A process for the preparation of toner compositions with controlled particle size and selected morphology comprising. (i) preparing a pigment dispersion in water, which dispersion is comprised of pigment, ionic surfactant, and optionally a charge control agent; PA1 (ii) shearing the pigment dispersion with a polymeric latex comprised of resin of submicron size, a counterionic surfactant with a charge polarity of opposite sign to that of said ionic surfactant and a nonionic surfactant thereby causing a flocculation or heterocoagulation of the formed particles of pigment, resin and charge control agent, and generating a uniform blend dispersion of solids of resin, pigment, and optional charge control agent in the water and surfactants; PA1 (iii) (a) continuously stirring and heating the above sheared blend to form electrostatically bound toner size aggregates; or PA1 (iii) (b) further shearing the above blend to form electrostatically bound well packed aggregates; or PA1 (iii) (c) continuously shearing the above blend, while heating to form aggregated flake-like particles; PA1 (iv) heating the above formed aggregated particles about above the Tg of the resin to provide coalesced particles of toner; and optionally PA1 (v) separating said toner particles from water and surfactants; and PA1 (vi) drying said toner particles.

The present invention is generally directed to toner processes, and more specifically to aggregation and coalescence processes for the preparation of toner compositions with certain morphologies. In embodiments, the present invention is directed to the economical preparation of toners without the utilization of the known pulverization and/or classification methods, and wherein toner compositions with an average volume diameter of from about 1 to about 25, and preferably from 1 to about 10 microns and narrow GSD of, for example, from about 1.16 to about 1.30, as measured on the Coulter Counter, can be obtained. Also, the morphology of the toner particles can be tuned, or preselected from like a bunch of grapes morphology through cauliflower, raspberries, potatoes to perfectly spherical particles. The resulting toners can be selected for known electrophotographic imaging and printing processes, including color processes, and lithography. In embodiments, the present invention is directed to a process comprised of dispersing a pigment, and optionally a charge control agent or additive in an aqueous mixture containing an ionic surfactant in amount of from about 0.01 percent (weight percent throughout unless otherwise indicated) to about 10 percent and shearing this mixture at high shear with a latex mixture comprised of suspended resin particles of from, for example, about 0.01 micron to about 2 microns in volume average diameter, in an aqueous solution containing a counterionic surfactant in amounts of from about 0.01 percent to about 10 percent with opposite charge to the ionic surfactant of the pigment dispersion, and nonionic surfactant in an amount of from 0 percent to about 5 percent, thereby causing a flocculation of resin particles, pigment particles and optional charge control particles, followed by (a) stirring at from 250 rpm to 600 rpm, or (b) stirring assisted with heating from about 40.degree. C. to about 5.degree. C. below the resin Tg and preferably 20.degree. C. to 5.degree. C. below the resin Tg, or (c) shearing of the flocculated mixture, for example by attrition at 20 rpm to about 400 rpm, or (d) shearing assisted by heating of the flocculent mixture which is believed to form statically bound aggregates of from about 1 micron to about 10 microns in volume average diameter comprised of resin, pigment, and optionally charge control particles. The morphology of the aforementioned statically bonded aggregated particles can be controlled by adjusting the temperature in the aggregation stage (below the resin Tg), the time of the aggregation, and by the shear. By extending the time of the aggregation and/or increasing the temperature and/or applying the shear, one can more densely pack the submicron particles in the aggregated particles and as a result form more uniform toner particles. The reverse causes formation of the particles with higher fractal dimensions (loosely packed) which upon heating can form particles with some voids or holes. The formation of electrostatically bonded aggregates is followed by coalescence which comprises heating above the resin Tg. It is believed that during the heating stage the components of aggregated particles fuse together to form composite toner particles. The coalescence step (iv) can have an impact on the toner particle morphology. Factors, such as coalescence temperature, time of heating as well as melt flow properties of the polymeric resin, contribute to the toner particle morphology. By increasing the temperature of the coalescence and/or extending the time of heating, the morphology of toner particles can be tuned from "bumpy" structures to smooth surfaces. The morphology can also depend on the melt flow properties of the resin, which is closely related to the type of resin, its molecular weight, Tg, degree of crosslinking, presence of plasticizer, and the like. Also, by increasing the melt flow properties of the polymeric resin, the morphology of the particles can be changed from "bumpy" to smooth and spherical as illustrated herein. In another embodiment thereof, the present invention is directed to an in situ process comprised of first dispersing a pigment, such as HELIOGEN BLUE.TM. or HOSTAPERM PINK.TM., in an aqueous mixture containing a cationic surfactant, such as benzalkonium chloride (SANIZOL B-50.TM.), utilizing a high shearing device, such as a Brinkmann Polytron, a microfluidizer or a sonicator, thereafter shearing this mixture with a latex of suspended resin particles, such as poly(styrenebutadiene acrylic acid), poly(styrenebutylacrylate acrylic acid) or PLIOTONE.TM. a poly(styrene butadiene), and which particles are, for example, of a size ranging from about 0.01 to about 0.5 micron in volume average diameter as measured by the Brookhaven nanosizer, in an aqueous surfactant mixture containing an anionic surfactant, such as sodium dodecylbenzene sulfonate, for example NEOGEN R.TM. or NEOGEN SC.TM., and nonionic surfactant, such as alkyl phenoxy poly(ethylenoxy) ethanol, for example IGEPAL 897.TM. or ANTAROX 897.TM., thereby resulting in a flocculation, or heterocoagulation of the resin particles with the pigment particles; and which on further stirring for 1 to about 24 hours, or further stirring while heating or shearing, for example, using the attritor, or shearing while heating, for example, from about 25.degree. C. to about 50.degree. C. results in the formation of statically bound aggregates ranging in size of from about 0.5 micron to about 10 microns in average diameter size as measured by the Coulter Counter (Multisizer II) with a morphology ranging from a bunch of grapes, loosely or densely packed, to flakes where the morphology of the aggregates can be controlled by temperature, shear, and time. Thereafter, heating about 5.degree. C. to about 50.degree. C. above the resin Tg, which Tg is in range of from about 50.degree. C. to about 80.degree. C., to provide for particle fusion or coalescence of the polymer and pigment particles with the morphology controlled by the temperature of coalescence, the time of coalescence and the melt flow properties of the resin; followed by washing with, for example, hot water to remove surfactant, and drying toner particles comprised of resin and pigment with various particle size diameters can be obtained such as from 1 to 12 microns in average volume particle diameter. The aforementioned toners are especially useful for the development of colored images with excellent line and solid resolution, and wherein substantially no background deposits are present.
While not being desired to be limited by theory, it is believed that the flocculation or heterocoagulation is caused by the neutralization of the pigment mixture containing the pigment and cationic surfactant absorbed on the pigment surface with the resin mixture containing the resin particles and anionic surfactant absorbed on the resin particle. Depending on the conditions of this flocculation step such as time, shear and temperature, submicron resin particles and pigment particles will pack in the aggregate more densely or loosely and this will be a factor contributing to their final morphology. Thereafter, heating the aggregates, for example 5.degree. C. to 80.degree. C. above the resin Tg, fuses the aggregated particles or coalesces the particles to enable toner composites of polymer and pigments and optionally charge control agents. The temperature of the coalescence as well as the time for which the aggregated particles were heated above their Tg (step iv) will effect the morphology of the final toner particles, ranging from a bunch of grapes type of morphology to perfectly spherical. Furthermore, in other embodiments the ionic surfactants can be exchanged, such that the pigment mixture contains the pigment particle and anionic surfactant, and the suspended resin particle mixture contains the resin particles and cationic surfactant; followed by the ensuing steps as illustrated herein to enable flocculation by charge neutralization while shearing, and thereby forming statically bound aggregate particles by stirring and heating (below the resin Tg), and thereafter, that is when the aggregates are formed, heating above the resin Tg to form stable toner composite particles.
Of importance with respect to the processes of the present invention in embodiments is controlling the shear time, shear rate and shear temperature, and the aggregation temperature and time since these factors can primarily contribute to the morphology of the aggregated particles and cause more densely or more loosely packed aggregates. Control of the temperature and the time of the coalescence or heating above the resin Tg (step iv) is of importance since these factors can effect the morphology of the final toner particles significantly; by increasing from about 1 hour to about 4 hours the temperature from about 5.degree. C. to about 50.degree. C. above the resin Tg, and/or the time of coalescence from about 1 hour to about 4 hours, the morphology of the particles can be tuned from "bumpy" to smooth. Another factor that can effect the morphology of the toner particles is the melt flow properties of the aggregated resin with increasing, from about 2 to about 10 grams per 10 minutes, the melt flow properties of the resin the surface of the toner particles can be changed from "bumpy" to smooth spherical. One factor contributing to the melt flow is the type of resin, for example polyester, polystyrene/butadiene, or polystyrene/acrylate, the molecular weight of the resin, the Tg, the degree of crosslinking and the presence of plasticizers like polyvinylbuturyal in an amount of from about 1 weight percent to about 20 weight percent.
In reprographic technologies, such as xerographic and ionographic devices, toners with average volume diameter particle sizes of from about 9 microns to about 20 microns are effectively utilized. Moreover, in some xerographic technologies, such as the high volume Xerox Corporation 5090 copier-duplicator, high resolution characteristics and low image noise are highly desired, and can be attained utilizing the small sized toners of the present invention with, for example, an average volume particle diameter of 3 to 11 microns and preferably less than about 7 microns, and with narrow geometric size distribution (GSD) of from about 1.16 to about 1.3. Additionally, in some xerographic systems wherein process color is utilized, such as pictorial color applications, small particle size colored toners of from about 3 to about 9 microns are desired to avoid paper curling. Paper curling is especially observed in pictorial or process color applications wherein three to four layers of toners are transferred and fused onto paper. During the fusing step, moisture is driven off from the paper due to the high fusing temperatures of from about 130 .degree. C. to 160.degree. C. applied to the paper from the fuser. Where only one layer of toner is present, such as in black or in highlight xerographic applications, the amount of moisture driven off during fusing is reabsorbed proportionally by paper and the resulting print remains relatively flat with minimal curl. In pictorial color process applications wherein three to four colored toner layers are present, a thicker toner plastic level present after the fusing step inhibits the paper from sufficiently absorbing the moisture lost during the fusing step, and image paper curling results. These and other disadvantages and problems are avoided or minimized with the toners and processes of the present invention. It is preferable to use small toner particle sizes, such as from about 1 to about 7 microns, and with higher pigment loading, such as from about 5 to about 12 percent by weight of toner, such that the mass of toner layers deposited onto paper is reduced to obtain the same quality of image and resulting in a thinner plastic toner layer onto paper after fusing, thereby minimizing or avoiding paper curling. Toners prepared in accordance with the present invention enable the use of lower fusing temperatures, such as from about 120.degree. C. to about 150.degree. C., thereby avoiding or minimizing paper curl. Lower fusing temperatures minimize the loss of moisture from paper, thereby reducing or eliminating paper curl. Furthermore, in process color applications and especially in pictorial color applications, toner to paper gloss matching is highly desirable. Gloss matching is referred to as matching the gloss of the toner image to the gloss of the paper. For example, when a low gloss image of preferably from about 1 to about 30 gloss is desired, low gloss paper is utilized, such as from about 1 to about 30 gloss units as measured by the Gardner Gloss metering unit, and which after image formation with small particle size toners of from about 3 to about 5 microns and fixing thereafter results in a low gloss toner image of from about 1 to about 30 gloss units as measured by the Gardner Gloss metering unit. Alternatively, if higher image gloss is desired, such as from about over 30 to about 60 gloss units as measured by the Gardner Gloss metering unit, higher gloss paper is utilized, such as from about over 30 to about 60 gloss units, and which after image formation with small particle size toners of the present invention of from about 3 to about 5 microns and fixing thereafter results in a higher gloss toner image of from about over 30 to about 60 gloss units as measured by the Gardner Gloss metering unit. The aforementioned toner to paper matching can be attained with small particle size toners such as less than 7 microns and preferably less than 5 microns, such as from about 1 to about 4 microns such that the pile height of the toner layer(s) is considered low.
