the liquid crystal display panel also differs according to the polarity of the M signal, and it sometimes happens that adjustment must be made for each polarity of the M signal so as to obtain a desired gamma characteristic. FIG. 11 shows changes in the gray scale number-gray scale voltage characteristics when a liquid crystal display panel is alternating-current driven. A curve indicated by reference numeral 1101 shows a gray scale number-gray scale voltage characteristic when the polarity of the M signal is positive or equals to zero. This curve shows that, when the liquid crystal display panel is in the normally black mode, as the gray scale number increases, the gray scale voltage increases. A curve indicated by reference numeral 1102 shows a gray scale number-gray scale voltage characteristic when the polarity of the M signal is negative or one. This curve shows that, as the gray scale number increases, the gray scale voltage decreases. The curve 1101 and the curve 1102 are symmetrical with respect to a center line 1103 . Suppose that the positive and negative gray scale number-gray scale voltage characteristics are symmetrical. Then, if the output order of the 64 gray scale voltages is reversed, or the relationship between gray scale voltage and gray scale number is reversed in such a way that the 64th gray scale voltage is output as the first gray scale voltage and the first gray scale voltage is output as the 64th gray scale voltage, and other gray scale voltages are output in descending order of gray scale numbers in the gray scale voltage generating circuit in FIG. 3 , it is not necessary to make adjustment to the gamma characteristic of according to the polarity of the M signal. However, depending on a liquid crystal display panel, there is a case where positive and negative gray scale number-gray scale voltage characteristics are not symmetrical, as shown in a curve indicated by reference numeral 1104 . In this case, in the gray scale voltage generating circuit in FIG. 3 according to the first embodiment, setting in the registers must be performed whenever necessary in accordance with the positive or negative gray scale number-gray scale voltage characteristic in order to make adjustment to obtain a desired gamma characteristic. In order to solve the problem described above, in the second embodiment of the present invention, resistance ladders for positive and negative gray scale voltages, which have the same effect as that in the first embodiment are provided separately to allow adjustment to both of the positive and negative gamma characteristics.
[0092] A configuration of a liquid crystal display apparatus according to the second embodiment of the present invention will be described with reference to FIG. 12 .
[0093] FIG. 12 shows the gray scale voltage generating circuit 302 in FIG. 3 according to the first embodiment, of which only the internal configuration is modified. The configurations and operations of the control register 301 and the decoder circuit 303 are the same as those according to the first embodiment. The gray scale voltage generating circuit 302 in FIG. 12 includes a resistance ladder 1202 for positive gray scale voltages and a resistance ladder 1203 for negative gray scale voltages obtained by dividing the resistance ladder 307 in FIG. 3 according to the first embodiment.
[0094] The resistance ladders 1202 and 1203 for positive and negative gray scale voltages are configured such that they can achieve the same effect as the first embodiment according to settings in the amplitude adjustment register 304 and the gradient adjustment register 305 .
[0095] The resistance ladders 1202 and 1203 for positive and negative gray scale voltages are configured to commonly use settings in the amplitude adjustment register 304 and the gradient adjustment register 305 to allow the same amplitude voltage adjustment to gray scale voltages and the same adjustment to the gradient characteristic as those in the first embodiment by using the settings, according to the polarity of a gray scale voltage. It is arranged such that setting of resistance values in the resistance ladder 1202 for positive gray scale voltages is different from setting of resistance values in the resistance ladder 1203 for negative voltages to allow different gray scale voltage adjustments depending on the polarity of a gray scale voltage according to the settings in the amplitude adjustment register 304 and the gradient adjustment register 305 .
[0096] Further, as described above, since two resistance ladders 1202 and 1203 for positive and negative gray scale voltages are provided, two types of selector circuits, which are a selector circuit 1204 for positive gray scale voltages and a selector circuit 1205 for negative gray scale voltages become necessary, in place of the selector circuits 308 to 313 in FIG. 3 . The selector circuit 1204 for positive gray scale voltages and the selector circuit 1205 for negative gray scale voltages have the same configuration as the selector circuits 308 to 313 in FIG. 3 according to the first embodiment, thus allowing micro adjustment which is the same as that in the first embodiment by using settings in the micro adjustment register 306 .
[0097] In the gray scale voltage generating circuit 302 having the configuration as described above, polarity selector circuits 1201 and 1206 for performing selection in response to the M signal makes selection between the outputs of the resistance ladders 1202 and 1203 for positive and negative gray scale voltages and the outputs of the selector circuits 1204 and 1205 for positive and negative gray scale voltages according to the polarity of the M signal. When the polarity of the M signal equals to zero, the polarity selectors 1201 and 1206 select the outputs of the resistance ladder 1202 for positive gray scale voltages and the selector circuit 1204 for positive gray scale voltages. When the polarity of the M signal equals to one, the polarity selectors 1201 and 1206 selects the outputs of the resistance ladder 1203 for negative gray scale voltages and the selector circuit 1205 for negative gray scale voltages.
[0098] By configuring the gray scale voltage generating circuit as described above, and including this circuit in the liquid crystal display apparatus system that is the same as the liquid crystal display apparatus system in FIG. 9 according to the first embodiment, a liquid crystal display apparatus that can separately adjust gamma characteristics for positive and negative gray scale voltages is realized. Settings in the respective adjustment registers 304 to 306 are assigned to respective addresses in the control register 301 to perform writing of the settings into the respective registers in response to the control signals in FIG. 10 as in the first embodiment.
[0099] Next, a configuration of a gray scale voltage generating circuit according to a third embodiment will be shown in FIG. 13 . In this embodiment, a single resistance ladder is provided in place of two resistance ladders according to the second embodiment. The adjustment registers according to the first embodiment such as the amplitude adjustment register, gradient adjustment register, and micro adjustment register are provided separately according to the polarities of gray scale voltage, thereby allowing separate adjustments to the gamma characteristics for both positive and negative gray scale voltages. FIG. 13 shows the gray scale voltage generating circuit in FIG. 3 according to the first embodiment, of which only the internal configuration of the control register 301 is modified. Thus, the configurations and the operations of the gray scale voltage generating circuit 302 and the decoder circuit 303 are the same as those in FIG. 1 . Referring to the internal configuration of the control register 301 in FIG. 13 , reference numeral 1301 denotes an amplitude adjustment register for positive gray scale voltages, reference numeral 1302 denotes an amplitude adjustment register for negative gray scale voltages, reference numeral 1303 denotes a gradient adjustment register for positive gray scale voltages, reference numeral 1304 denotes a gradient adjustment register for negative gray scale voltages, reference numeral 1305 denotes a micro adjustment register for positive gray scale voltages, and reference numeral 1306 denotes a micro adjustment register for negative gray scale voltages, in each of which setting can be performed separately according to the polarity of a gray scale voltage. The adjustment registers 1301 to 1306 select settings in the registers 1301 to 1306 according to the polarity of a gray scale voltage by using selector circuits 1307 to 1309 for performing selection in response to the M signal. When the polarity of the M signal is zero, the selector circuits 1307 to 1309 select settings in the registers 1301 , 1303 , and 1305 for positive gray scale voltages, respectively. When the polarity of the M signal is one, the selector circuits 1307 to 1309 select settings in the registers 1302 , 1304 , and 1306 for negative gray scale voltages, respectively. The amplitude adjustment registers 1301 and 1302 for positive and negative gray scale voltages achieve the same effects shown in FIGS. 5A, 5B , and 5 C as the amplitude adjustment register according to the first embodiment. The gradient adjustment registers 1303 and 1304 for positive and negative gray scale voltages achieve the same effects shown in FIGS. 6A, 6B , and 6 C as the gradient adjustment register according to the first embodiment. The micro adjustment registers 1305 and 1306 for positive and negative gray scale voltages achieve the same effects shown in FIG. 8 as the micro adjustment register according to the first embodiment.
