A solid marking composition comprises a solid matrix containing at least one type of optically variable interference pigment flakes. The solid marking composition provides a document or article with a copy and counterfeit protection feature, and is preferably used in a writing instrument for applying hand-written anti-counterfeit markings and signatures.

The present invention relates to a solid marking composition as writing means in a writing instrument, to a writing instrument comprising the solid marking composition, to an optically variable marking layer and to the use of a plurality of optically variable pigments according to the preamble of the independent claims. The solid marking composition of the present invention is particularly adapted for the application of hand-written markings to articles or documents which must be copy-protected or unambiguously marked as originals.
The fight against forgery of high value branded articles and against counterfeiting of currency or cheques has brought forward a large diversity of different security systems in the recent years. One of the most effective means especially for preventing unauthorized photocopying of documents is the application or incorporation of certain sections onto or in the document or article which exhibit a viewing angle dependent shift of color. This effect is producible by interference pigments. The pigments are either incorporated in the documents"" bulk material or blended in a coating composition or printing ink which afterwards is applied on the document.
Optically variable pigments are principally based on an interference effect which takes place when light is reflected at a first and a second surface of a thin layer of a suitable dielectric material. The interference of the two reflected waves enhances the reflected intensity in certain domains of the visible spectrum and extinguishes it in others. As a consequence, said thin layer appears colored; the colors depend upon the difference in optical paths between the two reflected waves. As the optical path in said thin layer is viewing-angle dependent, the color appearance is viewing-angle dependent, too.
Pigments showing a viewing-angle dependent variation of color are usually of a flake like shape and can be of inorganic or organic or mixed nature. The pigment flakes can be produced in various well known ways, e.g.:
i) by physical vapour deposition techniques, thereby creating a sheet of superposed layers which are plane and parallel to each other. This is done on a suitable carrier which is detached or dissolved afterwards to leave the unsupported film. The film is reduced to pigment size;
ii) by wet or dry chemical deposition techniques, thereby depositing layers of materials having the desired physical parameters onto the surfaces of already existing particles (such as aluminum flakes, mica, etc.);
iii) by chemical polymerization processes where an extended sheet of helically arranged or similar liquid crystal material is hardened by UV irradiation and the resulting sheet is subsequently comminuted to pigment flakes. In this case the interference effect results from the periodic modulation of the refractive index in the arranged liquid crystal stack;
iv) by providing an all-polymer multi-layer sheet as described in U.S. Pat. No. 3,711,176, and comminuting it to pigment.
In the case of i) and ii) two basic design configurations are possible for the multi-layer interference stack. The first of the two designs can be characterized as an all-dielectric stack consisting of a periodic structure of alternating high and low index dielectric films. The other design type can be characterized as a metal-dielectric system and consists of a periodic structure of alternating partially transmitting, partially reflecting metal and dielectric layers on an almost totally reflecting opaque metal layer. This definition includes all designs based on the Fabry-Perot resonator principle. Whereas in all-dielectric designs the reflectance in a given high reflectance band increases with the number of periods, the highest reflectance of the metal-dielectric design is achieved already by a three layer stack: an opaque totally reflecting metal layer, a layer of a dielectric material arranged on top of the totally reflecting layer having an index of refraction preferably not exceeding 1.65 and, arranged on top the dielectric layer, a semi-transparent partially reflecting layer of a metal or metal oxide. For printing pigments, a symmetric structure having the sequence of dielectric and partially reflecting layer arranged on both of the surfaces of the opaque totally reflecting layer is preferred. Pigment flakes consisting of multi-layer structure of more than three (asymmetric design) respectively more than five superposed layers (symmetric design) have also been described in the state of the art and are applicable as well.
Coating compositions for producing a viewing-angle dependent variation of color by means of interference pigment flakes have been extensively described. However, they are all of a liquid and/or pasty consistency before application.
U.S. Pat. No. 5,059,245 and U.S. Pat. No. 5,171,363 disclose liquid printing inks comprising optically variable pigments of type i). U.S. Pat. No. 5,059,245 mentions as another alternative to incorporate the optically variable paint flakes in a plastic material which may then be cast, molded or extruded into a final article. In the context of the patent specification it is evident that said plastic material having incorporated optically variable pigment flakes is not meant as a means for coating other articles, but is itself considered the final article, which is colored by the incorporation of optically variable pigment flakes.
The same patent, U.S. Pat. No. 5,059,245, teaches that the aspect ratio of the optically variable pigment flakes is xe2x80x9cimportant in that it helps to ensure that the flakes will land either on their top and bottom sides and not on their endsxe2x80x9d and that xe2x80x9cthe ink should have good flow characteristicsxe2x80x9d in order to develop the required effect. From this, it is evident that the authors of U.S. Pat. No. 5,059,245 did not consider the possibility of creating an optically variable effect by the mere abrasion of a solid composition containing optically variable pigment. The aspect ratio is defined as the largeness-to-thickness ratio of the flakes.
Plastic sheets having incorporated optically variable pigment flakes of type i) have been described in U.S. Pat. No. 5,424,119. Those plastic sheets are produced by casting or extrusion of a bulk material in its thermoplastic state.
The fabrication and use of optically variable pigment of type ii) is described in EP 571 836, EP 668 329, EP 741 170 and EP 353 544. No application in solid-abrasion writing compositions is claimed.
Solid marking compositions comprising aluminum glitter pigments are known from U.S. Pat. No. 4,990,013. The aluminum pigments provide the layer produced therewith with a glitter effect. The glitter effect is the better pronounced, the more disordered the pigments are arranged in the layer. A disorderly arrangement provides a variety of planes and edges which reflect the incident light in a variety of different directions thereby producing the glitter effect. No optically variable appearance is produced.
The incorporation of pearlescent pigments, i.e. mica flakes coated with titanium dioxide, into solid-abrasion writing compositions, i.e. crayons, has been disclosed in JP 59174668 and JP 09078019. The aim of these patents was a marking material which develops a high reflective brightness and a lustrous color tone in particular on dark areas, remaining transparent on white areas. No substantial color shift is observed.
Pearlescent, or luster pigments, although they belong to the class of interference pigments, do not exhibit the strong angle-dependent color shifts which are observed with optically variable pigments. This is a direct consequence of their structure and of the impossibility to control their optical parameters: To obtain iridescent pigment, low-refractive-index (n=1.6) mica platelets having diameters of about 50 xcexcm and thickness of about 1 xcexcm are coated on both sides with a thin layer of high-refractive-index (n=2.0) titanium dioxide or similar materials. This results in a transparent, 3-layer interference stack, where part of the incident light is reflected at the top titanium dioxide layer, and part of it is reflected at the bottom titanium dioxide layer, interfering with the top-reflected light after having traveled twice through the dielectric mica layer.
The thickness of the mica platelets of the order of 1 xcexcm results on one hand in a larger numberxe2x80x944 to 8xe2x80x94of interference maxima and minima throughout the visible range of the spectrum. Such an amount of spectral features does not result in a defined color. On the other hand, the thickness of the individual mica flakes cannot be precisely controlled, as mica is a mineral which is milled down to obtain the said flakes through the action of natural cleavage. Iridescent pigment is, in consequence, always a mixture of flakes having different spectral characteristics, and which, through the laws of additive mixing, together result in a white appearance.
As a consequence, titanium dioxide coated mica cannot be used as a color-generating pigment, nor as a color-shifting pigment. It allows, however, to obtain iridescent light reflection effects, in particular on dark backgrounds and at flat observation angles, said effects being useful for color-copy protection. The orientation of the iridescent pigment flakes on the final substrate is hereby not of preeminent importance; hence, for the skilled in the art, their application by the means of a solid-abrasion writing composition is to result in the desired effect.
U.S. Pat. No. 5,851,604 teaches the use of liquid crystal optically variable pigment flakes (type iii) in liquid coating compositions for producing optically variable color impression. Powder coating systems and incorporation of the flakes into bulk medium are disclosed as well.