Numerous processes are known for the preparation of toners, such as, for example, conventional processes wherein a resin is melt kneaded or extruded with a pigment, micronized and pulverized to provide toner particles with very irregular shape with sharp edges, which may not be an optimum morphology from the charging and dry toner flow point of view. With the present invention, tuning of the toner particle morphology can be achieved to enable, for example, selected excellent morphologies desired for superior toner flow and excellent charging properties of the toner particles. Also, in conventional processes wherein a resin is melt kneaded or extruded with a pigment, micronized and pulverized toner particles with an average volume particle diameter of from about 10 microns to about 20 microns and with broad geometric size distribution of from about 1.4 to about 1.7 result. In such processes, it is usually necessary to subject the aforementioned toners to a classification procedure such that the geometric size distribution of from about 1.2 to about 1.4 is attained. Also, in the aforementioned conventional process, low toner yields after classifications may be obtained. Generally, during the preparation of toners with average particle size diameters of from about 11 microns to about 15 microns, toner yields range from about 70 percent to about 85 percent after classification. Additionally, during the preparation of smaller sized toners with particle sizes of from about 7 microns to about 11 microns, lower toner yields are obtained after classification, such as from about 50 percent to about 70 percent. With the processes of the present invention, in embodiments small average particle sizes of, for example, from about 3 microns to about 9, and preferably 5 microns are attained without resorting to classification processes, and wherein narrow geometric size distributions are attained, such as from about 1.16 to about 1.30, and preferably from about 1.16 to about 1.25. High toner yields are also attained such as from about 90 percent to about 98 percent in embodiments. In addition, by the toner particle preparation process of the present invention in embodiments, small particle size toners of from about 3 microns to about 7 microns can be economically prepared in high yields such as from about 90 percent to about 98 percent by weight based on the weight of all the toner material ingredients, such as toner resin and pigment.
There is illustrated in U.S. Pat. No. 4,996,127 a toner of associated particles of secondary particles comprising primary particles of a polymer having acidic or basic polar groups and a coloring agent. The polymers selected for the toners of the '127 patent can be prepared by an emulsion polymerization method, see for example columns 4 and 5 of this patent. In column 7 of this '127 patent, it is indicated that the toner can be prepared by mixing the required amount of coloring agent and optional charge additive with an emulsion of the polymer having an acidic or basic polar group obtained by emulsion polymerization. Also, note column 9, lines 50 to 55, wherein a polar monomer such as acrylic acid in the emulsion resin is necessary, and toner preparation is not obtained without the use, for example, of acrylic acid polar group. In U.S. Pat. No. 4,983,488, there is disclosed a process for the preparation of toners by the polymerization of a polymerizable monomer dispersed by emulsification in the presence of a colorant and/or a magnetic powder to prepare a principal resin component and then effecting coagulation of the resulting polymerization liquid in such a manner that the particles in the liquid after coagulation have diameters suitable for a toner. It is indicated in column 9 of this patent that coagulated particles of 1 to 100, and particularly 3 to 70, are obtained. This process is thus directed to the use of coagulants, such as inorganic magnesium sulfate which results in the formation of particles with wide GSD. Similarly, the aforementioned disadvantages, for example poor GSD are obtained, hence classification is required resulting in low yields as illustrated in U.S. Pat. No. 4,797,339, wherein there is disclosed a process for the preparation of toners by resin emulsion polymerization, wherein similar to the '127 patent polar resins of oppositely charges are selected, and wherein flocculation as in the present invention is not disclosed; and U.S. Pat. No. 4,558,108, wherein there is disclosed a process for the preparation of a copolymer of styrene and butadiene by specific suspension polymerization. Other prior art that may be of interest includes U.S. Pat. Nos. 3,674,736; 4,137,188 and 5,066,560.
The process described in the present application has several advantages as indicated herein including the effective preparation of small toner particles with narrow particle size distribution with the desired morphology which can be tuned for particular xerographic applications.
In U.S. Pat. No. 5,290,654, the disclosure of which is totally incorporated herein by reference, there is illustrated a process for the preparation of toners comprised of dispersing a polymer solution comprised of an organic solvent, and a polyester and homogenizing and heating the mixture to remove the solvent and thereby form toner composites. Additionally, there is disclosed in U.S. Pat. No. 5,278,020, the disclosure of which is totally incorporated herein by reference, a process for the preparation of in situ toners comprising an halogenization procedure which chlorinates the outer surface of the toner and results in enhanced blocking properties. More specifically, this patent application discloses an aggregation process wherein a pigment mixture, containing an ionic surfactant, is added to a resin mixture, containing polymer resin particles of less than 1 micron, nonionic and counterionic surfactant, and thereby causing a flocculation which is dispersed to statically bound aggregates of about 0.5 to about 5 microns in volume diameter as measured by the Coulter Counter, and thereafter heating to form toner composites or toner compositions of from about 3 to about 7 microns in volume diameter and narrow geometric size distribution, as measured by the Coulter Counter, and which exhibit, for example, low fixing temperature of from about 125.degree. C. to about 150.degree. C., and image to paper gloss matching.
In U.S. Pat. No. 5,308,734, the disclosure of which is totally incorporated herein by reference, there is illustrated a process for the preparation of toner compositions which comprises generating an aqueous dispersion of toner fines, ionic surfactant and nonionic surfactant, adding thereto a counterionic surfactant with a polarity opposite to that of said ionic surfactant, homogenizing and stirring said mixture, and heating to provide for coalescence of said toner fine particles.
In U.S. Pat. No. 5,346,797, the disclosure of which is totally incorporated herein by reference there is disclosed a process for the preparation of toner compositions comprising
(i) preparing a pigment dispersion in a water, which dispersion is comprised of a pigment, an ionic surfactant and optionally a charge control agent; PA1 (ii) shearing the pigment dispersion with a latex mixture comprised of a counterionic surfactant with a charge polarity of opposite sign to that of said ionic surfactant, a nonionic surfactant and resin particles, thereby causing a flocculation or heterocoagulation of the formed particles of pigment, resin and charge control agent to form electrostatically bounded toner size aggregates; and PA1 (iii) heating the statically bound aggregated particles above the Tg to form said toner composition comprised of polymeric resin, pigment and optionally a charge control agent. PA1 (i) preparing a pigment dispersion in water, which dispersion is comprised of pigment, an ionic surfactant and an optional charge control agent; PA1 (ii) shearing at high speeds the pigment dispersion with a polymeric latex comprised of resin, a counterionic surfactant with a charge polarity of opposite sign to that of said ionic surfactant, and a nonionic surfactant thereby forming a uniform homogeneous blend dispersion comprised of resin, pigment, and optional charge agent; PA1 (iii) heating the above sheared homogeneous blend below about the glass transition temperature (Tg) of the resin while continuously stirring to form electrostatically bound toner size aggregates with a narrow particle size distribution; PA1 (iv) heating the statically bound aggregated particles above about the Tg of the resin particles to provide coalesced toner comprised of resin, pigment and optional charge control agent, and subsequently optionally accomplishing (v) and (vi); PA1 (v) separating said toner; and PA1 (vi) drying said toner. PA1 (i) preparing by emulsion polymerization a charged polymeric latex of submicron particle size; PA1 (ii) preparing a pigment dispersion in water, which dispersion is comprised of a pigment, an effective amount of cationic flocculant surfactant, and optionally a charge control agent; PA1 (iii) shearing the pigment dispersion (ii) with a polymeric latex (i) comprised of resin, a counterionic surfactant with a charge polarity of opposite sign to that of said ionic surfactant thereby causing a flocculation or heterocoagulation of the formed particles of pigment, resin and charge control agent to form a high viscosity gel in which solid particles are uniformly dispersed; PA1 (iv) stirring the above gel comprised of latex particles, and oppositely charged pigment particles for an effective period of time to form electrostatically bound relatively stable toner size aggregates with narrow particle size distribution; and PA1 (v) heating the electrostatically bound aggregated particles at a temperature above the resin glass transition temperature (Tg) thereby providing said toner composition comprised of resin, pigment and optionally a charge control agent. PA1 (i) preparing a pigment dispersion in water, which dispersion is comprised of a pigment, an ionic surfactant in amounts of from about 0.5 to about 10 percent by weight of water, and an optional charge control agent; PA1 (ii) shearing the pigment dispersion with a latex mixture comprised of a counterionic surfactant with a charge polarity of opposite sign to that of said ionic surfactant, a nonionic surfactant and resin particles, thereby causing a flocculation or heterocoagulation of the formed particles of pigment, resin and charge control agent; PA1 (iii) stirring the resulting sheared viscous mixture of (ii) at from about 300 to about 1,000 revolutions per minute to form electrostatically bound substantially stable toner size aggregates with a narrow particle size distribution; PA1 (iv) reducing the stirring speed in (iii) to from about 100 to about 600 revolutions per minute and subsequently adding further anionic or nonionic surfactant in the range of from about 0.1 to about 10 percent by weight of water to control, prevent, or minimize further growth or enlargement of the particles in the coalescence step (iii); and PA1 (v) heating and coalescing from about 5.degree. to about 50.degree. C. above about the resin glass transition temperature, Tg, which resin Tg is from between about 45.degree. to about 90.degree. C. and preferably from between about 50.degree. and about 80.degree. C., the statically bound aggregated particles to form said toner composition comprised of resin, pigment and optional charge control agent. PA1 (i) preparing a pigment dispersion, which dispersion is comprised of a pigment, an ionic surfactant, and optionally a charge control agent; PA1 (ii) shearing said pigment dispersion with a latex or emulsion blend comprised of resin, a counterionic surfactant with a charge polarity of opposite sign to that of said ionic surfactant and a nonionic surfactant; PA1 (iii) heating the above sheared blend below about the glass transition temperature (Tg) of the resin to form electrostatically bound toner size aggregates with a narrow particle size distribution; and PA1 (iv) heating said bound aggregates above about the Tg of the resin. PA1 (i) preparing a pigment dispersion in water, which dispersion is comprised of pigment, a counterionic surfactant with a charge polarity of opposite sign to the anionic surfactant of (ii) and optionally a charge control agent; PA1 (ii) shearing the pigment dispersion with a latex comprised of resin, anionic surfactant, nonionic surfactant, and water; and wherein the latex solids content, which solids are comprised of resin, is from about 50 weight percent to about 20 weight percent thereby causing a flocculation or heterocoagulation of the formed particles of pigment, resin and optional charge control agent; diluting with water to form a dispersion of total solids of from about 30 weight percent to 1 weight percent, which total solids are comprised of resin, pigment and optional charge control agent contained in a mixture of said nonionic, anionic and cationic surfactants; PA1 (iii) heating the above sheared blend at a temperature of from about 5.degree. to about 25.degree. C. below about the glass transition temperature (Tg) of the resin while continuously stirring to form toner sized aggregates with a narrow size dispersity; and PA1 (iv) heating the electrostatically bound aggregated particles at a temperature of from about 5.degree. to about 50.degree. C. above about the Tg of the resin to provide a toner composition comprised of resin, pigment and optionally a charge control agent.
In U.S. Pat. No. 5,370,463, filed concurrently herewith, the disclosure of which is totally incorporated herein by reference, there is illustrated a process for the preparation of toner compositions with controlled particle size comprising:
In U.S. Pat. No. 5,344,738, filed concurrently herewith, the disclosure of which is totally incorporated herein by reference, there is illustrated a process for the preparation of toner compositions with a volume median particle size of from about 1 to about 25 microns, which process comprises:
In copending patent application U.S. Ser. No. 083,157, filed concurrently herewith, the disclosure of which is totally incorporated herein by reference, there is illustrated a process for the preparation of toner compositions with controlled particle size comprising:
In U.S. Pat. No. 5,364,729, filed concurrently herewith, the disclosure of which is totally incorporated herein by reference, there is illustrated a process for the preparation of toner compositions comprising:
In copending patent application U.S. Ser. No. 083,116, filed concurrently herewith, the disclosure of which is totally incorporated herein by reference, there is illustrated a process for the preparation of toner compositions comprising
Toner particles with mechanical stability for extended time periods to withstand the development system in xerographic processes, and more spherical and more densely packed toner particles are desired. From a charging standpoint, a bumpy type of toner morphology is preferred and from a toner flow point of view, it is believed that spherical particles are preferable. These and other advantages are achievable with the processes of the present invention and more specifically these processes provide a method for the modification or tuning of the morphology of toner particles. This tuning of the morphology can be achieved by adjusting the processing conditions, such as temperature, time and shear, as well as selecting the proper polymeric materials with desired melt flow properties, such as about 20 to about 50 grams/10 minutes.