[0100] Accordingly, the adjustment registers 1301 to 1306 for positive and negative gray scale voltages, described above can provide the same effect as the first embodiment. Adjustment to gray scale voltages and the gamma characteristics according to the characteristics of respective liquid crystal display panels can be thereby made separately for both of positive and negative gray scale voltages.
[0101] By including the control register 301 having the configuration as described above in a liquid crystal display apparatus system in FIG. 14 , a liquid crystal display apparatus with a circuit size smaller than that according to the second embodiment is realized, which can adjust the gamma characteristics for both positive and negative gray scale voltages. Settings in the adjustment registers 1301 to 1306 for positive and negative gray scale voltages are written into the control register 301 at the respective addresses assigned to the positive and negative adjustment registers 1301 to 1306 in response to the control signals like those in FIG. 10 .
[0102] Next, a configuration of a liquid crystal display apparatus according to a third embodiment of the present invention will be described.
[0103] In liquid crystal display panels, depending on an application, an image is sometimes displayed by backlighting. In this case, the gray scale number-gray scale voltage characteristic of a liquid crystal display panel sometimes changes according to turning ON or OFF of backlight, so that adjustment to the gamma characteristic should be made. In this embodiment, a method of adjusting the gamma characteristic during the period where the backlight is turned ON or OFF as described above will be described with reference to FIG. 15 .
[0104] FIG. 15 is the liquid crystal display apparatus system in FIG. 9 according to the first embodiment, in which the internal configurations of the MPU 906 and the control register 301 in the signal line driving circuit 902 are modified. Although the configurations and the operations of other blocks are the same as those in the first embodiment, the liquid crystal display panel 901 includes a circuit for backlighting described above. Backlight ON/OFF determination unit 1501 for determining whether the backlight is turned ON or OFF is provided inside the MPU 906 , and a backlight ON time register 1502 and a backlight OFF time register 1503 are provided separately inside the control register 301 . The backlight ON time register 1502 includes the amplitude adjustment register 304 , gradient adjustment register 305 , and micro adjustment register 306 that achieve the same effects as those according to the first embodiment. The backlight OFF time register 1503 also includes the amplitude adjustment register 304 , gradient adjustment register 305 , and micro adjustment register 306 that achieve the same effects as those according to the first embodiment. In response to a determination signal 1504 indicating the state where the backlight is turned ON or OFF, supplied from the backlight ON/OFF determination unit 1501 , the selector circuit 1505 makes selection between a setting in the backlight ON time register 1502 and a setting in the backlight OFF time register 1503 to use the register setting selected by the selector circuit 1505 in the gray scale voltage generating circuit 302 which has the same configuration as that according to the first embodiment.
[0105] As described above, by providing for the control register 301 two types of amplitude adjustment registers, gradient adjustment registers, and micro adjustment registers all of which achieve the same effects as those according to the first embodiment during the periods where the backlight is turned ON and OFF, separate adjustments to the gamma characteristic of the respective liquid crystal display panels can be made, depending on whether the backlight is turned ON or OFF. A liquid crystal display apparatus where high image quality can be effected is thereby realized. Settings in the backlight ON time register 1402 and the backlight OFF time register 1403 are assigned to respective addresses in the control register 301 and written into the control register 301 at the respective addresses in response to control signals in FIG. 10 , as in the first embodiment.
[0106] Next, a configuration of a liquid crystal display apparatus according to a fifth embodiment of the present invention will be described.
[0107] This embodiment allows separate gamma characteristic adjustments for respective liquid crystal display panel colors of red, green, and blue (to be referred to as R, G, and B, respectively). The configuration of the apparatus will be described with reference to FIG. 16 .
[0108] FIG. 16 is the liquid crystal display apparatus system in FIG. 9 according to the first embodiment, in which only the internal configuration of the control register 301 is modified, as in FIG. 15 according to the fourth embodiment. The configurations and the operations of other blocks are the same as those in the first embodiment. In order to make separate gamma characteristic adjustments for respective R, G, and B, an R adjustment register 1601 , a G adjustment register 1602 , and a B adjustment register 1603 are provided separately in the control register 1603 . All of the adjustment registers 1601 to 1603 include the amplitude adjustment register 304 , gradient adjustment register 305 , and micro adjustment register 306 , respectively, which achieve the same effects as those according to the first embodiment.
[0109] As described above, registers for respective display colors are separately provided in the control register 301 in the liquid crystal display. These registers include the R adjustment register 1601 , G adjustment register 1602 , and B adjustment register 1603 each of which comprise the amplitude adjustment register, gradient adjustment register, and micro adjustment register that achieve the same effects as those according to the first embodiment. With this arrangement, separate gamma characteristic adjustments for the respective display colors of R, G, and B in the liquid crystal display panel become possible, so that the liquid crystal display apparatus is realized in which high image quality can be effected. Settings in the R adjustment register 1601 , G adjustment register 1602 , and B adjustment register 1603 are assigned to respective addresses in the control register 301 and written into the control register 301 at the respective addresses in response to the control signals in FIG. 10 , as in the first embodiment.
[0110] The present invention is not limited to the embodiments described above, and various modifications are possible. To take an example, the above description was given, assuming that the liquid crystal display panel is in the normally black mode. The present invention, however, can be practiced irrespective of the modes of the liquid crystal display panel. Further, a description was given, assuming that the number of gray scale levels is 64. The present invention, however, can be practiced irrespective of the number of gray scale levels.
[0111] According to the first to fourth embodiments, in order to make adjustment to the gamma characteristic, the amplitude adjustment register and the gradient adjustment register are provided. Then, a resistance ladder is provided which can make rough adjustments to gray scale voltages such as amplitude voltage adjustments to the gray scale voltages and the gradient characteristic of the gray scale voltages of intermediate gray scale levels. These adjustments are made according to the characteristics of the respective liquid crystal display panels, by using settings in the registers. With this arrangement, adjustment to the gamma characteristic can be facilitated, so that an adjustment time can be shortened. Further, by using the resistance ladder to allow the adjustments to be made, the size of the gray scale voltage generating circuit can be reduced at a low cost.