U.S. Pat. No. 5,851,604 explicitly states the need, for obtaining the color effects described, to have the individual pigment flakes arranged xe2x80x9cas uniformly as possible over relatively large surface areas, resulting in a homogenous spatial orientation of the helical axes.xe2x80x9d The authors teach that xe2x80x9cthe pigments can be oriented by methods in which shear forces are exerted. Examples of such orientation methods are spraying, knife coating, rolling, brushing, air brushing, sprinkling, dipping, flow coating, printing, casting, extrusion, blowing, calendering, dry coating, fluidized-bed sintering, triboelectric coating, electrostatic spraying, electrostatic coating, or lamination.xe2x80x9d
Solid-abrasion is not disclosed as a useful coating method for applying these optically variable pigments, and a closer look to the coating examples given in U.S. Pat. No. 5,851,604 reveals that all of them pass through a liquid state: Powder coating implies a baking step, where the binder is molten, allowing the pigment flakes to get oriented; knife-coating is done in a pasty state of the coating composition, whereby the pigment flakes are oriented by shear forces; plastic-molding implies as well a pasty state of the molding mass, where the pigment flakes are oriented by shear forces; casting allows for pigment orientation by natural effects, such as gravitational forces; in paint films, the flakes are oriented by capillary forces and surface tension; during lamination the thermoplastic binder melts, allowing for an orientation of the flakes; etc.
U.S. Pat. No. 5,851,604, enumerates also the use of liquid-crystal optically variable pigment in a variety of applications, among others xe2x80x9cwriting utensilsxe2x80x9d. From the context it is clear, however, that the pigments are to be used to create color effects in a series of articles which are themselves final products (i.e. the writing utensil itself is colored with OVP); said articles are thus not considered as the means to create said color effects on other products (i.e. an OVP-crayon is not even implicitly comprised in said enumeration).
DE 198 20 225 A1 refers to another category of optically variable liquid-crystal pigments and claims compositions containing them. Again, the context of the disclosure is centered on liquid or pasty compositions, which are hardened after application. It does not even implicitly comprise application by solid-abrasion.
It is one drawback of the prior art that the production of layers, documents or images exhibiting a viewing-angle dependent variation of color requires time consuming processes and costly equipment, such as printing machines or extruders. The compositions are not adapted for quickly producing copy-protection markings such as signatures on single documents.
It was now highly surprisingly discovered that optically variable writings, i.e. such that exhibit substantial color shift with viewing angle, can successfully be obtained with solid-abrasion marking compositions, i.e. crayons, comprising optically variable pigment contained in a binder matrix which can be abraded in contact with a writing substrate, such as paper, fabric, wood, plastic metal, etc. Solid-state abrasion, against what one might intuitively think, apparently yields a sufficient alignment of the optically variable flakes on the substrate, as to result in a well-perceived and measurable angle-dependent color shift of the resulting writing.
In particular means and methods shall be provided for quickly applying anti-copy, anti-counterfeit or effect markings to a variety of documents. The application of the markings shall not require special know-how and shall not include costly equipment, time consuming preparation or special treatments of the layers after application.
The objects are solved by the features of the independent claims.
In particular they are solved by a solid marking composition as writing means in particular in a writing instrument for producing hand-written anti-counterfeit markings, comprising a solid matrix containing at least one type of optically variable interference pigment capable of producing a color-shift between two colors at first and second viewing angles.
As already described, the coating compositions comprising optically variable pigments disclosed in the prior art are without any exception of a liquid or of a pasty consistency. This consistency was deemed necessary to bring the flakes in a flat and parallel position with respect to each other and with respect to the surface of the underlying substrate. Three effects have been evoked responsible for the alignment of the flakes in said desired parallel position. 1) Right after the application of a liquid optically variable coating composition, gravitational forces are effective in directing the flakes parallel to the substrate surface (sedimentation). 2) This lay-down is enhanced by the surface tension, created by the draft of the solvent into the substrate and by the evaporation of the solvent (drying). The binder polymer furthermore tends to shrink and to pull the flakes flat. 3) A further alignment help for the pigment flakes can be achieved through a mechanical movement (draw-down), e.g. during bi-axial orientation of the film. Summarized, a liquid or pasty consistency of optically variable coating compositions or bulk materials prior to application was deemed absolutely necessary in the prior art to allow for alignment of the pigment flakes in a parallel position to each other and/or to the under-lying substrate, in order to obtain said viewing-angle dependent color variation of the features.
It has now surprisingly been found that layers produced on a substrate with the solid coating composition of the present invention exhibits a color-shift between two colors at first and second viewing angles, even though the coating composition is not of a liquid or of a pasty consistency and thus even without any of the mentioned alignment forces being effective. Seemingly, the lay-down of the optically variable pigment flakes on the substrate surface by mere abrasion from a crayon or pencil lead results in sufficient alignment for producing an angle-dependent color shift. This orientation of the flakes within the matrix on the substrate is improved by an aspect (i.e. largeness to thickness) ratio of the flakes of not less than 2:1, preferably of a ratio of greater than 5:1. That means that the flakes are (in average) five times larger (or wider) than thick. This assists in applying them substantially parallel to the surface of the substrate.
Contrary to the coating compositions of the prior art, the solid marking composition of the present invention does not form a film after being applied to the substrate. No inherent film forming processes like flowing and cross-linking take place after the application of the layer. In the context of the present invention the term layer stands for any image or marking applicable with the solid marking composition of the present invention. The terms film, film formation, film forming substances are defined according to the definition given in Rxc3x6mpp Lexikon, Lacke und Druckfarben, ed. U. Zorll, Georg Thieme Verlag, Stuttgart, 1998. The layer is formed by mere abrasion of the solid, pigmented matrix on the substrate. The solid matrix can be of any material with sufficient hardness to be handled, yet soft enough that abrasion of the material at reasonable pressure against the substrate (such as paper or fabric) will result in the matrix composition adhering to the substrate, particularly when applied by hand.
Solid matrices for the fabrication of the solid marking compositions e.g. for the production of pencils, crayons according to the present invention are well known in the art. They are formulated from combinations of waxes, resins, fatty acids, emollients, colorants, fillers and other additives. Different types of waxy or resinous materials can be used. Traditional crayons are based on paraffin wax and stearic acid. Plastic crayons use polyethylene resin and a plasticizer. Water soluble crayons utilize water soluble polyethylene glycol resins. The term xe2x80x9csolidxe2x80x9d stands for form stability of the substances forming the matrix under standard conditions (25xc2x0 C., 1.013 bar, 60% humidity). The hardness of the solid matrix is best defined by the application. A smooth layer of constant uniform thickness shall adhere to a standard substrate when the marking composition is applied with a reasonable pressure exerted by a human being. As a matter of experience, pressures in the order of between 20 g and 500 g (0.2 N and 5 N) on contact surfaces in the order of between 0.05 mm2 and 1 mm2 are exerted on writing pens by their users. The solid matrix is formulated such that the marking composition has good lay-down properties, preferably shows no flaking and is easily used as writing instrument. The solid marking composition of the present invention can be used to produce any type of writing instruments, such as e.g. crayons, pencil leads, etc.. Lay-down is a measure of the smoothness qualities with which the solid marking composition transfers to the underlying surface. Children in particular prefer crayons having good lay-down since they make it possible to produce images, marks and drawings while exerting minimal pressure on the crayon.
The said solid matrices may contain additional coloring agents, such as dyes and/or pigments, foreseen they remain sufficiently transparent in at least part of the visible spectrum, to display said substantial viewing-angle dependent color variation. Transparency is also dependent on the thickness of the layer of the composition which is deposited on the surface of the substrate. Any optically variable interference pigment which can produce a color-shift between two colors at first and second viewing angles is suitable for the solid marking composition of the present invention. However, a preferred embodiment is a solid marking composition wherein the optically variable pigment flakes comprise an inorganic multi-layer thin film interference stack, said multi-layer stack including an opaque totally reflecting metal layer, which may optionally comprise other layers, said totally reflecting layer having a first and a second surface and at least one sequence arranged on at least one of said first and/or second surfaces of the opaque totally reflecting metal layer, said sequence comprising a dielectric layer with an index of refraction of equal or less than 1.65 and a semitransparent partially reflecting metal and/or metal oxide layer, whereby the dielectric layer of said sequence is arranged adjacent next to the opaque totally reflecting layer.
Such inorganic multi-layer interference stack can be produced by both methods i) and ii). Whereas the pigment flakes produced by method i) have a deep chroma and a strong color-shift with variation of the viewing-angle, they can show lack of chemical resistance in the surrounding medium. To the contrary the optically variable pigment flakes produced by the method ii) have a considerable chemical resistance but weaker color effects. Preferably optically variable pigment flakes are used in the present invention which have been produced by method i).