A method of manufacturing a rolling cone with hard-facing coating for use in drilling boreholes is disclosed. The method includes a step of depositing a layer of hardfacing material by an arc process, e.g., a gas-shielding tungsten arc welding process, a plasma-transferred arc welding process, or a metal inert gas arc welding process, over areas susceptible to erosion on the rolling cone surface. A rolling cone rock bit for drilling boreholes with a layer of hardfacing material deposited by an arc process either on the lands or in grooves or both of the cone surface is provided. Furthermore, a cone for attachment to the bit body of a rock bit with a layer of hardfacing material deposited on selected lands or in selected grooves or both of the cone surface also is provided.

Drilling in the earth is commonly accomplished by using a drill bit having a plurality of rock bit rolling cones ("cutter cones") that are set at angles, through earth formations. The bit essentially crushes the formations through which it drills. The rolling cones rotate on their axes and are, in turn, rotated about the main axis of the drill string. In drilling boreholes for oil and gas wells, blast holes, and raise holes, rock bit rolling cones constantly operate in a highly abrasive environment. This abrasive condition exists during drilling operations even with the use of a medium for cooling, circulating, and flushing the borehole. Such a cooling medium may be either drilling mud, air, or another liquid or gas .
When drilling a hard formation, a bit with tungsten carbide inserts projecting from the body of a rolling cone generally is utilized due to the inserts' relative hardness. However, the carbide inserts are mounted in a relatively soft metal (e.g. steel) that forms the body of the rolling cone. This relatively soft body may be abraded or eroded away when subjected to the high abrasive drilling environment. This abrasion or erosion occurs primarily due to the presence of relatively fine cuttings and chips from the formation that are in the borehole. Additional causes include the direct blasting effect of the drilling fluid utilized in the drilling process, and the rolling or sliding contact of the cone body with the formation. When the material supporting the inserts is substantially eroded or abraded away, the drilling forces either may break the inserts or may force them out of the rolling cone body. As a result, the bit is no longer effective in cutting the formation. Moreover, the inserts that break off from the rolling cone may further damage other inserts, the rolling cones, or other parts of the bit, eventually leading to a catastrophic failure.
Erosion of the rolling cone body usually is most pronounced on the inner and outer edges of the lands of the cone surface. This area is immediately adjacent to the insert and the groove between two rows of inserts. The heaviest wear on the rolling cone surface lands is usually on the inner edges of the outer rows and on the outer edges of the inner rows. When drilling relatively soft but abrasive formations, the bit is able to penetrate at an extremely high rate. This can result in individual cutting inserts penetrating entirely into the abrasive formation causing the formation to come into contact with the cone shell body. When such abrasive contact occurs, the relatively soft cone shell material will wear away at the edges of the surface lands until the interior portion of the insert becomes exposed. The retention ability of the cone body is reduced, thereby ultimately resulting in the potential loss of the insert and reduction of bit life. Because the penetration rate is related to the condition of the bit, the drill bit life and efficiency are of paramount importance in the drilling of boreholes. Accordingly, various methods of hardfacing rock bit cones for erosion or abrasion protection have been attempted. For example, thermal spraying has been used to coat the entire exposed surfaces, including the inserts, of a rolling cone with a hardfacing material. Another method involved placing small, flat-top compacts of hard material in the vulnerable cutter shell areas to prevent cone erosion. Since erosion of groove surface can be the main cause of insert loss due to erosion, methods were developed to apply hardfacing material to both the lands and the grooves of a rolling cone.
It should be noted that inserts are typically retained in a rolling cone by the "hoop" tension generated when the insert is press-fitted into a drilled hole in the rolling cone body. Accordingly, any method to alleviate the erosion of the rolling cone must take into consideration that the "hoop" tension holding the insert must be retained. It has been found undesirable to press the inserts into the cutter before applying hardfacing material. This is because the utilization of heat to adhere the hardfacing material to the surface of the rolling cone relieves the stresses (e.g., "hoop" tension) in the rolling cone. Therefore, it is more desirable to apply hardfacing material to both the lands and grooves of a rolling cone surface for erosion protection before the insert holes are drilled.
For the foregoing reasons, there exists a need for an effective yet economic method of applying hardfacing material to rolling cone surfaces for effective erosion protection. To reduce the cost of manufacturing such rock bits with hardfacing material, it is desirable that the method not be complicated and tedious. Further, the hardfacing material should be applied to the rolling cone surfaces before the insert holes are drilled.