[0112] Further, in addition to the amplitude adjustment register and the gradient adjustment register, the micro adjustment register is provided. With this arrangement, micro adjustment to the gray scale voltages which have been adjusted by the amplitude and gradient adjustment registers becomes possible. Adjusting accuracy can be thereby increased, and high image quality can be effected.
[0113] Still further, according to the first to fourth embodiments, gamma characteristic adjustments according to the characteristics of respective liquid crystal display panels become possible. Thus, a versatile circuit configuration can be constructed.
[0114] According to the present invention, the accuracy of gamma characteristic adjustment is improved in a liquid crystal display apparatus. Image quality is thereby improved.
[0115] It should be further understood by those skilled in the art that although the foregoing description has been made on embodiments of the invention, the invention is not limited thereto and various changes and modifications may be made without departing from the spirit of the invention and the scope of the appended claims.
|
A display driver adjustable for a gamma specification of a liquid display panel, including: a system interface receiving display data from an external; a memory storing the display data; a grayscale voltage generator generating a plurality of grayscale voltages; a gamma adjusting circuit adjusting the gamma specification; and an output circuit outputting the grayscale voltage in response to the display data from the memory to the liquid display panel, wherein the gamma adjusting circuit includes: a gradient adjustment register controlling variable resistors of a ladder resistor; an amplitude/reference adjustment register; and a micro adjustment register, wherein the gradient adjustment register, the amplitude/reference adjustment register and micro adjustment register, are independently set in accordance with red, green and blue, respectively.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of U.S. Ser. No. 07/768,831 filed Sep. 30, 1991 by John L. Allan, et al. and entitled Bonded Composite Nonwoven Web And Process, now abandoned.
FIELD OF THE INVENTION
The invention relates to a elastomeric meltblown webs. More particularly, the invention relates to elastomeric meltblown webs produced from blends of saturated diblock and/or triblock copolymer elastomers with plasticizing copolymers which provide for the production of the elastomeric meltblown webs having desirable strength and stretch/recovery properties, at relatively high throughputs and/or relatively low die pressures.
BACKGROUND OF THE INVENTION
Elastomeric meltblown webs have been proposed for use in a variety of products including composite fabrics including hydroentangled fabrics; in diapers, training pants and other personal hygiene products in which stretch and conformability to body shapes are considered important. Fully hydrogenated (saturated) diblock and/or triblock copolymers and mixtures thereof based on polystyrene blocks and poly(ethylene-butylene) blocks have been the subject of considerable attention for producing meltblown elastomeric webs because of their high temperature stability and their ability to produce meltblown webs with desirable properties.
Commercially available polystyrene-(ethylene-butylene) diblock and triblock copolymers include the KRATON-G resins commercially available from Shell Chemical Company. Because of the high viscosities associated with these resins, the manufacturer's literature suggests blending of the resins with certain relatively low molecular weight materials. The blending of such materials with the KRATON resins can reduce the processing temperatures, thereby minimizing the degradation of the materials, or can reduce melt processing viscosities, thereby enabling throughputs to be increased at lowered pressures in extrusion processes, such as meltblowing processes. The Shell literature teaches that the lower molecular weight materials which are useful in blends include those which are compatible with the polystyrene (PS) segments of the copolymer, and materials which are compatible with the ethylene-butylene (EB) segments. Materials which are compatible with the (PS) segments include polystyrene and poly(methylacrylate) while polyolefins are compatible with the (EB) segments.
U.S. Pat. No. 4,663,220 to Wisneski and U.S. Pat. No. 4,692,371 to Morman disclose the preparation of meltblown webs from blends of saturated (PS)-(EB) diblock and triblock elastomers together with polyolefin resins. However, the preparation of meltblown webs at high throughput rates using these blends can result in processing difficulties rendering the high throughput meltblowing process uneconomical.
U.S. Pat. No. 4,323,534 to Des Marais discloses the use of fatty acids or fatty alcohols as plasticizers useful in the meltblowing of KRATON G, fully saturated elastomers. More recently, U.S. Pat. No. 4,892,203 to Himes discloses blends of the fully saturated KRATON G-type resins plasticized with anionically polymerized styrene or alpha-methyl styrene or their copolymers, or hydrogenated polystyrene. Optionally, a microcrystalline wax may also be added.
U.S. Pat. No. 4,874,447 to Hazelton discloses a method for preparing a nonwoven web from a blend comprising (i) an elastomeric copolymer of an isoolefin and a conjugated diolefin, and (ii) a thermoplastic olefin polymer resin. The elastomers (i) disclosed include copolymers of styrene and butadiene, but none of the fully hydrogenated block copolymers of the KRATON G-type are disclosed. A wide range of thermoplastic resins are disclosed as component (ii), including polyolefins, such as polyethylene, polypropylene, polybutylene, polypentene, copolymers of ethylene and propylene, copolymers of ethylene with unsaturated esters of lower carboxylic acids including copolymers of ethylene with vinylacetate or alkyl acrylates, and the like. However, the unsaturated block copolymers lack the high temperature stability of the saturated block copolymers, and thus elastomeric webs from these materials or blends of these materials can be more difficult to process.
U.S. Pat. No. 4,769,279 to Graham discloses meltblown webs formed from blends of ethylene-acrylic copolymer or ethylene-vinylacetate blended with a second fiber-forming polymer such as a polyolefin. However, the elastomeric webs formed from blends based on ethylene-acrylic copolymers and/or ethylene vinylacetate copolymers, as the elastomeric material, have only limited stretch and recovery properties.
Despite substantial effort and experimentation in the art, only a limited number of elastomeric materials have been used with any substantial commercial success to produce elastomeric webs. Moreover, various processing difficulties are still encountered when attempts are made to produce meltblown elastomeric webs at relatively high throughput rates.
SUMMARY OF THE INVENTION
The invention provides elastomeric meltblown webs which can be produced at relatively high throughputs and/or low die pressures, or both, at given melt temperatures as compared to comparable elastomeric meltblown webs produced according to prior art processes. Moreover, the invention provides elastomeric meltblown webs having improved adhesive properties.
The meltblown elastomeric webs of the invention comprise a blend of (i) a fully hydrogenated diblock or triblock thermoplastic elastomer copolymer or mixtures thereof, based on polystyrene (PS) and poly(ethylene-butylene) (EB) having the formula:
(PS).sub.a --(EB).sub.b or (PS).sub.a --(EB).sub.b --(PS).sub.c
wherein a, b and c are integers; and, (ii) from about 5% by weight up to about 50% by weight of a copolymer of ethylene and acrylic acid (EAA) or a lower alkyl ester thereof such as poly(ethylene-methylacrylate) or poly(ethylene-ethylacrylate). The acrylic acid or ester component of this copolymer ranges from about 5% to about 50% by weight, preferably from about 15% to about 30% by weight. The ethylene-acrylic acid or ester copolymer is preferably present in the blend in an amount ranging from about 10% to about 40% by weight.