In a further preferred embodiment the multi-layer interference stack is of symmetrical design having arranged at least one of said sequences (dielectric layer and semitransparent partial reflecting layer) on both of said first and second surface of the opaque totally reflecting metal layer. Preferably the dielectric layer is of SiO2 or MgF2. Aluminum or aluminum alloys are the preferred metals for the totally reflecting metal layer. However, metals such as gold, silver, copper, nickel or their alloys can be used as well. The semitransparent partially reflecting layer is preferably made of chromium. However, materials such as chromium alloys, nickel, Monel or Inconel can be used, too.
In a further preferred embodiment of the present invention a solid marking composition is provided having incorporated optically variable interference pigment flakes comprising an all-dielectric structure which is formed of at least four alternating layers of at least one low refractive index material and at least one high refractive index material. A wide variety of low and high index materials known in the art can be used for the production of the said all-dielectric structure. Exemplary embodiments of such devices can be found in U.S. Pat. No. 3,858,977 (J. A. Dobrowolski et al.) and references cited therein. In particular, five-layer structures of the types ZrO2/Al2O3/ZrO2/Al2O3/ZrO2 and ZrO2/SiO2/ZrO2/SiO2/ZrO2 have been used in practice (J. A. Dobrowolski, xe2x80x9cOptical Thin-Film Security Devicesxe2x80x9d, in xe2x80x9cOptical Document Securityxe2x80x9d, 2nd edition, R. L. van Renesse (ed.), Artech House, London, 1998). Particularly useful are combinations of titanium dioxide, zirconium dioxide or zinc sulfide for the high refractive index material with magnesium fluoride or silicon dioxide for the low refractive index material. Other high refractive materials include transition metal oxides, cerium dioxide, rare-earth sesquioxides, rare-earth trifluorides, cadmium sulfide and zinc selenide. Other low refractive materials include lithium fluoride, calcium fluoride, aluminum fluoride and cryolithe (Na3AlF6). xe2x80x9cLow refractive indexxe2x80x9d refers to materials having an index of refraction n of less or equal than 1.65.
In another preferred embodiment, metallic particles, such as aluminum flakes, are coated by a dielectric layer of low refractive index material e.g. silicon dioxide, followed by a reflector layer of a high refractive index material such as iron(III) oxide (Fe2O3).
A further preferred embodiment is a solid marking composition wherein the optically variable interference pigment flakes comprise a liquid crystal material, preferably a polymeric cholesteric liquid crystal material.
In case the pigment flakes are of a liquid crystal type or comprise an all-dielectric multilayer structure, evidencing the color-shifting-effects may require a dark-colored or black underlying substrate.
The solid marking composition can further include optically variable interference pigments based on an all-polymer organic multi-layer foil as described in U.S. Pat. No. 3,711,176.
The matrix of the solid marking composition is defined as to include all components of the marking composition which are neither pigments nor fillers. The matrix does not contain solvents which evaporate under standard application conditions.
The matrix is in general composed of a wax or a mixture of waxes (saturated compounds) selected of the types mentioned above, i.e. paraffin waxes, stearic acid, other carboxylic acids, carboxylic acid derivatives, polyethylene resins, polyethylene glycol resins, etc. Plasticisers may be used to improve the lay-down characteristics of the matrix.
In a particular embodiment, the matrix may comprise as well un-saturated components, such as unsaturated fatty acids or derivatives thereof, and/or oxidative siccativating agents such as cobalt stearate or the like, and/or photocatalytically active compounds (sensitizers). These components allow to harden the laid-down layer by a post-treatment (fixation) by heat (melting), ultraviolet irradiation, or oxidative siccativation. Such fixation may be desirable to increase the durability (resistance) of the laid-down layer.
In the context of the present invention the term color is defined according to the CIELAB system. The terms xe2x80x9csemitransparentxe2x80x9d, xe2x80x9ctransparentxe2x80x9d, xe2x80x9copaquexe2x80x9d, xe2x80x9ctotally reflectingxe2x80x9d and xe2x80x9cpartially reflectingxe2x80x9d all relate to light in the visible range of the electromagnetic spectrum, i.e. having wavelengths in the range of 400 nm to 700 nm.
Further part of the present invention is a writing instrument comprising the solid marking composition of the present invention. Such writing instruments have many applications. They can be used for producing effects on documents and/or to authenticate and copy-proof documents. They are useful to authenticate official signatures in order to mark it as original. Thus further part of the present invention is an optically variable marking layer, preferably for authentication purposes, providing a color-shift between two distinct colors at first and second viewing angles produced with a solid marking composition, respectively with the writing instrument of the present invention.
The solid marking composition can additionally comprise further pigments or fillers, in particular security pigments, such as luminescent or magnetic pigments. In particular, the marking composition can also comprise optically variable pigment with incorporated additional security features, such as luminescence or magnetic features, tied to the optically variable pigment""s own dielectric and metallic materials. The marking composition can also comprise a plurality of different optically variable pigments.
The solid marking composition can in particular comprise forensic marking compounds and particles, as described in WO9934315 and U.S. Pat. No. 6,200,628.
The solid marking composition according to the invention can be applied to any substrate by all of the methods known in the art for applying such compositions. Part of the present invention is further the use of a plurality of optically variable pigment flakes in particular in a writing instrument for producing hand written preferably anti-counterfeitable markings on documents.

Solid marking composition as writing means, a writing instrument, an optically variable marking layer and use of a plurality of optically variable pigments


Controlled chemical etching of rotating metal substrates has been shown to be a feasible and economic method for the reproducible production of thin, reactive metallic foils such as copper foils. Foils thus prepared react readily with chemical substances, apparently by chemisorption. The organic-metal assemblies exhibit the same corrosion and wetting behavior as those prepared by other processes, and they readily undergo additional functional group transformations.

The ability to prepare and manipulate organic thin-film-metal structures in a well-defined way is critically important in areas as diverse as sensing, adhesion, tribology, corrosion and nanoscale electronics. For example, FTIR spectroscopy in the Attenuated Total Reflection mode (ATR-FTIR) is a widely used surface analytical method for investigating an organic-metal interface. One of the most popular ATR attachments employs a 45xc2x0 ZnSe single crystal with an available sample area of 10 mmxc3x9770 mm (Horizontal Contact Sampler, Spectra-Tech, Inc.). In order to obtain the maximum possible ATR-FTIR signal strength, it is necessary to ensure maximum interfacial contact between the ZnSe crystal and the sample. Thin, smooth metallic foils are, therefore, a practical requirement for such surface studies.
Many types of thin metallic foils necessary as substrates in this area of research are commercially available but the cost of such materials is frequently too high for researchers with limited resources. For instance, single crystal pieces of any metal, whether precious or non-precious, and polycrystalline pieces of all precious metals typically cost at least about $1500 cmxe2x88x922. Thus, each 4 cm2 piece of commercial thin copper foil costs about $16 and many such pieces must be used during an investigation. Accordingly, an inexpensive way to obtain high quality thin metallic foils is desirable.
There has been a surge of interest in fundamental studies involving the properties in chemical reactivity of organic films on metallic copper evident in the recent scientific literature. A method of producing thin copper foils is therefore expected to be of particular interest to those presently involved in organic-copper interfacial chemistry, as well as people who are contemplating entry into this area.
This invention provides a new method for the preparation of thin metallic foils and organic thin film-metal composites using such foils. More particularly, the invention provides a method in which a metallic substrate is rotated and contacted with an etchant so as to reduce the thickness of the metal substrate by corrosion and realize the desired foil thickness. The resulting thin foil can then be contacted with the organic material so as to form a thin film of the organic material on the surface of the foil.
The process of the present invention is applicable to any metal substrate. While it can be applied to precious and rare metals, because the process depends on a controlled corrosion, it is generally impractical for such metals because of the cost involved. A non-precious metal is therefore preferred. At present, the most preferred metal to which the process of the present invention can be applied is copper.
The thickness and other dimensions of the metal substrate employed are not restricted as long as the substrate can be rotated. Relatively thick metallic foils are commercially available and the use of such substrates is generally preferred. In general, it is preferred to employ a substrate having a thickness in the range from about 0.01 to about 1 mm and preferably from about 0.1 to 0.6 mm. It is also generally preferred, although not essential, that the substrate employed be in the form of a circular disk.