Hardfacing rock bit cones for erosion protection


A delivery wire assembly for delivering an occlusive device to a location in a patient's vasculature, includes delivery wire conduit defining a conduit lumen, a core wire disposed in the conduit lumen, the core wire having a distal detachment zone, and an enhancing coil disposed around the distal detachment zone, the enhancing coil configured to transfer a distally directed force from the delivery wire assembly to objects located distal of the delivery wire assembly without damaging the distal detachment zone. In one embodiment, the enhancing coil includes a proximal section having a first diameter, a distal section having a diameter larger than the diameter of the proximal section, and a transition section connecting the respective proximal and distal sections, wherein the transition section flares radially in a distal direction.

Vaso-occlusive devices or implants are used for a wide variety of reasons, including treatment of intra-vascular aneurysms. Commonly used vaso-occlusive devices include soft, helically wound coils formed by winding a platinum (or platinum alloy) wire strand about a "primary" mandrel. The coil is then wrapped around a larger, "secondary" mandrel, and heat treated to impart a secondary shape. For example, U.S. Pat. No. 4,994,069, issued to Ritchart et al., describes a vaso-occlusive coil that assumes a linear, helical primary shape when stretched for placement through the lumen of a delivery catheter, and a folded, convoluted secondary shape when released from the delivery catheter and deposited in the vasculature.
In order to deliver the vaso-occlusive devices to a desired site in the vasculature, e.g., within an aneurismal sac, it is well-known to first position a small profile, delivery catheter or "micro-catheter" at the site using a steerable guidewire. Typically, the distal end of the micro-catheter is provided, either by the attending physician or by the manufacturer, with a selected pre-shaped bend, e.g., 45°, 90°, "J", "S", or other bending shape, depending on the particular anatomy of the patient, so that it will stay in a desired position for releasing one or more vaso-occlusive device(s) into the aneurysm once the guidewire is withdrawn. A delivery or "pusher" wire is then passed through the micro-catheter, until a vaso-occlusive device coupled to a distal end of the delivery wire is extended out of the distal end opening of the micro-catheter and into the aneurysm. The vaso-occlusive device is then released or "detached" from the end delivery wire, and the delivery wire is withdrawn back through the catheter. Depending on the particular needs of the patient, one or more additional occlusive devices may be pushed through the catheter and released at the same site.
One well-known way to release a vaso-occlusive device from the end of the pusher wire is through the use of an electrolytically severable junction, which is a small exposed section or detachment zone located along a distal end portion of the pusher wire. The detachment zone is typically made of stainless steel and is located just proximal of the vaso-occlusive device. An electrolytically severable junction is susceptible to electrolysis and disintegrates when the pusher wire is electrically charged in the presence of an ionic solution, such as blood or other bodily fluids. Thus, once the detachment zone exits out of the catheter distal end and is exposed in the vessel blood pool of the patient, a current applied through an electrical contact to the conductive pusher wire completes an electrolytic detachment circuit with a return electrode, and the detachment zone disintegrates due to electrolysis.
In "monopolar" systems, return electrodes include electrodes attached to the patient's skin and conductive needles inserted through the skin at a remote site. In "bipolar" systems, return electrodes are located on the pusher wire, e.g. on a delivery wire conduit, but electrically insulated from the conductive path ending in the detachment zone. The anode is made up of a polyimide insulated core wire, which runs through the pusher wire, is attached to the electrical contact at the proximal end, and forms the detachment zone at the distal end.
Perceived problems with current vaso-occlusive coil delivery systems include buckling, kinking, or bending of the exposed detachment zone of the pusher wire. The detachment zone is typically the weakest part of the pusher wire structure. Buckling, kinking, or bending may lead to fatigue failure and premature detachment as the vaso-occlusive coil and pusher wire are navigated through a patient's vascular system. For instance, the detachment zone may fail as the pusher wire is withdrawn to position the attached vaso-occlusive coil, separating the vaso-occlusive coil from the pusher wire. Such premature detachment would require another procedure to retrieve the misplaced vaso-occlusive coil.

Delivery wire assembly for occlusive device delivery system


A volume transform system, which includes a computer processor and a novel volume transform software, receives a set of invasion parameters from a parameterization system, the parameterization system producing a set of invasion parameters which represent a resistivity profile of a formation traversed by a wellbore. The volume transform system functions to perform a quantitative invasion analysis on the invasion parameters in the volume dimension by computing the volume of mud filtrate (Vmf) for each unit of depth in the wellbore and producing a new output record medium, or a new log, which quantitatively illustrates the volume of the mud filtrate (vmf) invasion into the formation traversed by the wellbore as a function of depth in the wellbore. The aforementioned quantitative invasion analysis in the volume dimension compensates for variations in drilling mud, porosity, formation water, and saturation gradient from well to well and between hydrocarbon and water zones with a wellbore.

The subject matter of the present invention relates to a system adapted to be disposed at the surface of a wellbore for determining mud filtrate volume data as a function of depth in a wellbore from a set of parameterized, processed, and wellbore corrected induction logging array signal data, which data is produced by an array induction tool disposed in the wellbore, and for generating an output record medium which reflects and illustrates the mud filtrate volume data in the form of a log, the log being analyzed in order to determine information regarding wellbore formation properties, such as layering, vertical permeability, and formation damage.
During the drilling of a wellbore, mud pumps introduce mud into the well in order to flush rock chips and other unwanted debris out of the wellbore. The mud is introduced into the wellbore under pressure, the mud pressure being slightly greater than the pressure of a formation traversed by the wellbore thereby preventing a phenomenon known as well blowout. The resultant pressure differential between the mud column pressure and the formation pressure forces mud filtrate into the permeable formation, and solid particles of the mud are deposited on the wellbore wall forming a mudcake. The mudcake usually has a very low permeability and, once developed, considerably reduces the rate of further mud filtrate invasion into the wellbore wall. In a region very close to the wellbore wall, most of the original formation water and some of the hydrocarbons may be flushed away by the mud filtrate. This region is known as the "flushed zone", or the "invaded zone". If the flushing is complete, the flushed zone pore space contains only mud filtrate; in addition, if the flushed zone was originally hydrocarbon bearing, it would contain only residual hydrocarbons. Further out from the wellbore wall, the displacement of the formation fluids by the mud filtrate is less and less complete thereby resulting in a second region, this second region undergoing a transition from mud filtrate saturation to original formation water saturation. The second region is known as the "transition zone". The extent or depth of the flushed and transition zones depends on many parameters, among them being the type and characteristics of the drilling mud, the formation porosity, the formation permeability, the pressure differential, and the time since the formation was first drilled. The undisturbed formation beyond the transition zone is known as the "uninvaded, virgin, or uncontaminated zone". In FIGS. 1a-1b, a schematic representation of an invasion and resistivity profile in a water-bearing zone is illustrated. FIG. 1a illustrates a cross section of a wellbore showing the locations of the flushed zone, the transition zone, and the uninvaded zone extending radially from the wellbore wall. FIG. 1b illustrates a radial distribution of formation resistivity extending radially from the wellbore wall, into the flushed zone, into the transition zone, and into the uninvaded zone. In FIGS. 2a-2b, a schematic representation of an invasion and resistivity profile in an oil-bearing zone is illustrated. FIG. 2a illustrates the radial distribution of fluids in the vicinity of the wellbore, oil bearing bed. FIG. 2b illustrates the radial distribution of resistivities for an oil bearing zone, similar to the radial distribution of resistivities for a water bearing zone shown in FIG. 1b. Sometimes, in oil and gas bearing formations, where the mobility of the hydrocarbons is greater than that of the water, because of relative permeability differences, the oil or gas moves away faster than the interstitial water. In this case, there may be formed, between the flushed zone and the uninvaded zone, an "annular zone or annulus", shown in FIG. 2b, with a high formation water saturation. Annuli probably occur, to some degree, in most hydrocarbon bearing formations; and their influence on measurements depends on the radial location of the annulus and its severity. However, the existence of these zones (the flushed, transition, annular, and uninvaded zones) influence resistivity log measurements and therefore the accuracy of the resistivity log itself that is presented to a client. The resistivity log is utilized by the client to determine if oil exists in the formation traversed by the wellbore. The client is mainly interested in the true and correct value of Rt, the resistivity (reciprocal of conductivity) of the uninvaded zone, since Rt is the best measure of the possibility of oil existing in the formation. However, the existence of the flushed and transition zones in the formation adjacent the wellbore wall adversely affect a measurement of Rt. Therefore, since large amounts of money may be spent based on the resistivity log presented to the client, it is important to understand the true resistivity of the formation in the flushed and transition zones in order to improve the accuracy of the resistivity log in general. Prior art well logging tools function to log the formation and generate signals, which signals are processed by a well logging truck computer situated at the well surface. The well truck computer produces a resistivity log. For a particular depth in the wellbore, the shape of a resistivity radial profile (hereinafter, resistivity profile), produced by the prior art well tool at the particular depth and extending radially outward from a point at the wellbore wall, is shown in FIG. 3. In FIG. 3, the resistivity profile indicates a flushed zone resistivity "Rxo" an uninvaded zone (true) resistivity "Rt", and a transition zone resistivity represented by an abrupt step function indicated generally by the diameter of invasion symbol "di". This step function transition zone resistivity does not accurately reflect the true resistivity distribution of the transition zone in the wellbore; therefore, the value of the resistivity Rt of the uninvaded zone is also adversely affected. The resistivity of the transition zone does not change abruptly as shown in FIG. 3; rather, it changes gradually as shown in FIG. 1b. Therefore, the resistivity profile generated by the prior art well logging tool was at least partially inaccurate. To correct this deficiency, a new transition zone has been defined. In FIG. 4, a resistivity curve is plotted using a set of invasion parameters, that is, the flushed zone 14 resistivity is Rxo, the uninvaded zone 16 resistivity is Rt, and the transition zone 10 resistivity is a gradual decrease (or increase) from Rxo to Rt. The flushed zone 14 extends a radius r1 from the borehole wall radially into the formation; the uninvaded zone 16 begins at a radius r2 from the borehole wall and extends into the formation. Therefore, the transition zone 10 lies within a region defined between radii r2 and r1. In FIG. 4, the transition zone resistivity changes gradually from Rxo to Rt, and not abruptly as shown in FIG. 3. A true and accurate reading of Rt must be obtained to determine if oil exists in the formation traversed by the borehole. In FIG. 5a, a diagram of depth in a borehole versus radius is illustrated, the diagram depicting the radial extension of the flushed zone, the transition zone, and the uninvaded zone over a plurality of depths in a borehole. For example, in FIG. 5a, the flushed zone extends from the borehole wall to radius r1; the transition zone extends from radius r1 to radius r2, and the uninvaded zone extends from radius r2 radially outward into the formation. Notice that there is a distinct difference between radius r2 and radius r1, indicating that the radial width of the transition zone is more than an abrupt step function, as in FIG. 3. In FIG. 5b, a resistivity log or diagram of depth in a borehole versus resistivity is illustrated. In this example, the lowest reading of resistivity is the uninvaded zone resistivity Rt (the conductivity is the highest). The highest reading of resistivity, relative to the other zones, is the flushed zone resistivity Rxo (the conductivity is the lowest). A complete description of the method and apparatus for deriving the invasion parameters useful for defining the transition zone of FIG. 4 is filed Apr. 16, 1991, entitled "Method and Apparatus for Determining Parameters of a Transition Zone of a Formation traversed by a Wellbore and Generating a More Accurate Output Record Medium", the disclosure of which is incorporated by reference into this specification.
Mud filtrate invasion analysis from resistivity logs is commonly attempted by qualitative inspection of the separation between measurement displays representing different depths of investigation. However, general comparisons cannot be based exclusively on radial resistivity differences. As described above, an improvement can be obtained by performing an inversion of resistivity differences through an assumed model to yield a parameter dimensioned in length, and FIG. 4 illustrates a model for a radial resistivity profile originating at the wellbore, incorporating a transition zone between undisturbed rock and rock flushed by drilling fluid invasion. The resulting invasion description in length units may adequately describe invasion in water zones, but may not adequately describe invasion in hydrocarbon zones which are the principle zones of interest. A number of variables should be taken into account. For example, hydrocarbon zones are more complicated because depth based variation in the saturation gradient through the flushed zone/undisturbed zone interface may be confused with changes in invasion character. In addition, variations in drilling mud properties between wells will change the radial resistivity profile, as will differences in formation water properties. Furthermore, depth variation in porosity and hydrocarbon saturation must also be taken into account. Therefore, unless these variables are taken into consideration, an interpretation of the resistivity profile could be wrong.
To solve this problem, invasion analysis should be performed in the volume domain in accordance with the present invention. This volume domain mud filtrate invasion analysis normalizes the effect of all these variables and is useful for comparing well to well and between zones within a well for both water and hydrocarbon zones of interest.