The elastomeric resin blends of the invention can be meltblown at higher throughput rates and/or at lower die pressures or both at given melt temperatures as compared to blends used to produce elastomeric meltblown webs in prior art processes. Nevertheless, the meltblown webs of the invention have excellent stretch and recovery properties, modulus and strength properties and other physical properties. In addition, the meltblown webs of the invention have excellent adhesive properties and thus, the meltblown webs of the invention can be provided as a component of a composite nonwoven fabric and thereafter thermally treated to bond to the composite fabric while providing elastomeric properties to the composite fabric.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description of the preferred embodiments of the invention, specific terms are used in describing the invention; however, these are used in a descriptive sense only and not for the purpose of limitation. It will be apparent that the invention is susceptible to numerous variations and modifications within its spirit and scope.
The meltblown webs of the invention are formed by blending the elastomeric (PS)-(EB) diblock or triblock copolymers with the ethylene-acrylic acid or ethylene-acrylic acid ester copolymer and thereafter meltblowing fibers from the blended material. Meltblowing processes and apparatus are known to the skilled artisan and are disclosed, for example, in U.S. Pat. No. 3,849,241 to Buntin, et al. and U.S. Pat. No. 4,048,364 to Harding, et al., which are hereby incorporated by reference. In general, the meltblowing process involves extruding molten polymeric material through fine capillaries into fine filamentary streams. The filamentary streams exit the meltblowing spinneret head where they encounter converging streams of high velocity heated gas, typically air, supplied from converging nozzles. The converging streams of high velocity heated gas attenuate the polymer streams and break the attenuated streams into meltblown fibers.
The attenuated meltblown fibers are collected as a nonwoven mat typically at a distance within the range of about 7 inches to about 27 inches from the spinneret head. In general, the nonwoven webs which are collected at a relatively short distance will be more compact than those collected at a greater distance. The meltblown webs are collected on a moving collection device such as a rotating drum, an endless belt, or the like. Because the meltblown webs of the invention have advantageous adhesive properties, the collector device, such as a wire collector drum, can be advantageously coated with a release agent. In addition, it is preferred to cool the collector drum with fine sprays of cold water to prevent the meltblown web from sticking to the wire. Suitable release agents can be incorporated into the cooling spray.
Any of various methods well known in the prior art can be used to blend the ethylene-acrylic acid or ethylene-acrylate copolymer with the diblock and/or triblock copolymer. For example, pellets of each of the materials can be premixed or physically admixed using solid mixing equipment and the solid mixture then passed to the extruder portion of the meltblowing apparatus. Alternatively, the resins can be physically admixed together as solids and then melt blended together and the resultant meltblend passed to the extruder portion of the meltblowing apparatus.
Once the blend of the elastomeric diblock or triblock copolymer and the ethylene-acrylic acid or ethylene-acrylate copolymer has been formed, the blend is passed to the meltblowing apparatus. In general, the blend is fed into the extruder portion of the apparatus wherein it is heated to a temperature preferably within the range of between about 500° F. and about 900° F., more preferably to a temperature above about 550° F. up to about 650° F. As is well known, the extruder is driven by a suitable motor and the blend is passed through the screw portion of the extruder and forced into a die head. The die head typically contains a heating plate which may be used to impart any further thermal treatment required to render the blend suitable for meltblowing. From the die head, the feed blend is forced through a row of fine die openings and into a gas stream or streams which attenuate the blend into fibers which are collected on the moving collection device such as a rotating drum to form the continuous nonwoven web. The gas stream or streams which attenuate the fibers generally has a temperature within the range of between about 500° F. and about 900° F.
The die portion of the meltblowing apparatus includes a plurality of linearly oriented orifices having a cross-sectional flow area within the range of about 3×10 -6 sq. in. to about 7.5×10 -4 sq. in. In general, there are from about 15 to about 40 orifices per linear inch of die head.
The diblock and/or triblock elastomeric polymer used in the blend is commercially available from various sources including Shell Chemical Company as KRATON-G polymer. A particularly preferred commercially available material is KRATON G-1657 which is a mixture of 35 weight percent diblock (PS)-(EB) copolymer and 65 weight percent triblock (PS)-(EB)-(PS) copolymer. The thermoplastic elastomer is advantageously present in the blend in an amount ranging from about 50 wt. % to about 95 wt. %, preferably, from about 60 wt. % to about 80 wt. %.
The ethylene-acrylic acid copolymers and ethylene-alkyl acrylate copolymers are well known in the art. As indicated previously, the copolymers employed in the present invention have an ethylene content ranging from about 5 wt. % up to about 50 wt. % and preferably from about 15 to about 30 wt. %. Ethylene-acrylic acid copolymers and ethylene-methacrylate and ethylene-ethylacrylate copolymers are preferred for use in the invention. However, other ethylene-lower alkyl acrylate copolymers can advantageously be used herein. The term "lower alkyl" is used herein to mean straight and/or branched alkyl moieties having from one to about six carbons.
The elastomeric webs of the invention are useful in numerous environments and products. For example, the elastomeric webs of the invention can be joined to a second woven or nonwoven fabric by adhesive bonding or thermal bonding in order to impart elastic properties to the resultant composite fabric. The elastomeric web can be stretched prior to and/or during the joining process. Following bonding, the composite multi-layer fabric can be relaxed to provide a composite fabric having elastic properties.
The elastomeric webs of the invention can also be hydroentangled with staple fibers and/or wood pulp fibers as disclosed in U.S. Pat. No. 4,775,579 to Hagy, et al. which is hereby incorporated by reference. Hydroentangling of the elastomeric web with staple fibers can provide a composite fabric having aesthetic characteristics similar to those of knit textile cloth while providing desirable elastic extensibility and recovery properties.
Intimately hydroentangled composite fabrics including elastomeric webs of the invention can advantageously be thermally treated to convert the elastomeric web into a substantially film-like non-fibrous layer extending throughout the width and length of the fabric as disclosed in U.S. patent application Ser. No. 07/768,831, filed Sep. 30, 1991 by John L. Allan, et. al. and entitled Bonded Composite Nonwoven Web And Process, which is hereby incorporated by reference. Such nonwoven fabrics are provided by intimately hydroentangling a layered web including a fibrous nonwoven layer, such as a layer of carded staple fibers, with the meltblown elastomeric web of the invention. Following hydroentangling, the fabric is subjected to a bonding treatment for thermal fusion of the meltblown fibers sufficiently that the meltblown fibers are deformed into a substantially non-fibrous structure extending throughout the width and length of the fabric. The thermal bonding treatment is conducted under thermal conditions insufficient to cause substantial thermal fusion of the fibers in the fibrous layer, thus allowing the fibrous layer to maintain a desirable softness and hand.