The metal substrate is rotated in any convenient manner, for instance by being mounted on a suitable rotatable supporting structure. The mounting also serves to protect one of the major faces of the substrate from the etchant and thereby minimize point breakthroughs which are more likely to occur when two opposing surfaces are being simultaneously etched. The speed of rotation can be adjusted as desired depending on the particular metal substrate employed, the particular etchant, the temperature and pressure conditions employed, and the desired rate of etching. In general, the rotation is usually within the range of about 100-1000 rpm, preferably 200-600 rpm.
Any etchant which acts chemically on the metal substrate to remove surface from that substrate can be employed. In general, inorganic acids such as hydrochloric acid, sulphuric acid, nitric acid and hydrofluoric acid can be used, with nitric acid being particularly preferred, but the range of etchants usable is not limited to this list. The etchant and metal substrate are contacted under etching conditions. For some combinations of etchant and metal, elevated temperature and/or pressure may be appropriate while other combinations can be processed under ambient or other conditions.
The etchant and metal substrate are contacted under the etching conditions for a time sufficient to reduce the substrate thickness to the foil thickness desired. If desired or convenient, the contacting may be done a plurality of times until the desired foil thickness is achieved. For example, the metal substrate can be separated from the etchant periodically and the exposed surface washed or otherwise cleaned before contact with the etchant is reestablished. The thickness of the desired thin foil is typically on the order of about 1 to 100 xcexcm and preferably about 10 to 90 xcexcm. Frequently about 60-90% and more frequently about 70-85% of the initial mass of the metal is eliminated as a result of the etching procedure.
Forming an organic thin film on a thin metal foil is per se known. The foil and the organic material are brought into contact under suitable conditions so as to form an organic thin film on the surface of the metal foil. Any procedure and any organic material which has been used heretofore can be used in accordance with the present invention which differs from such prior procedures by using the thin metal foil produced by the rotating etching procedure described above.
In order to further illustrate the present invention, experimental procedures and results are described below. It will be understood that these examples are intended to be illustrative and non-limiting. Unless otherwise indicated, all temperatures are in degrees Centigrade and all parts and percentages are by weight throughout this specification and claims.
General. Kinetic data were obtained with copper sheet (Johnson Matthey, 0.60 mm thickness, 99.9% purity). Copper xe2x80x9cHeavy Foilxe2x80x9d (J. T. Baker, 0.127 mm thickness, xe2x89xa799.90% purity) was used for all other experiments. Water was deionized (DI) via reverse osmosis (Barnstable Nanopure II system, resistivity 16.7 Mxcexa9). Anhydrous ethanol (Phannco), hexane (Fisher, HPLC grade), acetone (Fisher, reagent grade), dichloromethane (Fisher, HPLC grade), dodecane (Aldrich, 99.9+%), concentrated nitric acid (Fisher, reagent grade), dodecanethiol (Aldrich, 98+%), 11-mercapto-1-undecanol (Aldrich, 97%) and acetyl chloride (Aldrich, 97%) were used as received. Visible spectroscopy was carried out on a Milton Roy Model Spectronic 20 spectrophotometer. FTIR spectra were obtained on a Mattson Galaxy Model 3000 spectro-photometer, using Win 1st software for processing (DTGS detector, 2-cmxe2x88x921 resolution). ATR-FTIR spectra were obtained using a Horizontal Contact Sampler (Spectra-Tech, Inc.) fitted with a 10-mmxc3x9770-mm ZnSe crystal (45xc2x0, 12 internal reflections). Two 10 mmxc3x9735 mm strips were cut from each sample and were laid end-to-end on the ZnSe crystal before application of pressure by the gripper. The ATR-FTIR sample compartment was purged with nitrogen before analysis of samples. IR spectral assignments were assigned, in part, with the aid of molecular modeling data (PC Spartan Plus(trademark), Wavefunction, Inc.), using a PM3 basis set.
Kinetics. A circular disk 48 mm in diameter was cut from copper sheet of nominal 0.60-mm thickness (8.28 g, 0.130 g-atom, 99.9% purity). The center of the disk was fastened to the circular end of a wooden dowel (6 mm in diameter, 15 cm in length) with two-part xe2x80x9c5-minutexe2x80x9d epoxy adhesive. After the adhesive cured, the disk/dowel assembly was attached to a digital stirring motor (IKA Tech, Inc., Eurostar(trademark) model). The disk was vigorously abraded with emery paper and then lowered into 6 N HNO3 (75 mL, 0.45 mol, contained in a 4-mmxc3x9780-mm crystallizing dish). The disk was allowed to rotate at room temperature for 5 minutes at a total spinning rate of 500 rpm. Evolution of hydrogen gas was evident, as was the development of the characteristic blue color of aqueous Cu(NO3)2. The resulting solution showed a maximum in the visible spectrum at xcex=370 nm. The copper disk was rinsed with DI water, then lowered into 75 mL of fresh 6 N HNO3. The rotating rate was adjusted to 250 rpm, and 3.1-mL aliquots were removed at periodic intervals for spectroscopic analysis at xcex=370 nm. Absorbance values for each kinetic point were corrected by a factor of (solution volume at time t)/(initial volume of solution) to compensate for the volume of each aliquot removed. The observed pseudo-first order rate constant, Kobsd, was determined from the semilog plot of the corrected absorbance values, Abscorr, vs. time, t.
Standard Etching Protocol. Hydrogen gas and NOx fumes are rapidly generated in the initial phase of this exothermic reaction. Therefore, this procedure was carried out in a good fume hood, using appropriate personal protective gear, and ensuring that no potential sources of ignition are present. A circular disk was cut from the copper xe2x80x9cHeavy Foilxe2x80x9d of nominal 0.127-mm thickness (xe2x89xa799.90% purity). The disk diameter was 60.0 mm (3.45 g Cu). The disk was fastened to the end of a wooden dowel as described above. The disk/dowel assembly was attached to the digital stirring motor, and the disk was carefully lowered onto the surface of a cooled nitric acid solution (30 mL, 7.5 N, ice water bath, T≈20xc2x0 C.) contained in a 80 mmxc3x9740 mm crystallizing dish. Stirring was immediately begun (200 rpm). The corrosion reaction of copper was quite vigorous initially. Hydrogen gas and brown NOx fumes evolved from the metal-solution interface; the first-formed product had a deep emerald-green color before its complete dispersal into the bulk medium. An additional 15-mL portion of DI water was added within ca. 15 s, and the disk was raised so that the lower disk surface continued its rotation at the liquid-air interface. At that point, the volume of solution was ca. 45mL and the HNO3 concentration was 5.0 N. The solution developed an intense blue color as reaction progressed. Stirring was allowed to continue for an additional 7-8 min; the size of the evolving H2 gas bubbles appeared constant (≈0.5 mm) throughout the reaction period. Stirring was discontinued and the thin copper disk was slowly raised from the liquid. After quickly rinsing with DI water and acetone, the disk was allowed to air dry. Using a scalpel, the thin-foil disk was carefully detached from the epoxy adhesive that had fastened it to the dowel. The foils were subsequently handled only with polypropylene tweezers. The thin foils were either stored in polyethylene bags, stored in the open atmosphere, or used immediately for chemical adsorption experiments.
Adsorption Experiments. Thin copper foils were subjected to a preadsorption protocol immediately prior to chemical adsorption regimens. This preadsorption protocol consisted of a quick treatment with 2 N HNO3 (ca. 5 mL for 2-10 s), followed by rinses by DI water and either anhydrous ethanol or acetone. The foils were then treated within ca. 5 s with chemical reagents in adsorption experiments (either as 0.05-020 M ethanolic solutions or as neat liquids). While not effected in an oxygen free system, high quality organic material monolayers could be obtained as long as the exposure to air was minimized between the etching, rinsing and absorption steps.
Kinetics. In the kinetics experiment, a plot of [In(Abscorr)] vs. time (t) gave a straight line, with an observed pseudo-first order rate constant of 0.038 sxe2x88x921 (txc2xd=18 s). This pseudo-first order kinetic behavior is expected for a diffusion-controlled reaction at a rotating disk. Immediately after the etch reaction, the copper surface had a glittery, pinkish appearance. After rinses with DI water and acetone, tarnishing of the dry surface became evident within ca. 25 min. Additionally, the copper disk displayed the characteristic swirled, pattern of etching. The final thickness of the disk was ca. 50 xcexcm. This particular disk was neither flat nor malleable; it was only used to demonstrate that the expected kinetic behavior was obtained.