Method and apparatus for producing a new output record medium illustrating a quantitative description in the volume dimension of mud filtrate invasion into permeable zones of a formation in a wellbore


A temperature-regulating fiber may include a spun phase change polymeric material that may include a plurality of phase change polymer blocks. The fiber may have a fixity ratio of at least 80% and a recovery ratio of at least 74%.

Phase change materials, also known as latent heat-storage materials, may store and release heat energy within a slight change in temperature or no change in temperature. These materials may find application in temperature-regulating textiles, solar energy storing, smart housing, agricultural greenhouses, heat management of electronics, telecommunications and microprocessor equipment, and biomedical products.
Existing organic, inorganic, polymeric, and eutectic phase change materials may have latent heat storage properties. When the temperature of these materials is raised above the phase change temperature, energy may be absorbed and may be used to convert the solid structure into a liquid. Heat may be absorbed during the phase change while the temperature remains constant. When these materials are cooled down, the latent heat may be released into the surrounding environment. However, these conventional phase change materials are not suitable for use as temperature-regulating fibers, because these materials typically become a liquid when heated above the phase change temperature, which would cause a loss of fiber structure and integrity.
Attempts have been made to prepare temperature-regulating fibers by incorporating microencapsulated phase change materials into fibers during wet spinning or melt spinning process. However, experimental results have exposed several disadvantages in this method. First, microcapsules may form clusters and may cause discontinuity in the spinning process. Second, the thermal capacity of the prepared fibers is unsatisfactorily low, typically about 8 to 12 J/g, because there is an upper loading limit for the microencapsulated phase change materials. Third, incorporating phase change materials into melt spun fibers can be difficult, because phase change materials typically are volatile materials that may be unfit for high temperature extrusion and pumping processes.
Physical blending of long chain polymeric phase change materials with other fiber-forming polymers, such as polypropylene and polyester, has been used to fabricate temperature-regulating fibers. However, the fibers as prepared may have a tendency to lose their phase change characteristics after only several heating-cooling cycles.
It is therefore desirable to develop a fiber that can be used for temperature regulation. It is also desirable to develop a fiber that has a shape memory effect and good physical properties. It is further desirable to develop a simple and effective method of making fibers having these properties.

Temperature-regulating fiber and a method of making the same


The panel-like formed product includes a polygonal top board, two or more vertical walls, and a flange. The vertical walls extend from two or more sides of the top board, and include at least two adjacent vertical walls extending from at least two adjacent sides of the top board. The top board includes a frame portion, and a concave portion which is located at an inner side of the frame portion. The two or more adjacent vertical walls include a first vertical wall section, a stair, and a second vertical wall section. The stair connects to a lower end of the first vertical wall section. The second vertical wall section connects to an outer edge of the stair. The flange connects to a lower end of the second vertical wall section.

An automobile door is produced typically by fitting a door inner panel and a door outer panel together. A window, a window drive device, an audio speaker, a handle, and other various components are to be attached to the automobile door. For set-in of these components, a space must be made between the door inner panel and the door outer panel. In order to make the space, for example, vertical walls are made in the door inner panel. Also, when the door is closed, the inside of the automobile must be sealed by the door. In order to seal the inside of the automobile, for example, a stair is provided in the vertical walls of the door inner panel. The stair of the vertical walls is caused to face a pillar or the like of the vehicle body, and this ensures tight sealing of the inside of the automobile.
The door inner panel is produced by press working of a steel plate. Such a door inner panel generally has a complicated shape, and accordingly, in producing such a door inner panel, it is necessary to deform a steel plate largely. In this case, the door inner panel after the press working may have cracks, wrinkles, and the like. In order to suppress generation of cracks, wrinkles, and the like, usually, a soft steel plate with high workability is used as the material of the door inner panel.
However, the soft steel plate has low strength. Accordingly, a door inner panel formed of a soft steel plate has low strength. Therefore, a reinforcing member (for example, a beltline reinforcement, a door impact beam, and the like) is often attached to the door inner panel.
Door inner panels are disclosed, for example, in Japanese Patent Application Publication No. 2007-296953 (Patent Literature 1), Japanese Patent Application Publication No. 2008-94353 (Patent Literature 2) and Japanese Patent Application Publication No. 2013-112133 (Patent Literature 3).
The door inner panel disclosed in Patent Literature 1 includes a beltline reinforcement. The beltline reinforcement is attached to a beltline portion of the door inner panel and extends in the front-rear direction of the vehicle. Patent Literature 1 states that the beltline reinforcement bears a collision load applied to the vehicle in the vehicle front-rear direction, which effectively decreases the bending moment acting on the beltline portion.
In the door inner panel disclosed in Patent Literature 2, when a collision load is applied from a side of a vehicle, the door inner panel and the beltline reinforcement contact with each other, and a load absorbing portion of the door inner panel is deformed. Patent Literature 2 states that the load absorbing portion absorbs a part of a load applied in the thickness direction of the door inner panel, which ensures rigidity of the door inner panel.
In the side door disclosed in Patent literature 3, the rear end portion and the front end portion of a beltline reinforcement formed by hot stamping have strength and rigidity which are lower than those of the body of the beltline reinforcement. Accordingly, when a collision load is applied from the front side of the vehicle, the rear end portion of the beltline reinforcement is plastically deformed, and the contact area between the rear end portion of the beltline reinforcement and the center pillar increases. Patent Literature 3 states that the deformation of the rear end portion of the beltline reinforcement allows absorption of collision energy.

Panel-like formed product, vehicle door, and method for manufacturing a panel-like formed product


A toner monitor in an electrostatographic machine is automatically calibrated when a toner monitor is periodically caused to read a simulated nominal toner concentration. Any difference between the monitor's output and that expected for the simulated nominal toner concentration is applied to a compensation device. The simulated nominal toner concentration signal is obtained by periodic alignment of the toner monitor with a magnetically permeability member.