Because the elastomeric webs of the invention exhibit advantageous adhesive properties, the above-described thermal treatment results in the firm anchoring of the fibrous materials in the composite fabric. Due to the minimal migration of the fibers of the meltblown web during hydroentanglement, the subsequent thermal fusion treatment which melts and forms the meltblown layer, has a minimal or insubstantial aesthetic effect on the remainder of the fibrous layer. Thus, the thermally fused meltblown layer is confined beneath at least one surface of the fabric so that the surface of the fabric has a desirable textile hand. Both surfaces of the composite fabric can exhibit a desirable textile-like hand by advantageous adjustment of hydroentangling conditions so that fibers from the fibrous layer are provided on both surfaces of the elastomeric web; or, at least two fibrous layers can be hydroentangled with the elastomeric web by sandwiching the elastomeric web between two fibrous layers and hydroentangling on both sides of the elastomeric web prior to thermal bonding.
The following examples serve to illustrate the elastomeric webs of the invention but are not intended to limit the invention.
In all examples, a two-inch, 36/1 length to diameter single screw extruder with a 3/1 compression ratio and five heating zones was used. A ten-inch die with 251 spinneret holes was used for meltblowing. The spinneret hole diameter was about 0.014 inches. The fibers were drawn by two streams of high velocity, heated air directed on either side of the single row of spinnerets (set back 0.040 inch with air gaps of 0.040 inch), and the fibers were collected as a web on a moving wire mesh collector. The distance from the spinnerets to the collector was 8 inches, and the collector, which was moved at a rate to achieve the desired base weight web, was cooled with fine sprays of cold water to prevent the web from sticking to the wire. Advantageously, the wire collector was coated with a release agent, or a suitable release agent could be incorporated into the fiber quench or collector table sprays.
Unless otherwise stated, physical properties reported were determined using the following test methods.
Basis weight was determined by cutting the sample using a razor blade and a metal template (measuring 50×200 mm.), and weighing to the nearest 0.001 gram after equilibration to ambient conditions. The basis weight in grams per square meter (g/m 2 ), was calculated as the weight of the sample multiplied by 100.
Web thickness (caliper) was measured using an Ames Gauge (Model 79-011; Ames, Inc., Waltham, Mass.) with a zero load and a 4 inch by 4 inch square measuring foot.
Tensile strength and elongation were measured using an Instron Tester (Model 4202; Instron Corp., Canton, Mass.). Samples (3.0 by 5.0 inch) were cut in the machine direction (MD) and the cross-machine direction (CD). Samples were mounted in 3-inch jaws at an initial separation of 4 inches and were drawn at a rate of 4 inches per minute.
For the stretch and recovery tests, the specimens were extended 100 percent, and the load was noted immediately. After the sample had been held at 100 percent extension for one minute, the load was released and the permanent extension was noted after one minute without tension. The recovery was recorded as 100 minus the percentage permanent extension. Four MD and four CD samples were tested, and averages were calculated for each.
Fresh samples were used to obtain values for the maximum load and the elongation at maximum load. Four tests were run in each case, and averages calculated for the MD and CD directions.
All load values were normalized to a base weight of 100 g/m 2 .
Fiber diameters were determined using scanning electron micrographs taken using a Joel Model JSM-84DA unit (Joel, U.S.A., Inc., Peabody, Mass.). Specimens were sputtered-coated with gold and palladium using a Model Desk II Coater (Delton Vacuum, Inc., Cherry Hill, N.Y.) and mounted for viewing along the web z-axis. The mounts were positioned so the maximum number of fibers at a 250 or 500 magnification were aligned at right angles to the longest axis of the Polaroid print, and fiber diameters along a 3-inch line on the print were measured using a Baush and Lomb magnifier (Model 81-34-35) and scale (Model 81-34-38; Baush and Lomb, Rochester, N.Y.).
Webs and fibers were dyed using a fiber-and polymer-selective mixed dye available as Heft No. 4 (Heft, Inc., Charlotte, N.C.). Samples were immersed in an aqueous solution of the dye (3.0 weight percent) at 50° C. After one minute, the samples were air-dried on blotter stock, and the colors were compared with standards supplied by Heft, Inc. or similarly dyed specimens of known composition. Color densities (A*, Red; B*, Yellow-Red) were measured using a MacBeth Color Eye (Series 1500/Plus; MacBeth Division, Kollmorgan Corp., Newberg, N.Y.).
The thermoplastic polymers used to prepare elastomeric webs in the following examples are set forth in the following Table I:
TABLE 1__________________________________________________________________________RESINS USED CommerciallyResin Available As Components Supplier MF*__________________________________________________________________________EVA Escorene LD-764.36 Ethylene/vinyl acetate (27%) Exxon 415(PS)(EB)(PS) Kraton G-1657** Styrene/ethylene-butylene (87%) Shell 9EMA Optema XS-13.04 Ethylene/methylacrylate (20%) Exxon 325PE(I) Petrothene NA-250 Ethylene (100%) Quantum 535PE(I) Petrothene NA-601 Ethylene (100%) Quantum ca. 5300EAA(I) Primacor 5981 Ethylene/acrylic acid (20%) Dow Chem. 725EAA(I) Primacor 5990 Ethylene/acrylic acid (20%) Dow Chem. 1340__________________________________________________________________________ *Melt flows by ASTM 1238 at 230° C. and 2.16 kg. **Kraton G1657 is a mixture of 35% diblock (PS)(EB) copolymer and 65% triblock (PS)(EB)-(PS) copolymer.
EXAMPLES 1-10
Blends containing 20% and 40% of plasticizing resins with (PS)-(EB)-(PS) were meltblown following the general method described above to obtain webs. Process conditions are given in Tables 2 and 3; physical properties of the webs are summarized in Table 4.
Data in Table 2 show that, at comparable throughputs and melt temperatures, blends of (PS)-(EB)-(PS) with EAA(I), with a melt flow of 725 gave significantly lower die pressure than blends of (PS)-(EB)-(PS) with PE(II) with a melt flow of about 5300 (Examples 1 and 5). Moreover, screw slippage and surging was apparent when using PE(II). Similarly, EMA with a melt flow of 325 gave a lower die pressure than PE(I) with a melt flow of 535, even at 11° F. lower melt temperature (Examples 2, 3, and 4). Again, slight surging was experienced with PE(I).
Similar results were obtained at the 40% plasticizer level. EAA(I) gave a lower die pressure than PE(II) (Examples 6 and 10), and EMA gave a lower die pressure than PE(I) (Examples 7, 8, and 9). Slippage was more pronounced with PE(I) and PE(II) at this higher level.
Physical data (Table 4) show that the EAA(II) and EMA plasticizers give good stretch recovery values. EAA(II) gave significant increases in the modulus, that is, the load for 100% extension.