Standard Etching Protocol. The Standard Etching Protocol described above successfully and reproducibly provided thin, flat, smooth foils of metallic copper of reasonably uniform thickness. The thickness of each foil thus prepared was measured at four points at the edge of the piece and at its center with a micrometer. Typical values were: 10 xcexcm, 15 xcexcm, 28 xcexcm, 12 xcexcm (four equally-spaced points around the perimeter); 82 xcexcm (at the center). It is noteworthy that 70-85% of the initial mass of copper was lost as a result of the controlled etch. The initial appearance of the resulting thin copper foil was smooth, glittery and rose pink in color. The individual grains of the polycrystalline metal were visible to the eye. Each grain appeared to be ca. 0.01-0.10 mm2 in area.
Adsorption Experiments. Treatment of the prepared thin copper foils with ethanolic solutions of dodecanethiol (DT) or 11-mercapto- 1-undecanol (MUD) afforded samples which were characterized by their corrosion and wetting behavior, and by their ATR-FTIR spectra. In the case of MUD on copper, subsequent chemical reactivity of the putative hydroxy-terminated monolayer was also tested.
Corrosion protection of metallic copper was conveyed by both DT and MUD, as judged by visual inspection of samples which were stored in polyethylene bags. DT on copper (DT/Cu) showed little evidence of tarnishing over a 12-month period. In contrast, some darkening of the MUD/Cu samples was apparent over a period of 1-2 weeks. These observations generally agree with results reported previously. DT/Cu samples that were gently swiped with a dry lab tissue showed a tendency to darken within hours at the location of mechanical disruption, indicating reoxidation of the metal.
DT/Cu is completely wetted by dodecane and not wetted by DI water (50 xcexcL, sessile drop). MUD/Cu is completely wetted by dodecane and partially wetted by DI water (contact angle≈130xc2x0, initially: the contact angle with water decreased to ca. 80xc2x0 after 22 hr). The general wetting/repellancy behavior of both DT/Cu and MUD/Cu is consistent with contact angle measurements previously reported.
The results of ATR-FTIR analyses of DT/Cu and MUD/Cu samples, as well as IR data for the absorbates, are presented in Table I and Table II. Generally, lower frequency skeletal stretches and bends were easily discernible for these samples (1500-600 cmxe2x88x921 region). The appearance of new absorbance bands in this region, characteristic for Cxe2x80x94C and Cxe2x80x94O stretching modes, CH2 bending modes, and related coupled vibrational modes, strongly suggests that organic thin-film/copper structures were formed. For each sample, however, xcexd(Sxe2x80x94H) was absent, which is consistent with the formation of a covalent Cu(I)-thiolate linkage on the metallic surface.
The experimental IR signals can be compared with computational predictions for the model mononuclear compounds dodecylthiolatotriphosphinecopper(I), (CH3xe2x80x94(CH2)11xe2x80x94Sxe2x80x94Cu(PH3)3, (A in Table III) and 11-hydroxyundecylthiolatotriphosphinecopper(I), (HOxe2x80x94CH2)11xe2x80x94Sxe2x80x94Cuxe2x80x94(PH3)3, (B in Table III). Because of the overall broadness of the experimental IR absorptions in the 1350-600 cmxe2x88x921 region and the low signal strengths involved (Table II), it is not possible to make definitive assignments. It can be concluded, however, that the experimental data generally agree with the computational predictions, further supporting the conclusion that thin copper foils prepared by the protocol described are viable substrates for chemisorption with DT and MUD.
Freshly prepared MUD/Cu assemblies undergo additional chemical derivatization. When treated with acetyl chloride (neat, followed by an ethanol rinse and air drying), the resulting organic-copper samples exhibit the expected changes in the ATR-FTIR spectrum, with characteristic signals appearing for the new ester moiety: CH3xe2x80x94C(O)xe2x80x94Oxe2x80x94(CH2)11xe2x80x94Sxe2x80x94Cus.
Clean, reactive metallic copper surfaces can b prepared in a well-defined manner by taking advantage of the hydrodynamics of he rotating disk system. Copper disks can be corroded uniformly to produce thin, reactive metallic foils, to which organic materials adhere. The nature of the resulting organic films on copper, as examined by ATR-FTIR spectroscopy and by wetting and corrosion-protection behavior, is the same as for those reported previously.
The standard etching protocol was developed it order to (1) product flat, chemically reactive metallic copper pieces; and (2) produce thin and flexible copper pieces so that optimal interfacial contact between a copper thin foil-organic sample and the ZnSe ATR crystal would result. These two practical requirements, which are sine qua non for obtaining useful ATR-FTIR data, have been achieved. The absorbance values obtained in spectra of DT/Cu and /Cu samples strongly imply the existence of chemisorbed monolayers. Thus, the chemical viability of copper surfaces which have been prepared according to the controlled etching and preadsorption protocols has also been demonstrated. The reactivity of MUD/Cu samples towards acetyl chloride confirms that addition 2-dimensional chemistry is accessible in suitably functionalized metal-organic assemblies.
It is important to note that all experimental work described herein has been carried out with readily available and relatively inexpensive materials, chemical reagents, analytical instruments, computer resources an molecular modeling software. Thus, meaningful surface science research can be carried out on a limited budget.

Process for preparation of thin metallic foils and organic thin-film-metal structures


A whirlpool bath has a combination suction fixture and disposable filter. The suction fixture is a plastic semi-cylindrical housing attachable to the tub. A removable faceplate is reinforced and resistant to body and hair entrapment. The disposable filter is fibrous having a porous core, wherein the porous core has a series of holes and/or slots graduating in size from small at the outlet end to large at the remote end. The filter, sloped floor of the housing and drain slots provide for low water retention during shutdown. A safety/sanitation port on the outlet port creates cavitation if the whirlpool bath is operated without the disposable filter. The preferred embodiment removable faceplate is attached to the housing via a magnet and a peripheral ledge providing a pop off design. The preferred embodiment filter also has a pop off design.

The present invention relates to combining a replaceable filter and a suction device in a closed loop home or hotel whirlpool bath, hydrotherapeutic baths, and other bathing receptacles.
Whirlpool-type baths have been employed to treat discomfort resulting from strained muscles, joint ailments and the like. More recently, such baths have been used increasingly as means of relaxing from the daily stresses of modern life. A therapeutic effect is derived from bubbling water and swirling jet streams that create an invigorating sensation to massage the user""s body.
To create the desired whirlpool motion and hydro massage effect a motorized water pump draws water in through a suction fitting in a receptacle, such as a bathtub. The user first fills the bathtub. Then the user activates the closed loop whirlpool system. The water travels through a piping system and back out jet fittings. Jet fittings are typically employed to inject water at a high velocity into a bathtub. Usually the jet fittings are adapted to aspirate air so that the water discharged into the receptacle is aerated to achieve the desired bubbling effect. (See for instance, U.S. Pat. No. 4,340,039, incorporated herein by reference).
Whirlpool baths currently do not have a filtration system to filter debris in the water as do indoor and outdoor spas. Whirlpool baths are designed as with a normal bathtub to be drained after each use. However, debris in the form of dead skin, soap, hair and other foreign material circulates throughout the piping and pump system. This debris does not completely drain and over time accumulates in the piping system and may cause a health risk. Also hair may get twisted and entrapped in the whirlpool bath pumps impeller. Whirlpool bath manufactures for some time have been trying to devise a way to incorporate a filtration system on a closed loop whirlpool bath. The major obstacle they face in using a filtration system for a whirlpool bath is in complying with the plumbing codes. There is no filtration system that is specifically designed for a drain down whirlpool bath that allows a whirlpool bath to pass requirements set forth by plumbing codes. Another reason why there are no filtration systems for Whirlpool bathtubs is because Whirlpool baths must meet stringent drain downcode requirements set up by the American Society of Mechanical Engineers (ASME). The code that governs whirlpool baths is entitled xe2x80x9cWhirlpool Bath Appliancesxe2x80x9d (ASME A112.19.7M 1995). Section 5 of this code covers water retention. It states the xe2x80x9cwhirlpool bath appliances shall be of such design as to prevent retention of water in excess of 44 ml. (1xc2xd fl oz) for each jet and suction filter. The average whirlpool bath has a 6-jet system and has one suction fitting. This system configuration can only retain 10xc2xd ounces of water in the complete whirlpool bath system after draining to meet code. This is for a six jet one suction whirlpool bath. Most quality whirlpool baths retain less than 4 ounces of water in the whirlpool bath system after draining. Therefore, the filter part of the system cannot retain over six and a half ounces of water, because the total water retention would exceed 10xc2xd ounces. These requirements for whirlpool baths fall under the American Society of Mechanical Engineers code entitled xe2x80x9cWhirlpool Bathtub Appliances.xe2x80x9d Currently there are no known filtration systems designed for whirlpool baths. Currently there are no known filtration systems designed for whirlpool baths that retain less than 6xc2xd ounces of water except for the present invention.