1. Technical Field
This invention relates generally to developer mix monitors for electrostatographic machines, and more particularly to such machines capable of developing a series of electrostatic images with different toners, for example, different color toners.
2. Background Art
U.S. Pat. No. 4,928,146 issued to Yamada on May 22, 1990, is illustrative of a number of references which show the development of a series of electrostatic images carried on a photoconductive drum with different colored toners at a single development position. See also, U.S. Pat. No. 3,797,930, Tanaka et al, issued Mar. 17, 1974; U.S. Pat. No. 4,275,134, Knechtel, issued June 23, 1981; Japanese Kokai 1-244477 (1989); U.S. Pat. No. 4,728,983, Zwaldo, issued Mar. 1, 1988. A series of four development units are moved one after another to the development position. Each unit develops an image and is replaced by another unit as the series of units is indexed to apply a different color toner to the next image. The series of units are arranged side-by-side and moved linearly through a position in which the unit to be used is aligned with the development position. After or as it is aligned, a cam is rotated to push the entire unit toward the development position, generally moving transverse to the motion of the series of units. Other references show the units arranged on a rotary support with the units being rotated through alignment with the development position.
This general approach has the advantage of utilizing only a single development position for applying four different color toners to electrostatic images. This permits the use of development units whose size and number would prohibit them being spaced around the periphery of a relatively small photoconductive drum. It thus also permits the use of a small photoconductive drum. The use of a small drum has many advantages including both reduced expense and reduced size of the apparatus. U.S. patent application Ser. No. 07/621,681, filed in the names of Kroll et al on Dec. 3, 1990, relates to such apparatus.
Electrostatographic machines generally uses a two-component developer mix comprised of a toner powder and a magnetizable carrier material. During the use of the apparatus, toner powder has to be replenished in a quantity necessary to compensate for the consumption of toner powder used for the development of images. Various automatic toner replenishment systems are known wherein a signal representative of the detected concentration of toner powder in the developer mix is compared with a reference signal corresponding to a predetermined reference toner concentration. When the detected concentration is lower than the reference concentration, replenishment occurs.
U.S. Pat. No. 4,620,783 discloses a color copier having a plurality of development units indexable into alignment with a photoconductive drum. A single toner monitor is provided for ascertaining the ration of toner particles to carrier particles in the development mixture of the particular development unit aligned with the drum. No provision is made for compensation for long-term variables (noise) in the monitored signal, such as noise due to the thermal characteristics of the monitor, contamination, mechanical misalignment of structural parts, pressure changes between the monitor and the toning station walls, etc.

Developer mix monitoring for color developer stations


A method for downloading and managing a test tool of a test system is proposed, which is applied to the test system having a test service server and a tested machine. A test tool required for performing a test for the tested machine is available as being downloaded from the test service server through a network, which connects the tested machine and the test service server, so as to examine if the tested machine works properly. As such, the test service server acts as a reservoir for the test tools and is used to activate start-up for the test, allowing the tested machine to be initiated with test conditions and user conditions for using the test tool being inputted to the test tool.

The present invention relates to methods for downloading and managing test tools of test systems, and more particularly, to a method for downloading and managing a test tool of a test system having a test service server and a tested machine.
In a conventional test system, a tested machine needs to be installed and loaded with a test tool prior to a test being applied thereto. Although the efficiency of using the test tool on performing the test for the tested machine is satisfactory, the prior preparation is rather time-consuming, that is, it is quite complex for loading the tested machine with the test tool, and proper adjustment and upgrading for the test tool are required in accordance with the increase in types of the tested machine and the change of the test environment, allowing the test for the tested machine to be performed with the optimal test tool.
Additionally, in application of the foregoing conventional method for managing the test tool of test system, the installation and loading of the test tool on each tested machine are performed by a user in person, rather than by mean of a network. Moreover, for the quicker loading of the test tool, a plurality of disks or CDs of the test tools are required, and thus problems in the preparation and distribution of the disks or CDs are generated. For example, for the tested machines distributed over various areas or countries, the use of the disks or CDs of the test tools is rather inconvenient. Therefore, the conventional method is inhered with drawbacks described as follows.
The tested machine is installed and loaded with the test tool prior to the test being applied thereto, wherein the loading process is rather complicated and needs the disks or CDs of the test tools which generate problems in preparation and distribution thereof.
The preparation of the disks or CDs of the test tools is time-consuming and costly if newly-edited or upgraded test tools are needed for the tested machines.
The current version of the test tools is hardly maintained.
As concluded from the above-mentioned, it is necessary to seek a method for downloading and managing a test tool of a test system, which allows a user to download a test tool from a test service server through a network, rather than to install the test tool in person or prepare disks or CDs of the test tools used for a tested machine. Moreover, if any adjustment or alteration for the tested machine is required during a test, the newly-edited or upgraded test tool is downloaded from the test service server. In addition, according to the increase in types of the tested machines and the change of the test environment, various test tools are available if necessary from the test service server so as to perform the test for the test machine with the optimal test tool.
In order to solve the foregoing drawbacks present in the conventional method for managing the test tool for the test system, a novel method for downloading and managing a test tool of a test system is proposed, which is applied to the test system having a test service server and a test machine. The test service server is connected with the tested machine through a network, allowing the tested machine to download the test tool from the test service server through the network and to be performed with the test in use of the downloaded test tool; that is, the test tool downloaded from the test service server is used to examine if the tested machine works properly. The test service server executes the managing process for the test tools, which includes the instructions of the test tools, explanation of the test process, layout of the tools and maintenance of versions. Moreover, the test service server provides the test tools through the network, so as to activate the start-up for a test for the tested machine. The start-up process is used to initiate the tested machine and to connect the tested machine and the test service server through the network, allowing the test tools to be downloaded from the test service server through the network. Then, the test for the tested machine can be performed with test conditions and user conditions for using the test tools being inputted to the test tools.
The primary objective of the present invention is to provide a method for downloading and managing a test tool of a test system having a test service server and a tested machine. The test service server is connected with the tested machines through a network, allowing a user to download the test tool from the test service server for using in the tested machine, so that the user does not need to install and loading the test tools in person or prepare disks or CDs of the test tools required for the tested machine. Moreover, the newly-edited or upgraded test tool can be downloaded from the test service server through the network in accordance with the adjustment or alteration for the tested machine. In addition, with the increase in types of the tested machines and the change of the test environment, various test tools are available if necessary from the test service server, so as to perform a test for the tested machine with the optimal test tool.
According to the above objectives, a method for downloading and managing a test tool of a test system is proposed in the present invention, which is applied to the test system having a test service server and a tested machine. The test service server is connected with the tested machine through a network, allowing a test tool in the test service server to be downloaded, installed and loaded through the network on the tested machine. The tested machine and the test service server can be located in different local area networks (LAN), wherein data transmission therebetween is accomplished by using internet and a browser, and the data obtained is displayed in the browser of the tested machine.
In the process for downloading and managing the test tool of the test system, the tested machine downloads the test tool from the test service server through the network which connects the tested machine and the test service server, wherein the downloaded test tool is used to examine if the tested machine works properly. The test service server executes the managing process for the test tools, which includes the instructions of the test tools, explanation of the test process, layout of the tools and maintenance of versions. Moreover, the test service server provides the test tools through the network, so as to activate the start-up for a test for the tested machine. The start-up process is used to initiate the tested machine and to connect the tested machine and the test service server through the network, allowing the test tools to be downloaded from the test service server through the network. Then, the test for the tested machine can be performed with test conditions and user conditions for using the test tools being inputted to the test tools.
In use of the method for downloading and managing a test tool of a test system of the invention, the test tool is downloaded through the network for using in the tested machine instead of being installed and loaded on the tested machine by a user in person. As such, there is required no disk or CD of the test tools as previously described, particularly for the tested machines being located in different areas or countries, it is advantageous to utilize the network for obtaining the test tools from the test service server. If the tested machine is subjected to any adjustment or alteration in the test, the newly-edited or upgraded test tool is provided from the test service server through the network. Moreover, in accordance with the increase in types of the tested machines and the change of the test environment, various test tools are available in the test service server, so as to perform the test for the tested machine with the optimal test tool.

Method for downloading and managing test tool of test system


An electrically small, planar ultra wide bandwidth (UWB) antenna is disclosed. The antenna has a conductive outer ground area that encompasses a tapered non-conducting clearance area, which surrounds a conductive inner driven area. The feed is unbalanced with the terminals are across the narrowest part of the non-conducting clearance area which is tapered to provide a low VSWR across ultra wide bandwidths exceeding 100%. The antenna can be arrayed in 1D and 2D on a single common substrate. Amplifiers can be readily mounted at the feed.