TABLE 2______________________________________(PS)-(EB)-(PS) PLASTICIZATIONPROCESS CONDITIONSPlasticizing resin: 20 wt %; remainder (PS)-(EB)-(PS) Melt. DiePlas- Rate Screw Temp. Press Air FlowEx. ticizer (lb/hr) (RPM) (°F.) (psig) (cfm) (°F.)______________________________________1 PEII 24.6 41 622 680 350 6152 PE(I) 23.4 30 621 750 350 6203 PE(I) 26.7 36 620 800 350 6204 EMA 23.3 35 611 725 350 6295 EAA(I) 22.2 45 617 335 350 631______________________________________
TABLE 3______________________________________(PS)-(EB)-(PS) PLASTICIZATIONPROCESS CONDITIONSPlasticizing resin: 40 wt %; remainder (PS)-(EB)-(PS) Melt. DiePlas- Rate Screw Temp. Press Air FlowEx. ticizer (lb/hr) (RPM) (°F.) (psig) (cfm) (°F.)______________________________________6 PEII 22.8 54 619 405 350 6167 PE(I) 22.9 38 621 540 350 6248 EMA 22.6 35 614 495 350 6269 EAA(I) 22.8 35 623 515 350 60510 EAA(I) 27.6 56 620 360 350 629______________________________________
TABLE 4__________________________________________________________________________WEB PHYSICAL PROPERTIES Base Fiber Data for 100% Stretch Data for Max. Load Weights Caliper Diam. Load (g/p) Recovery (%) Load (g/p) Elong (%)Ex. Plasticizer (g/m.sup.2) (mils) (mils) MD CD MD CD MD CD MD CD__________________________________________________________________________1 PE(II) 20% 72 38 18.1 390 350 90 89 595 635 445 6102 PE(I) 20% 67 50 21.3 460 355 89 89 580 640 265 5603 PE(I) 20% 66 53 18.6 435 350 89 89 610 665 265 5504 EMA 20% 63 30 17.7 410 300 91 90 495 520 515 5555 EAA(I) 20% 67 39 17.8 1090 840 83 83 1375 1200 260 2806 PE(II) 40% 70 35 16.4 700 685 86 87 900 870 315 3707 PE(I) 40% 69 52 17.4 835 770 85 85 1075 1205 240 4758 EMA 40% 66 28 17.5 420 410 84 84 590 610 365 4809 EAA(I) 40% 67 33 15.1 500 440 85 85 620 615 375 39010 EAA(I) 40% 69 31 23.6 900 815 82 81 1290 1205 260 310__________________________________________________________________________
EXAMPLES 11-17
Webs were meltblown from blends of (PS)-(EB)-(PS) containing increasing amounts of EMA, and from unblended (PS)-(EB)-(PS) and EMA (Tables 5 and 7). The data showed reduced die pressures with increasing amounts of EMA plasticizer.
EXAMPLES 18
A blend of 40% EMA in (PS)-(EB)-(PS) was meltblown to form a continuous web (Tables 5 and 7). No screw slippage or surging was noted at a throughput as high as 43.1 lb/hr.
EXAMPLES 19 and 20
A blend of 20% EAA(II) (melt flow 1340) with 80% (PS)-(EB)-(PS) was meltblown to a continuous web (Tables 6 and 7). Very low die pressures resulted.
EXAMPLE 21
A blend of 20% EMA in (PS)-(EB)-(PS) was meltblown to a continuous web (Tables 6 and 7). Contrary to prior art disclosures and claims, the blend was difficult to process and a very weak web was obtained which could only be collected at a high base weight.
EXAMPLE 22
Webs from Examples 11-17 were dyed with Heft No. 4 die and the intensities of the imparted A* and B* color ranges were measured. The data indicated that the intensities of the colors attributable to the EMA resin plasticizer were higher than predicted at the lower concentrations, indicating the possibility that the EMA resin was migrating to the surface of the fiber and thereby increasing fiber adhesive properties.
TABLE 5______________________________________(PS)-(EB)-(PS) PLASTICIZATION WITH EMAPROCESS CONDITIONSEMA in Melt DieBlend Rate Screw Temp. Press. Air FlowEx. (wt %) (lb/hr) (RPM) (°F.) (psig) (cfm) (°F.)______________________________________11 0 12.1 15 617 770 350 61612 20 22.5 35 611 695 400 64613 30 23.1 35 615 625 350 62514 40 22.6 35 614 495 350 62615 50 20.4 35 622 405 360 62216 60 23.2 35 617 375 350 61217 100 19.8 36 505 325 350 49818 40 43.1 70 616 730 400 644______________________________________
TABLE 6______________________________________(PS)-(EB)-(PS) PLASTICIZATIONPROCESS CONDITIONSPlasticizing resin: 20 wt %; remainder (PS)-(EB)-(PS) Melt DiePlas- Rate Screw Temp. Press Air FlowEx. ticizer (lb/hr) (RPM) (°F.) (psig) (cfm) (°F.)______________________________________19 EAA(II) 8.0 15 616 365 350 62420 EAA(II) 16.2 40 615 385 400 63121 EVA 21.6 35 612 715 350 625______________________________________
TABLE 7__________________________________________________________________________(PS)-(EB)-(PS) PLASTICIZATIONWEB PHYSICAL PROPERTIES Base Fiber Data for 100% Stretch Data for Max. Load Weights Caliper Diam. Load (g/p) Recovery (%) Load (g/p) Elong (%)Ex. Plasticizer (g/m.sup.2) (mils) (mils) MD CD MD CD MD CD MD CD__________________________________________________________________________11 None 57 21 20.4 230 180 91 90 405 385 540 62512 EMA (20%) 60 25 13.5 560 310 90 87 715 665 605 59513 EMA (30%) 66 32 19.8 495 435 85 86 730 675 415 43514 EMA (40%) 82 33 17.6 465 425 86 86 580 600 360 52515 EMA (50%) 66 33 14.0 625 570 81 81 710 720 310 39016 EMA (60%) 70 32 14.2 570 555 78 78 665 660 265 31017 EMA (100%) 65 43 24.2 1010 765 65 67 1135 955 150 22018 EMA (40%) 71 34 17.0 460 405 84 84 665 635 345 40519 EAA(II) 60 23 10.8 355 295 88 86 610 595 470 595 (20%)20 EAA(II) 57 22 17.5 415 325 89 89 770 675 505 565 (20%)21 EVA (20%) 152 53 19.2 275 190 89 87 495 520 515 555__________________________________________________________________________
The invention has been described in considerable detail with reference to its preferred embodiments. However, variations and modifications can be made without departure from the spirit and scope of the invention as described in the foregoing detailed specification and defined in the appended claims.
|
The invention is directed to elastomeric meltblown webs having desirable strength and stretch/recovery properties which can be produced at relatively high throughputs and/or relatively low die pressures. The meltblown webs of the invention comprise a blend of (i) a fully hydrogenated diblock or triblock thermoplastic elastomer copolymer or mixtures thereof based on polystyrene and poly(ethylene-butylene) blocks; and (ii) from about 5% by weight up to about 50% by weight of a copolymer of ethylene and acrylic acid or ethylene and a lower alkyl ester of acrylic acid in which the ethylene content ranges from about 5% by weight up to about 50% by weight.
| 3
|
BACKGROUND OF THE INVENTION
This invention is directed to a measure to help control water, erosion and sediment run-off. More particularly, the invention relates to a check tube and system to control water and/or sediment flow.