Another important consideration in developing a filtration system for whirlpool baths is the ease of replacing the filter. It needs to be designed so the filter can be replaced from inside the bath. This way access panels on the underside of the whirlpool bath to access the filter can be eliminated. The most logical choice for a filter location is in the suction fitting. Placing the filter in the suction fitting presents a whole other range of design concerns. First placing a filter in the suction fitting might cause undue stress on the pump motor. The suction filter must pass the codes set up by ASME for suctions. The code for suctions from ASME is titled Suction Fittings for use in swimming pools, spas, hot tubs, and whirlpool bathtub appliances (ASME/IAMPO reaffirm 1996). There are a variety of load and structural tests the suctions have to pass. The present invention provides a cavity that houses a filter that could be installed to have the filter replaced from the inside of a whirlpool bath. The complete filtration system retains less than 4 ounces of water and as little as 2 ounces of water; so most whirlpool bath companies could use it on their whirlpool bath models and pass the drain down codes for whirlpool baths. The filter had to be made small to meet the drain down requirements. However, since it was small it had to be very efficient. The present invention has a specially designed filter core. The core is engineered with varying spaced and sized holes along the length of the core. This design allows water to be drawn through just about the entire filter. Without this design the filter would only pull water through about 20% of the filter near the outlet.
The present invention also provides a new face plate cover. This cover has to be easily removable. It also has to pass the heavy load, impact and hair entrapment tests set out by ASME/IAMPO. One cover embodiment has a radius and back ribbing on it and a removable insert support to pass the strength tests. The preferred embodiment faceplate is flat with structural fins on its back side, thus eliminating the removable insert. Each cover has just the right amount of sized holes to pass the hair entrapment tests. The result is the fluid suction filter device that is especially made just for whirlpool baths.
U.S. Pat. No. 4,340,039 (1982) to Hibbard et al. discloses a hydromassage apparatus for a whirlpool bath system. It has a closed loop water circulation system, adjustable nozzles and venturi air injector, (incorporated herein by reference).
U.S. Pat. No. 4,637,873 (1987) to DeSousa et al. discloses a front load skimmer type filter for spas and pools. A skimmer housing supports a polyester fabric filter having pleated filter media and a central polyvinyl chloride (PVC) pipe with a porous core, a solidified potting compound for a solid top, and an open bottom. It does not support a series of expanding diameter holes for the porous core as does the present invention, (incorporated by reference). It does not meet draindown requirements of ASME for whirlpool baths as does the present invention. It does not meet the ASME requirements for suction fittings and therefore needs to operate in conjunction with a below the waterline suction.
U.S. Pat. No. 4,349,434 (1982) to Jaworski discloses a filtration system piped in away from a pool, spa, hot tub and the like. A filter cartridge and filter is used.
U.S. Pat. No. 4,359,790 (1982) to Chalberg discloses a three piece whirlpool bath suction outlet assembly.
U.S. Pat. No. 6,283,308 (2001) to Patil et al. discloses a bacteriostatic filter cartridge having elements impregnated with an anti-microbial agent.
U.S. Pat. No. 6,038,712 (2000) to Charlberg et al. discloses a whirlpool bath suction device with a cavitation assembly to cause the pump to lose its prime when hair blocks the faceplate.
U.S. Pat. No. 5,799,339 (1998) to Perry et al. discloses a suction device for a spa or jetted tub with a turbulence reduction design to reduce the possibility of entangling a user""s hair in the faceplate.
The main aspect of the present invention is to provide in a whirlpool bath a suction fixture and replaceable filter combination apparatus.
Another aspect of the present invention is to provide a safety plate for the suction intake which resists hair entrapment.
Another aspect of the present invention is to provide a pop off suction faceplate and a pop out filter core to provide safety features to prevent drowning.
Another aspect of the present invention is to provide a safety/sanitation port to cause cavitation if the filter is absent or improperly inserted.
Another aspect of the present invention is to provide a minimal water retention filter to retain less than 6xc2xd ounces of water after draindown.
Another aspect of the present invention is to provide a housing which is readily retrofitable and/or incorporated into a new whirlpool bath that retains minimal water.
Other aspects of this invention will appear from the following description and appended claims, reference being made to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
The housing of the suction filter is generally rectangular having a length of four inches to two feet. A semi-cylindrical recess extends behind the installation wall of the tub. The recess surrounds a disposable cylindrical fiber filter which has a support tube in its core. The support tube has a plurality of water holes having increasing diameters extending away from the water outlet. These holes provide for a water flow along the entire length of the filter, instead of just making use of the filter at the outlet and of the filter.
The housing has a sloped lower shelf and slots to allow water to drain back into the tub after shutdown. The housing has a sharp radius end opposite the outlet end, thus allowing the housing to be fitted into the side wall of a tub through a standard size opening cut.
The housing mounting flange has nominally 6-10 counter sunk holes for bolting to the tub via standard nuts and bolts. Silicone is used on the back of the housing flange to prevent leaks.
The original faceplate shown in FIG. 4 slides into the housing to provide for filter replacement. The faceplate has a radius shape to prevent a limb from being sucked up against it which could entrap a body part. ASME hair entrapment standards are met using a plurality of slots or holes. Impact and load tests are met.
In the preferred embodiment faceplate shown in FIG. 25 support bars are now built into the faceplate and fit into receiving slots in the housing. This creates a solid part and allows it to pass impact and load tests called out by ASME code. This is the only suction for whirlpool bathtubs that is designed for the structured supports to be removed after the suction is installed and allows a filter to be installed in the suction housing or replaced and still pass these test. All other known suctions have the main structured support as part of the body (housing) and these supports cannot be removed. See U.S. Pat. No. 5,799,339 which represents all other known suctions. FIG. 5 of U.S. Pat. No. 5,799,339 shows a face view of the support. FIG. 3 shows how FIG. 5 screws in permanently into body 20 of FIG. 3. These supports (26b, 28b called a guide) cannot be removed once the suction is installed.
The preferred faceplate is larger than standard faceplates because of the size of the removable filter. The combination of a filter and a suction in a single device is not known in the prior art. The faceplate now has slots to allow a larger volume of water to pass through it. Because of the increased size of the faceplate the slots have to be designed and engineered in a radiating pattern. This is very important for the plastic injected molding process. With the present design over a horizontal (see ""339 patent) or vertical design, the pressure of the injected plastic from the injection point of the mold, (usually the injection point of a mold is located in the center of the mold) hits the small end of the slots instead of the wide end of the slots. The shorter end of the slot can withstand a great deal more pressure over time before failure than if the pressure were subjected to the wide side of the slots. This allows for much longer mold life and a more pleasing finished product. The radiating pattern of slots gives a straight-line flow to the outer edge of the faceplate part. U.S. Pat. No. 5,799,339 FIG. 4 shows a standard slot opening arrangement that represents the arrangement of slots used by manufacturers of slotted face faceplates. U.S. Pat. No. 6,038,712 FIG. 2 shows circular hole openings which represents how other faceplates are made. Slots are preferable over circular holes to increase flow.
The preferred embodiment housing eliminates the drain down slots of the original design because water now evacuates through the bottom slots of the faceplate. The filter core ID is preferably 2xe2x80x3 to allow for 200 GPM flow. No other manufacturer makes a filter for whirlpool bathtubs or a filter that fits into a housing outlet that has a 2xe2x80x3 ID. Without this ID you would not be able to get 200 GPM to run through the filter core allowing a combination filter suction an overall 200 GPM rating and meets ASME entrapment requirements.
The filter core also has two slots cut into the end that fits into the outlet of the housing. The housing has two male ridges. This makes the preferred filter core the only filter core that fits the preferred housing. The core is designed with varying sized holes and slots. The holes furthest from the outlet port are larger than the holes near the outlet port. This allows water to pull through the entire filter.