The present invention relates generally to antenna apparatuses and systems, and more particularly, to planar antennas with non-dispersive, ultra wide bandwidth (UWB) characteristics.
With respect to the antenna of radar and communications systems, there are five principle characteristics relative to the size of the antenna: the radiated pattern in space versus frequency, the efficiency versus frequency, the input impedance versus frequency, and the dispersion. Typically, antennas operate with only a few percent bandwidth, and bandwidth is defined to be a contiguous band of frequencies in which the VSWR (voltage standing wave ratio) is below 2:1. In contrast, ultra wide bandwidth (UWB) antennas provide significantly greater bandwidth than the few percent found in conventional antennas, and exhibit low dispersion. For example, as discussed in Lee (U.S. Pat. No. 5,428,364) and McCorkle (U.S. Pat. Nos. 5,880,699, 5,606,331, and 5,523,767), UWB antennas cover at least 5 or more octaves of bandwidth. A discussion of other UWB antennas is found in xe2x80x9cUltra-Wideband Short-Pulse Electromagnetics,xe2x80x9d (ed. H. Bertoni, L. Carin, and L. Felsen), Plenum Press New York, 1993 (ISBN 0-306-44530-1).
As recognized by the present inventor, none of the above UWB antennas, however, provide high performance, non-dispersive characteristics in a cost-effective manner. That is, these antennas are expensive to manufacture and mass-produce. The present inventor also has recognized that such conventional antennas are not electrically small, and are not easily arrayed in both 1D (dimension) and 2D configurations on a single planar substrate. Additionally, these conventional antennas do not permit integration of radio transmitting and/or receiving circuitry (e.g., switches, amplifiers, mixers, etc.), thereby causing losses and system ringing (as further described below).
Ultra wide bandwidth is a term of art applied to systems that occupy a bandwidth that is approximately equal to their center frequency (e.g., greater than 50% at the xe2x88x9210 dB points). A non-dispersive antenna (or general circuit) has a transfer function such that the derivative of phase with respect to frequency is a constant (i.e., it does not change versus frequency). In practice, this means that an impulse remains an impulsive waveform, in contrast to a waveform that is spread in time because the phase of its Fourier components are allowed to be arbitrary (even though the power spectrum is maintained). Such antennas are useful in all radio frequency (RF) systems. Non-dispersive antennas have particular application in radio and radar systems that require high spatial resolution, and more particularly to those that cannot afford the costs associated with adding inverse filtering components to mitigate non-linear antenna phase distortion.
Another common problem as presently recognized by the inventor, is that most UWB antennas require balanced (i.e., differential) sources and loads, entailing additional manufacturing cost to overcome. For example, the symmetry of the radiation pattern (e.g., azimuthal symmetry on a horizontally polarized dipole antenna) associated with balanced antennas can be poor because of feed imbalances arising from imperfect baluns. Furthermore, the balun, instead of the antenna, can limit the antenna system bandwidth due to the limited response of ferrite materials used in the balun. Traditionally, inductive baluns are both expensive, and bandwidth limiting. Furthermore, other approaches used to deal with balanced antennas utilize active circuitry to build balanced (or differential) transmit/receive (TR) switches, differential transmitters, and differential receivers, in an effort to maximize the bandwidth at the highest possible frequencies. Such approaches, however, are more costly than simply starting with unbalanced antenna constructions.
Another problem with traditional UWB antennas is that it is difficult to control system ringing. Ringing is caused by energy flowing and bouncing back and forth in the transmission line that connects the antenna to the transmitter or receiverxe2x80x94like an echo. From a practical standpoint, this ringing problem is always present because the antenna impedance, and the transceiver impedance are never perfectly matched with the transmission line impedance. As a result, energy traveling either direction on the transmission line is partially reflected at the ends of the transmission line. The resulting back-and-forth echoes thereby degrade the performance of UWB systems. In other words, is, a clean pulse of received energy that would otherwise be clearly received can become distorted as the signal is buried in a myriad of echoes. Ringing is particularly problematic in time domain duplex communication systems and in radar systems because echoes from the high power transmitter obliterate the microwatt signals that must be received nearly immediately after the transmitter finishes sending a burst of energy. The duration of the ringing is proportional to the product of the length of the transmission line, the reflection coefficient at the antenna, and the reflection coefficient at the transceiver.
In addition to distortion caused by ringing, transmission lines attenuate higher frequencies more than lower frequencies, and sometimes delay higher frequency components more than lower frequency components (i.e. dispersion). Both of these phenomena cause distortion of the pulses flowing through the transmission line. Thus it is clear that techniques that allow shortening of the transmission line have many advantagesxe2x80x94reducing loss, ringing, gain-tilt, and dispersion.
In view of the foregoing, there exists a need in the art for a simple UWB antenna that has an unbalanced feed, and can be arrayed in 1D and 2D on a single substrate (i.e., planar or conformal). Additionally, there is a need for a UWB antenna that is electrically small yet has low VSWR and allows the transmit and or receiving circuits to be integrated onto the same substrate to eliminate transmission line losses, dispersion, and ringing. Furthermore, there is a need for a UWB that can be mass-produced inexpensively.
Accordingly, an object of this invention is to provide a novel apparatus and system for providing an electrically small planar UWB antenna.
It is also an object of this invention to provide a novel apparatus and system for providing a UWB antenna that is inexpensive to mass-produce.
It is also an object of this invention to provide a novel apparatus and system for providing a UWB antenna that has a direct unbalanced feed that can interface to low-cost electronic circuits.
It is also an object of this invention to provide a novel apparatus and system for providing a UWB antenna that has a flat frequency response and flat phase response over ultra wide bandwidths.
It is also an object of this invention to provide a novel apparatus and system for providing a UWB antenna that exhibits a symmetric radiation pattern.
It is also an object of this invention to provide a novel apparatus and system for providing a UWB antenna that is efficient, yet electrically small.
It is also an object of this invention to provide a novel apparatus and system for providing a UWB antenna that integrates with the transmitter and receiver circuits on the same substrate.
It is also an object of this invention to provide a novel apparatus and system for providing a UWB antenna that is planer and conformal, so as to be capable of being easily attached to many objects.
It is also an object of this invention to provide a novel apparatus and system for providing a UWB antenna that does not require an active electronic means or passive means of generating and receiving balanced signals.
It is a further object of this invention to provide a novel apparatus and system for providing a UWB antenna that can be arrayed in both 1D and 2D, in which the array of UWB antennas are built on single substrate with the radiation directed in a broadside pattern perpendicular to the plane of the substrate.
These and other objects of the invention are accomplished by providing a tapered clearance area (or clearance slot) within a sheet of conductive material, where the feed is across the clearance area. A ground element, which can be made of a conductive material such copper, has a xe2x80x9cholexe2x80x9d cut in it that is defined by the outer edge of the clearance area. A driven element, which is situated in the clearance area, is defined by the inner edge of the clearance area. The clearance area width at any particular point, measured as the length of the shortest line connecting the ground and the driven element, roughly determines the instantaneous impedance at that point. In some embodiments of the present invention, the clearance area width is tapered to increase as a function of the distance from the feed point, so that the impedance seen at the feed, for example with a time domain reflectometer (TDR), is tapered smoothly in the time domain.
Also in some embodiments of the present invention, the clearance area width, as well as the shape of the driven element, has an axis of symmetry about the line cutting through the feed point and the point on the driven element opposite the feed point. For example, the driven element can be circular, and the ground xe2x80x9cholexe2x80x9d can be a larger circle, wherein the centers are offset, such that the slot-width grows symmetrically about its minimum. The feed point is at the minimum width, in which the maximum width is on the opposite side, thus forming an axis of symmetry about the feed.
According to some embodiments of the present invention, the feed is at the minimum width. According to some embodiments, the ground xe2x80x9cholexe2x80x9d is oval shaped, and the driven element is oval with a depression in the side opposite the feed element. According to other embodiments, the ground xe2x80x9cholexe2x80x9d is oval shaped with a bulge in the side opposite the feed element, and the driven element is oval. According to still other embodiments, the ground xe2x80x9cholexe2x80x9d is oval shaped with a bulge in the side opposite the feed element, and the driven element is oval with a depression in the side opposite the feed element. An important factor is that the input impedance is tapered in the time domain in such a way as to provide the desired performance.
The antenna can be fed by connecting a coaxial transmission line to the feed point such that the shield of the coaxial cable is connected to the ground at the edge of the clearance area, and the center conductor of the coaxial cable is connected to the driven element also at the edge of the clearance area.
In some embodiments the ground element is cut to occupy only a thin perimeter so that the entire antenna is electrically small.
In order to meet these and other objects of the invention, an antenna device is provided having ultra wide bandwidth (UWB) characteristics. The antenna device includes a ground element having a cutout section with an inner circumference, the inner circumference having a first shape; and a driven element with an outer circumference having a second shape, the driven element being smaller in size than the cutout section and being situated within the cutout section to define a clearance area between the driven element and the ground element. The first shape may be a first simple closed curve having no cusps. The second shape may be a second simple closed curve having no cusps, including at least a concave portion and a convex portion. The first and second shapes may be formed such that any radial line from the center point of the driven element will intersect the first shape at a single first intersection point, and will intersect the second shape at a single second intersection point, a distance on the radial line between the first and second intersection points being defined as a clearance width between the driven element and the ground element for the radial line. The clearance area may be tapered such that a clearance width between the driven element and the ground element is monotonically nondecreasing from a minimum clearance width to a maximum clearance width.
The antenna device may further include a transmission line for providing an electrical signal to the driven element. The transmission line may be connected to a driven element at a feed point proximate to the minimum clearance width of the clearance area. The transmission line comprises a metal layer, a magnet wire, a coaxial cable, or other connection device. The transmission line may non-coplanar with either the driven element or the ground element.
The clearance area may be filled with one of FR-4, Teflon, fiberglass, or air. The ground element and the driven element may comprise a conductive material, and that conductive material may be copper.
The first and second shapes may be the same, except in different scale. The concave portion of the second shape may be formed proximate to the maximum clearance width. The driven element may have an axis of symmetry about a line that passes between the minimum clearance width of the clearance area and the maximum clearance width of the clearance area. The concave portion of the second shape may be centered on the axis of symmetry, proximate to the maximum clearance width.
An antenna device having ultra wide bandwidth (UWB) characteristics is also provided, including a ground element having a cutout section with an inner circumference, the inner circumference having a first shape; and a driven element with an outer circumference having a second shape, the driven element being smaller in size than the cutout section and being situated within the cutout section to define a clearance area between the driven element and the ground element. The first shape may be a first simple closed curve having no cusps, including at least a concave portion and a convex portion. The second shape may be a second simple closed curve having no cusps, including at least a concave portion and a convex portion. The first and second shapes may be formed such that any radial line from the center point of the driven element will intersect the first shape at a single first intersection point, and will intersect the second shape at a single second intersection point, a distance on the radial line between the first and second intersection points being defined as a clearance width between the driven element and the ground element for the radial line. The clearance area may be tapered such that a clearance width between the driven element and the ground element is monotonically nondecreasing from a minimum clearance width to a maximum clearance width.
The antenna device may further include a transmission line for providing an electrical signal to the driven element. The transmission line may be connected to a driven element at a feed point proximate to the minimum clearance width of the clearance area. The transmission line comprises a metal layer, a magnet wire, a coaxial cable, or other connection device. The transmission line may non-coplanar with either the driven element or the ground element.
The clearance area may be filled with one of FR-4, Teflon, fiberglass, or air. The ground element and the driven element may comprise a conductive material, and that conductive material may be copper.
The first and second shapes may be the same, except in different scale. The concave portion of the second shape may be formed proximate to the maximum clearance width. The driven element may have an axis of symmetry about a line that passes between the minimum clearance width of the clearance area and the maximum clearance width of the clearance area. The concave portion of the second shape may be centered on the axis of symmetry, proximate to the maximum clearance width.
With these and other objects, advantages and features of the invention that may become hereinafter apparent, the nature of the invention may be more clearly understood by reference to the following detailed description of the invention, the appended claims and to the several drawings herein.