This application claims priority to U.S. Provisional Application 60/889,193, filed Feb. 9, 2007, which is incorporated herein by reference in its entirety.
Ditch checks or check tubes are often used in areas of low elevation relative to the surrounding ground in order to slow the rate of water flow through the area. By slowing the rate of water flow, erosion can be reduced and silt is encouraged to settle in the areas of reduced water flow. Ditch checks can be made of natural inorganic materials, such as rocks, and/or natural organic materials, such as hay. Alternatively, check tubes can be manufactured using a variety of appropriate materials which may include natural and/or organic materials.
Some of the manufactured check tubes use an expanding material that significantly increases in size and weight when introduced to water. Some of the advantages of these types of check tubes are a reduction in preinstalled size and weight and simpler installation resulting from the reduced size and weight. During or after installation, when the check tube becomes wet, some or all of the material in the check tube will expand.
Check tubes with expanding material are often constructed as a hollow sleeve that is only partially filled with the expanding material. The check tube is only partially filled so as to allow for expansion of the fill material. As the check tube gets wet, the material inside expands and fills the check tube.
SUMMARY OF DISCLOSED EMBODIMENTS
However, since prior to installation, the material only fills a portion of the check tube, the material is largely free to move around the check tube. During transport and installation of the check tube, the fill material may move around resulting in some areas of the check tube being over-filled with the fill material, while other areas are under-filled with the fill material. The check tube can not be properly used in this condition. When the fill material gets wet it will expand, causing areas that are over-filled with fill material to expand improperly and/or rupture or otherwise damage the check tube. Likewise, in the areas that are under-filled with the fill material, the check tube may be ineffective at slowing the rate of water flow as it will not expand to the proper dimensions.
It can be difficult, time consuming and/or expensive to assure that the fill material is evenly distributed throughout the check tube prior to and/or during installation. It would be advantageous to be able to assure that the fill material would be evenly distributed during manufacture and would stay evenly distributed up to or throughout the installation of the check tube.
By holding the fill material in a limited space throughout the length of the check tube during manufacture and up to or throughout the installation of the check tube, it can be assured that the fill material is evenly distributed before it is introduced to water and thus expands. During or after the installation, the fill material can then be released so as to be free to expand throughout the entire volume of the tube after being introduced to water.
This invention provides a check tube for erosion control.
This invention separately provides a check tube that is partially filled with a fill material that expands during or after installation to increase the size and/or weight of the check tube.
This invention separately provides a check tube with a defined subsection of its volume that is separated from the rest of the check tube. The subsection is filled or nearly filled with a fill material during manufacture.
This invention separately provides a check tube with a hood to overlap or enmesh with another check tube.
This invention separately provides a check tube with a check flap to, among other things, help hold the check tube in place during installation.
This invention separately provides a check tube with a second flap or cape to help prevent erosion around the check tube.
In various exemplary embodiments of a check tube according to this invention, the check tube is filled with a fill material that expands when introduced to water. In such exemplary embodiments, the check tube is kept dry or mostly dry until or throughout the installation of the check tube. At that time, it is introduced to water and the fill material expands.
In various exemplary embodiments of a check tube according to this invention, the check tube is only partially filled with fill material that will expand after being introduced to water. In various ones of these exemplary embodiments the fill material is restricted to a subsection of the volume of the check tube until or through the installation of the check tube. In various ones of these exemplary embodiments the fill material is then unrestricted to the entire volume of the check tube before being introduced to water and thus expanding.
In various exemplary embodiments of a check tube according to this invention, the check tube has a secondary stitch that defines a subsection or pocket of the volume of the check tube. In various ones of these exemplary embodiments the subsection of the volume is filled with a fill material that expands after being introduced to water. In various ones of these exemplary embodiments the secondary stitch is removed just prior to, during or just after installation of the check tube to allow the fill material to expand throughout the entire volume of the check tube after being introduced to water.
It should be appreciated that the fill material can be restricted to a subset of the volume of the check tube for any length of time between the manufacture of the check tube and the actual use of the check tube. In some instances it may be beneficial and/or necessary to completely install the check tube before unrestricting the fill material. In other instances it may be beneficial and/or necessary to restrict the fill material to a subset of the volume of the check tube until just before installation and to install the check tube with the fill material unrestricted to the entire volume of the check tube.
In various exemplary embodiments of a check tube according to this invention, the check tube has a hood. In various ones of these exemplary embodiments the hood is attached to a first end of the check tube and is usable to overlap or enmesh with a second end of a second similarly constructed check tube. In such exemplary embodiments, the hood restricts water from flowing freely between two adjacent check tubes and allows construction of a check tube system made of any desired number of individual check tubes.
In various exemplary embodiments of a check tube according to this invention, the check tube has a check flap. In various ones of these exemplary embodiments, the check flap is installed beneath the surface of the ground that the check tube is installed upon. In such exemplary embodiments the check flap helps hold the check tube in place during and/or after installation and/or helps prevent water from undercutting and flowing beneath the check tube.
In various exemplary embodiments of a check tube according to this invention, the check tube has a second flap or cape. In various ones of these exemplary embodiments, the second flap or cape extends across the entire length of the check tube on the downstream side of the check tube. In such exemplary embodiments the second flap or cape dissipates water fall energy and prevents erosion on the downstream side of the check tube.
These and other features and advantages of various exemplary embodiments of systems and methods according to this invention are described in, or are apparent from, the following detailed descriptions of various exemplary embodiments of various devices, structures and/or methods according to this invention.
BRIEF DESCRIPTION OF DRAWINGS
Various exemplary embodiments of the systems and methods according to this invention will be described in detail, with reference to the following figures, wherein:
FIG. 1 is a perspective view of a plurality of check tubes shown installed according to one embodiment of the present invention;
FIG. 2 is a perspective view of one exemplary embodiment of a check tube;
FIG. 3 is a side view of an exemplary embodiment of a check tube;
FIG. 4 is a perspective view of a plurality of check tubes installed according to one embodiment of the present invention; and
FIG. 5 is a view of an exemplary embodiment of a check tube of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
FIG. 1 shows a barrier 100 comprising an exemplary embodiment of a check tube 110 . In one embodiment, the barrier 100 is installed on the ground or another surface at a determined location, such as across a ditch or swale that occasionally carries water, or perpendicular to an expected flow. In one embodiment, one or more check tubes 110 are aligned to extend substantially transversely across the ditch or swale. Adjacent check tubes 110 are aligned relative to each other for sufficient overlap of the sides, as more fully explained below. In FIG. 1 , arrow A indicates a downstream direction of water and/or sediment flow.
FIG. 2 shows a first exemplary embodiment of a check tube 110 . The check tube 110 comprises a sleeve 120 , a first end 130 and a second end 140 . In this exemplary embodiment, the check tube 110 is an elongate member having a longitudinal axis and defining a longitudinal cross-section resembling any closed shape, such as, for example, a circle, a non-circle such as an oval, and/or a polygon such as a square. In various exemplary embodiments, the first end 130 of the sleeve 120 is substantially closed. For example, the first end 130 of the sleeve 120 may be stitched shut. As shown, the second end 140 of the sleeve 120 may be open. As discussed below, the second end 140 may also be substantially closed.