The male ridges align a gasket to cover a safety/sanitation port. The core when inserted into the outlet port side of the filter covers the safety/sanitation port, a hole opening that has a plastic tube attached. If the filter were removed or if a person tried to operate the unit without the filter core covering this hole, air from the tube would be drawn into the pump and the pump would cavitate (draw more air than water). The whirlpool bathtub would not operate properly, and people would turn it off. The importance to this is no user would run the unit without the filter in place. The feature reduces the chance of drawing contaminates into the whirlpool bath system. Once contaminates such as hair are entrapped in the pumps impeller, the entire whirlpool bath system becomes contaminated until someone opens the whirlpool bath pump (a long and time consuming process usually requiring a professional), frees the entrapped hair and sanitizes the complete system.
Right now by code, every suction faceplate must be engineered so the faceplate cannot be removed without using a tool. See U.S. Pat. No. 6,038,712 FIG. 2 that shows screw hole openings and U.S. Pat. No. 5,799,339 FIG. 3 number 22 that shows the screw. All known suctions on the market use a form of screw or the like to attach the faceplate to the housing. There are some suction manufacturers that have a cavitation device in the faceplate of the suction, see U.S. Pat. No. 6,038,712. If the face of the suction is restricted significantly, the unit cavitates and the suction against the faceplate decreases. These designs are still dangerous. Hair can still become twisted in the faceplate before the unit shuts down. Once the hair is trapped, you need a tool by code to take the faceplate off. In most cases a screwdriver to remove the screw. The entrapped hair traps the head of the user underwater in the tub water. People still can drown with these devices. The reason for this code of needing a tool to remove the faceplate is that if the faceplate of current suctions are removed, body parts or hair could get trapped in the exposed housing support cross members that are an integral part of the suction body (nonremovable). Since the preferred embodiment suction filter will not operate without the filter in place, there is no need for the screw. If the filter were in place and someone did get their hair caught in the preferred faceplate, the faceplate is held in place by magnets; and the whole faceplate pops off easily. If hair got caught in the exposed filter if the unit were run without the faceplate cover, the filter also pops out easily. There is no chance of getting entrapped if the filter is removed, because the unit cavitates and ceases the suction action and trigger no obstructions in the outlet for anything to become entrapped
The filter core has a gasket that slides over the safety/sanitation port which is a cavitation hole. Without this gasket, the replaceable plastic filter core would rub against the plastic housing outlet and could cause wear over the years to the housing outlet.
The faceplate now preferably attaches to the housing with magnets.
The screw hole openings of the housing are recessed for flush mounting. They also are flat recessed.
The filter media is preferably made out of polypropylene. Others in the spa industry use polyester media No one has an approved filtration system for whirlpool baths, so filters are not used on whirlpool baths. Polypropylene media can be treated in the manufacturing process with antibacterial agents, whereas polyester media cannot be treated effectively with antibacterial agents.
The preferred filter is designed to retain less than 3 ounces of water.
The suction filter housing is installed by using screws to attach it to the whirlpool bathtub. No other suction currently uses screws for installation. All other suctions currently place the housing behind the hole-opening cut into the sidewall of the whirlpool bathtub, and a separate threaded base ""339 number 14 is screwed into the housing forming the installation. By using screws the present invention eliminates this extra plastic injected part.
The preferred housing is the only known housing that has sloped sides of the inner wall to allow water to drain back into the whirlpool bathtub when the whirlpool bathtub system is deactivated whether the unit is installed facing left or right.
The present suction filter device could be designed in other configurations than its current rectangular form. The unit could also be designed in a round form or any other shape or size. The filter and filter core could also be made shorter, longer, larger or smaller. The filter could be made smaller for less money to be disposable after each whirlpool bath use. The filter could even be designed in such a way to be incorporated into existing suctions with modification of those suctions. The filter media that filters the water could be pleated or wrapped without pleating around a filter core.
The housing could be designed to incorporate multiple filters. The ridges and slots at the end of the filter core could be made in a variety of shapes or locations to ensure the use of only one filter.
The main body housing could be vacuum formed and become an integral part of the whirlpool bathtub.
The magnets holding the faceplate to the housing could be larger or smaller and arranged in various other locations on each part. The amount of magnets used could be increased or decreased. The faceplate could also be attached using various snap-on configurations. An installation-sealing gasket could be used. The slope in the sidewalls of the housing could be increased or decreased. The overall size of the suction filter could be increased or decreased.
The housing body, faceplate or filter core could be made from other material than injected plastic; it could be stamped or machined out of metal or other material.
The radiating slotted design of the faceplate could have a radiating round hole design.
The safety cavitation hole could be placed anywhere rearward on the outlet of the housing and be various sizes or have multiple openings.
The filter could have various sanitizing materials in its core such as slow dissolving chlorine tablets or other sanitizing material incorporated into the filter core.
The screw and nuts that attach the housing to the sidewall of the whirlpool bathtub could have a washer or use locking nuts or clips and have varying sizes and be made out of a variety of materials, including plastic and nylon or some space age material.
The faceplate back support ribbing is designed in an X pattern, which offers outstanding structural integrity. The circular ribbing adds tremendous strength to the center impact point of the faceplate.
The faceplate is designed to protrude less than xc2xdxe2x80x3 into the tub when attached to the housing. This streamline design protrudes much less than most current suctions adding more room to the bathing area of the whirlpool bathtub.
The slotted holes on the top, sides and bottom of the faceplate extend out keeping in line with the radiating design pattern on the face of the faceplate. This makes it an easier part to inject with plastic.
The housing has a flange that provides a resting area for the peripheral ledge of the faceplate when the faceplate is attached to the housing. This resting area allows for weaker magnets to be used to keep the faceplate attached to the housing.
When a conventional suction fitting is operated under a high flow rate, the water flow inside of the fitting can become turbulent or can vortex like a tornado. When the water flow through such a fitting becomes turbulent or vortexes, hair extending through the faceplate of the fitting can become entangled within the fitting, thereby rendering the hair difficult to remove from the fitting. Accordingly, the conventional fitting cannot pass the five-pound pull test at high flow rates.
The present invention filter inside the housing disrupts this vortex. Tests have proved that the GPM actually increase with the filter installed by eliminating these vortexes than running the same test with the filter removed. Less vortex results in less of a chance someone could get his or her hair twisted in the faceplate and entrapped. Therefore, another feature of the present invention is to help provide a laminar flow through the suction/filter.

Whirlpool bath filter and suction device


A teat nozzle suitable for pediatric oral dosing of a fluid medicament comprising a tubular conduit which is engageable with a socket, and has at least one engagement part which can engage with an internal thread in the socket. The teat nozzle facilitates connection between the conduit and the socket. Dosing devices such as syringes and squeezable capsules provided with the nozzle, and a connection means for a vial having such a socket, are also described.

This invention relates to a novel device being a nozzle suitable for the oral administration of a paediatric fluid medicament from a dosing device such as a dosing syringe or a collapsible capsule. In particular the invention relates to such a nozzle which facilitates connection between containers of the fluid medicament. The invention also relates to a dosing device provided with such a nozzle, and to a connector device suitable for enabling a dosing device such as a syringe or compressible capsule having such a nozzle to be connected to a container such as a pharmaceutical vial.
Devices for the oral administration of fluid medicaments to paediatric patients are known, generally comprising a container for the medicament, in particular a dosing syringe provided with a teat nozzle in the form of a conduit for the medicament, terminating in a nozzle opening. Another such device comprises a compressible capsule, containing the liquid medicament, made of soft plastic material also provided with a teat nozzle in the form of a conduit for the medicament, terminating in a nozzle opening. Such devices are particularly suitable for use with very young children and babies who are incapable of drinking a fluid medicament from a cup or spoon, and can only suck from a teat. In use the nozzle is inserted into the mouth of a paediatric patient and a liquid medicament from the syringe is injected into the patient""s mouth. One such fluid medicament is that provide for treatment (curative and/or prophylactic) of the Rotavirus infection in paediatric patients.
It is known to provide syringes and like devices with connection means so that they can be connected to a second container of the medicament, in particular a vial of the medicament, e.g. by a screw connection. Such vials are often provided closed by a closure which includes a puncturable rubber seal, and connection means for such vials are known which include a hollow puncturing spike which can be driven through the seal, and through the hollow interior of which the medicament can be extracted from the vial into for example a dosing syringe.