Electrically small planar UWB antenna apparatus and related system


A collapsible steamer basket for insertion into the interior of a vessel. Vegetables or the like can be placed inside the basket and steamed. The basket has a plurality of foldable apertured leaves which overlap and conform to the interior of the vessel. A built-in signal device is provided for audibly signalling when the interior of the vessel reaches a predetermined temperature to avoid burning of the foods being steamed.

1. Field of the Invention
The invention relates to collapsible steamer baskets; and, more particularly, to steamer baskets which conform to the interior of a vessel.
2. Description of the Prior Art
Collapsible steamer baskets are well known in the art. Generally speaking, such baskets have a plurality of interconnected overlapping perforated leaves which conform to the interior of the vessel. Two such baskets are shown in U.S. Pat. Nos. 2,667,117 and 4,138,939 to Millard et al and Feld, respectively.
However, it is necessary to watch the foods being steamed in such baskets since no means are provided for signalling when the water in the vessel has boiled away.
There thus exists a need for a collapsible steamer basket which has a plurality of interconnected overlapping apertured leaves which fold to conform to the interior of a vessel, yet is free standing when removed from the vessel and has a built-in audible signal for indicating when the boiling water in such vessels has boiled away.


In a turbo machine, for example, a turbo compressor, the rotor shaft extends through and is sealed relative a housing via dry gas seals in which a seal clearance is achieved between a rotating, sealing body and a non-rotating sliding body in which the inner side of the dry gas seal is charged with a barrier gas, with the leakage of the dry gas seal being dammed via a back-up plate and the dynamic pressure is monitored via a pressure inspection device, wherein due to increasing dynamic pressure an alarm is given off or the turbo machine is automatically shutdown without delay so that the exit of gas, particularly of toxic or explosive gas from the inner area of the housing of the turbo machine is avoided, wherein, via the use of multiple seals the leakage pressure of one of the inner dry gas seals can initiate a warning or alarm signal and via the leakage pressure of the outer dry gas seal, the turbo machine can be shut down.

1. Field of the Invention
This invention pertains to a turbo machine having a driven rotor shaft extending at least on one side through the machine housing wherein the rotor shaft is provided with an axial seal arrangement with at least one dry gas seal which is impinged or charged with barrier gas and whose leakage is eliminated via a leakage conduit.
2. Background and Material Information
Machines of this type are known, for example from German DE 39 25 403 and serve for example, as turbo compressors or gas turbines. In this type of machine the rotor of the turbo machine is retained in a closed housing whose inner area is under high gas pressure.
The passage of the rotor shaft, through the housing to the outside or to an intermediate chamber is sealed via a seal arrangement in order to prohibit the exiting of the gas under pressure from the inner area. As a rule, when both sides of the rotor, carried on the shaft, extend through the housing such a seal arrangement is provided on both sides thereof, or in the case of a single sided axial opening, with machines of the overhang type, such a seal arrangement is utilized only on this single opening.
Dry gas seals, that are impinged or charged with a barrier gas have proven themselves to be particularly low in friction and low in losses, wherein the sliding surface of a sliding ring is pressed against a corresponding sealing surface, while maintaining a minimum clearance so as to minimize the exit of the pressure gas from the inner area whereby the leakage of the seal is kept at an as small as possible value and at the same time a clearance is produced so as to permit non-contact running or operation of the seal. The small, though still remaining leakage is, as a rule, channeled or removed to the outside. At low pressures, as a rule a single dry gas seal is sufficient. At higher pressures however and in order to obtain increased safety, the primary inner dry gas seal is followed by a secondary outer dry gas seal of analogous construction which seals the inner leakage area against the outside. This outer dry gas seal preferably is only called into action and is effective only when the primary leakage is excessive, particularly if there is a defect in the primary inner dry gas seal. If necessary more than two dry gas seals can be arranged in tandem.
In turbo machines which process dangerous gases, particularly explosive or toxic gases, it is especially important and urgent that the exit or leakage of these dangerous gases, under pressure, is prevented from the inner housing areas or to reduce same to a minimal value in order to avoid a catastrophe. In order to achieve same, on dangerous areas of the machine, for example in the proximity of the gas ducts, suitable gas sensors are provided which preferably have specific detection sensitivities for the gas to be detected and which, upon exceeding a specific gas concentration, emanate a warning or alarm signal or initiate suitable countermeasures. This however requires additional complicated devices which in addition can react initially only when already sufficient amounts of gas have exited from the housing in order to initiate the release of a signal. The required time delay however is often insufficient in order to totally prevent a catastrophe.

Turbo machine with an axial dry gas seal


In a method for concentrating solar energy waveform energy is directed to a predetermined region of the atmosphere located a pre-established distance above a surface of the earth. The directing of the energy is controlled so as to modulate an index of refraction of air in the predetermined region of the atmosphere to produce a predetermined refraction index pattern in the region. The distribution of solar radiation is modified as it passes through the atmospheric region to thereby concentrate the solar radiation at a predetermined location.

This invention relates to techniques for altering the distribution of solar energy falling on the earth's surface. More particularly, but not exclusively, this invention is related to methodology for concentrating solar energy.
It is well known that, with the exception of nuclear power, all of the energy on the earth originates with the sun. Extensive efforts in recent decades have been directed to harnassing solar radiation. Such efforts have resulted in huge mirrors erected on the earth's surface for concentrating incoming solar radiation on energy collectors. Another result of the continuing interest in solar energy is the development of solar cells and the arrangement of such cells in different configurations to convert the solar radiation into electricity. Yet another area of development in the field of solar energy is solar panels for converting solar radiation into heat energy.
One well known natural phenomenon is the bending of light waves by heated air. Light refracting convection currents are observable, for example, over road surfaces. The convection currents cause a shimmering or wavering effect in the perception of distant objects across roads or other heated surfaces.
The problem with such convection currents, as other natural phenomena, is that they are essentially uncontrollable. The variation in the index of refraction caused by localized heating of earth bound surfaces is random and unpredictable.

Method for changing solar energy distribution


A launder system for supplying molten metal from a crucible to a casting mould or a secondary process has a nozzle with a filter positioned therein to filter the molten metal as it flows through the nozzle. The nozzle and filter assembly is removably attachable to the launder system, and is used once and then replaced by a new nozzle and filter assembly. Efficient cleaning of the molten metal thus occurs without an increase in blockage due to the filter. Additionally, the scrapping rate of the launder system is reduced, allowing multiple usage of the launder.

1. Field of the Invention
The present invention relates to launder systems for supplying molten metal from a source of molten metal to a casting mould or a secondary process, and is particularly concerned with the launder nozzle.
2. Description of Related Art
It is current practice to melt a metal in a crucible and to supply the molten metal from the crucible to one or more casting moulds or to a secondary process. The molten metal is supplied along launders which have one or more channels to interconnect the crucible and the casting moulds or secondary process.
It is known to incorporate devices to remove or reduce the amount of inclusions present in the molten metal passing along the launder, so as to clean the molten metal and thereby improve the integrity of finished cast articles.
One way of achieving this is to provide one or more dams or weirs in the launder to trap the inclusions. However, some inclusions can still be carried through to the casting mould or secondary process.
Another way of achieving this is to provide a fixed filter in the launder. This is more efficient at cleaning the molten metal than the dams. However, the provision of the filter in the launder increases the possibility of blockages occurring which can result in the scrapping and remaking of the launder.
In some launders a ceramic lining is cemented into the launder, and is normally replaced after each casting operation.
In some crucibles a ceramic lining is provided, and it is usual practice with such crucibles to have a wash out melt which cleans the surface of the ceramic lining and removes any loose debris. Thus it can be seen that presently used launders are used only once and are wasteful of their ceramic linings.

Launder system for supplying molten metal and a launder nozzle