In various exemplary embodiments, a hood 150 is attached to the first end 130 of the sleeve 120 . The hood 150 allows the check tube 110 to overlap or enmesh with another check tube 110 . By enmeshing two or more adjacent check tubes 110 , a check tube system, such as the barrier 100 shown in FIG. 1 , can be constructed of any desirable length. Furthermore, the hood 150 restricts water from flowing freely between adjacent check tubes 110 thus preventing erosion between the adjacent check tubes 110 . It should be appreciated that any two adjacent check tubes 110 may be installed at any desirable angle to each other and that the flexible nature of the hood 150 may assist in enmeshing the check tubes 110 at angles other than one hundred eighty degrees (as shown in FIG. 1 ).
The second end 140 of the check tube 110 is generally left open to allow the check tube 110 to be filled at least partially with filler material 125 . The filler material 125 may comprise any number of materials. For example, the filler material 125 may be completely organic or may include polymer. For example, the filler material 125 may be comprised of native pellets and/or a polyacrylamide mix. The native pellets are composed of leaves, stems, stalks and/or other biomass material or natural components that are consistent with the native vegetation of the area where the check tube 110 is to be used. The material used to make the pellets is heated and compressed, thus rendering it substantially sterile. Any type of filler material 125 that absorbs water may be used to at least partially fill the check tube 110 .
The check tube 110 may be formed of a water-permeable material. In various exemplary embodiments, the check tube 110 will be formed of non-woven needle-punched polypropylene fabric.
As shown in FIGS. 2-3 , the check tube 110 of the present invention may also comprise a check flap 160 . During installation of the check tube 110 , the check flap 160 may be buried below grade to help hold the check tube 110 in place and to prevent water from undercutting the check tube 110 and/or eroding the ground, soil or other surface near the check tube 110 . The check flap 160 may also eliminate the necessity for installation of stakes or staples or other such apparatus to help hold the check tube 110 in place relative to the ground or other surface. However, such stakes or staples may be used to anchor the check tube 110 and/or check flap 160 , if desired.
The check tube 110 of the present invention may also comprise a cape flap 170 . In various exemplary embodiments, and as shown in FIGS. 1-3 , the cape flap 170 is connected to the sleeve 120 and positioned to prevent erosion on the downstream side of the check tube 110 . The cape flap 170 may help dissipate water fall energy as the water flows over the top of the sleeve 120 and thus may help prevent the formation of an erosion channel. The cape flap 170 also prevents water from back-flowing and eroding soil beneath the check tube 110 .
In various exemplary embodiments the cape flap 170 is covered with vegetation 175 . In such exemplary embodiments, the vegetation 175 helps anchor the cape flap 170 , and thus the check tube 110 , in place while increasing overall structural support. The cape flap 170 , and the accompanying vegetation 175 , may also help decrease the velocity of water flowing over the check tube 110 .
As shown in FIG. 4 , after the filler material 125 is inserted into the sleeve 120 , the second end 140 of the check tube 110 may be at least substantially sealed or closed. For example, in various exemplary embodiments, the second end 140 may be tied using a tying apparatus 200 , such as a plastic electrical tie, which may be punched through the material comprising the check tube 110 at a desired point and then pulled tight.
In various exemplary embodiments, a plurality of these check tubes 110 may be installed adjacent to each other. In various exemplary embodiments, the first check tube 110 may be positioned as desired. A second check tube 110 should be positioned adjacent to the first check tube 110 . In various exemplary embodiments the second check tube 110 may be at least partially covered by the hood 150 of the first check tube 110 as shown in FIGS. 1 and 4 .
As shown in FIG. 5 , the check tube 110 of the present invention may also comprise a pocket 180 provided in the sleeve 120 . In various exemplary embodiments, the pocket 180 is used to help maintain the filler material 125 evenly along the length of the sleeve 120 during transport and installation. In various exemplary embodiments, the pocket 180 is created by gluing a portion of the sleeve 120 together with non-toxic water-soluble glue along a longitudinal glue line to subdivide the sleeve 120 as desired. When water is introduced to the check tube 110 , the glue used to form the pocket 180 will dissolve and allow the filler material 125 to expand and fill the sleeve 120 . In various exemplary embodiments, a temporary stitching line 190 may be used instead of a glue line to create the pocket 180 in the sleeve 120 . The temporary stitching line 190 used to form the pocket 180 in the sleeve 120 may be removed after installation. For example, in various exemplary embodiments, the temporary stitching line 190 may be a chain stitch that allows easy removal of the temporary stitching line 190 by simple pulling of a loose end of the temporary stitching line 190 to permit the filler material 125 to expand within the sleeve 120 as needed or desired. In various exemplary embodiments, the pocket 180 may comprise a smaller tube 220 comprised of fabric and containing filler material 125 and other material, which fabric either dissolves or expands when water is introduced. Such a tubular pocket 220 may be inserted into the sleeve 120 during installation. In such exemplary embodiments, the glue and/or temporary line of stitching 190 may not be necessary.
In various exemplary embodiments, and as shown in FIG. 5 , the check tube 110 will be fabricated from a single piece of material. For example, in various exemplary embodiments, the check tube 110 may be fabricated from a single sheet of material folded over upon itself and closed with a line of stitching 210 or otherwise sealed or closed as shown in FIG. 5 , wherein the sleeve 120 is defined by portions of the folded sheet and fastening elements such as the line of stitching 210 .
FIG. 5 also illustrates the use of temporary fastening elements, such as a line of chain stitching 190 which extends from the open end of the check tube 110 to subdivide the sleeve 120 into a smaller pocket 180 for receiving the filler material 125 and maintaining a generally even distribution of the filler material 125 along the entire length of the pocket 180 and/or sleeve 120 during storage, transport, handling and installation of the check tube 110 . Although not necessary for the subdivision of the sleeve 120 , the chain stitching line 190 is shown extending beyond the stitched closed end of the sleeve 120 toward the far end of the folded check tube 110 . This simplifies the stitching step, and has the additional advantage that the chain stitching line 190 must be removed to permit nesting of the tied end of the sleeve 120 within the hood 150 of a previously placed check tube 110 , as shown in FIG. 4 . This prevents the installers from forgetting to remove the chain stitching 190 during installation of each check tube 110 .
While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims.
|
A check tube is sealed on one end and may be open on the opposite end. The check tube may have a cape, a flap and/or a hood attached to the check tube to, among other things, anchor the check tube and/or to prevent water flow, and thus erosion, between adjacent check tubes, beneath the check tube and/or downstream of the check tube. A temporary pocket defining a subset of the volume of the check tube is provided in the check tube and filled with fill material that expands after being introduced to water. Just prior to, during or after installation of the check tube, the pocket is opened, broken or dissolved and the check tube is introduced to water thereby allowing the fill material to expand to the full volume of the check tube.
| 4
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.