Such connection means are required to comply with an international standard, ISO 594/1 xe2x80x9cConical fittings with a 6% (Luer) taper for syringes, needles and certain other medical equipmentxe2x80x9d, which specifies their mode of construction, shape and dimensions, so as to enable interconnectability of such connection means.
A problem exists with dosing syringe nozzles made according to this international standard in providing connection means which can be readily adapted for use with oral dosing of small children and babies. It is an objection of this invention to provide a connection means which in part at least solves this problem.
According to the present invention a teat nozzle suitable for paediatric oral dosing of a fluid medicament comprises a tubular conduit having an internal channel along which a fluid medicament may be caused to flow toward a nozzle opening of the conduit, characterised in that the conduit is engageable in a male-female co-operation with a female socket, and the conduit is provided externally with at least one engagement part which can engage with an internal thread in such a female socket, to thereby facilitate connection between the conduit and the socket.
The conduit is suitably externally in the form of a substantially cylindrical tube having at least its part immediately adjacent to and upstream of the nozzle opening tapering in a shallow cone being narrowest at the nozzle opening end of the cone. The base of such a cone is adjacent to the cylindrical part of the conduit upstream of the cone, and the cross section of the base of the cone may be the same or different, e.g. smaller to the cross section of an immediately adjacent cylindrical part. Such a cone may for example comprise 25-75% of the length of the teat nozzle extending upstream from the nozzle opening. Alternatively all or substantially all of the conduit may be externally of a shallow conical shape. Alternatively the conduit may have a cylindrical part immediately adjacent to and extending upstream of the nozzle opening, and of a shallow conical shape over its further upstream part, the cylindrical part meeting the apex of the cone.
The term xe2x80x9ccylindricalxe2x80x9d as used herein includes oval and other distorted circular cross sections. The term xe2x80x9cconicalxe2x80x9d as used herein includes truncated cones, and includes both true cones, i.e. with straight sides and circular cross sections at all points along their base-apex axis, and distorted cones, e.g. with stepped or concave or convex curved sides and oval and other distorted circular cross sections. A typical amount of conical taper is ca. 2-10xc2x0. For example the cone may be of the 6% cone shape defined in ISO 594/1 xe2x80x9cConical fittings with a 6% (Luer) taperxe2x80x9d. The terms xe2x80x9cupstreamxe2x80x9d and xe2x80x9cdownstreamxe2x80x9d as used herein refer to the direction in which the fluid medicament flows from a dosing device through the nozzle towards the patient""s mouth during dosing to a patient.
Such a shallow cone shape is particularly advantageous for use as a teat which can be inserted, for dosing, into the mouth of a small child or baby, and which will be comfortable for such a patient.
The conduit may be shaped and dimensioned externally out of compliance with ISO 594/1 mentioned above, in particular being made larger than the dimensions given therein, so that it is impossible to fit a standard hypodermic needle to the conduit. This would prevent any accidental use of the nozzle of the invention with such a needle when it is intended for oral use. This is important because dosing devices such as syringes etc. intended for oral use are not necessarily provided for use in a sterile state, whereas for use with a hypodermic needle for injections through the skin a sterile dosing device must be used.
When the conduit comprises a conical part and an upstream cylindrical part, the engagement part(s) is/are preferably provided upstream of the conical part, for example immediately adjacent upstream of the conical part, or at the junction between the conical part and the cylindrical part. For example the engagement part(s) may be provided at or immediately upstream of the wide base of such a conical part. When the conduit comprises a cylindrical part and an upstream conical part, the engagement part(s) is/are preferably provided upstream of the cylindrical part, for example immediately adjacent upstream of the cylindrical part, or at the junction between the conical part and the cylindrical part. For example the engagement part(s) may be provided at or immediately upstream of the wide base of such a conical part. When substantially the whole of the conduit is externally conical the engagement part(s) may be provided at any point upstream of the nozzle opening. Preferably the engagement part(s) may be provided between 25-75% of the length between the nozzle opening and the other end of the teat nozzle, e.g. the point where the nozzle is joined to a dosing device.
The at least one engagement part(s) may be suitable for engagement with a helical or part helical internal thread on the said female socket. A screw thread enables a tight connection to be made, which can help resist build up of pressure within the device and socket. Preferably the engagement parts comprise at least two, but suitably two, rounded bumps, e.g. wings, on the outer surface of the conduit. Such bumps may for example be smoothly curved e.g. substantially hemispherical or rounded conical, and may be regularly circumferentially disposed around the conduit. For example if two such bumps are present they may be oppositely disposed around the circumference, e.g. 180xc2x0 apart. Such bumps may be engageable with an internal helical thread on the female socket having a section corresponding to that of the bumps. The use of such bumps is advantageous as they can have a smoothly rounded profile which is comfortable to the mouth of small children and babies for which the device is used for oral dosing.
In another aspect the invention also provides a dosing device suitable for dosing a liquid medicament, particularly such a device suitable for oral dosing, and being provided with a teat nozzle as described above. Such a dosing device is preferably a syringe, e.g. a tubular barrel provided with a piston which can be driven toward a nozzle opening of the syringe to dispense fluid contents of the barrel, e.g. a single dose of medicament, through the nozzle, or a collapsible capsule, e.g. a envelope made of a flexible soft plastics material, e.g. containing a single dose of medicament, which can be compressed to reduce its internal volume and to drive the fluid contents out through a nozzle part of the capsule. The term xe2x80x9cdosing devicexe2x80x9d as used herein is not intended to limit the invention to dosing devices in which the dose administered is measured and/or controlled by a meter, although the invention may be used with metered dosing devices.
Preferably the teat nozzle of the invention may be made integrally with a dosing device which includes a reservoir for a liquid medicament, for example the teat nozzle may comprise the integral nozzle part of a dosing syringe or collapsible capsule. The present invention therefore further provides a dosing device having a teat nozzle as described above as its integral nozzle. Such an integral syringe and teat nozzle may be made of conventional materials such as glass or preferably of plastic. Such an integral collapsible capsule and nozzle may be made of conventional materials such as soft plastic.
Alternatively the teat nozzle of the invention may be made as a separate part attachable to a dosing device which includes a reservoir for a liquid medicament, such as a dosing syringe or a collapsible capsule, and for this purpose the conduit may be provided at its upstream end with a suitable connection for a dosing device, e.g. of a syringe or of a collapsible capsule. For example the connection may comprise a widening of the internal channel to enable connection with a male nozzle part of the dosing device. The present invention therefore further provides a teat nozzle being a separate part attachable to a dosing device, for example having a conduit provided at its upstream end with a connection to enable connection with a dosing device such as a syringe or collapsible capsule. If provided as such a separate part extreme care must be taken to ensure that the separate part cannot become detached from the dosing device during use in oral dosing, with the consequent risk of swallowing of the part by the patient.
The teat nozzle of the invention may be provided with a protective removeable closure, e.g. a flexible conforming cap, to prevent contamination etc., which is removed before use.
By means of the engagement of the conduit with the female socket the conduit is made connectable with the socket and consequently a fluid medicament may flow between the conduit and the socket. If the conduit and socket are themselves in communication with respective containers such as the reservoir of a dosing device and a vial, the fluid medicament may be transferred therethrough from one container to the other. For example a vial may contain a medicament provided for reconstitution, and a syringe or collapsible capsule may contain a medium for reconstitution, and the medium may be transferred from the syringe or capsule into the vial via the connection to reconstitute the medicament, and the reconstituted medicament may then be transferred back into the syringe or capsule for dosing to the patient. Alternatively the vial may be provided containing a liquid medicament which may be transferred from the vial to the dosing device.
In another aspect of this invention there is provided a connection means by which the teat nozzle of the invention may be connected to a container of the medicament.
A preferred form of such a connection means is provided for a container which is closed with a puncturable seal, the connection means having a female socket having an internal thread which is engageable with the engagement parts of the teat nozzle such that the nozzle may make a fluid connection with the socket, a hollow puncturing spike having an internal channel therein which is in communication with the socket, the puncturing spike able to be driven through the puncturable seal of the container to thereby establish fluid communication between the contents of the container and the teat nozzle.
The container may for example comprise a pharmaceutical vial, and may for example be provided containing a dried solid medicament for reconstitution with reconstitution fluid, e.g. an aqueous medium, passed into the vial via the teat nozzle, socket and spike, and subsequently withdrawn along the same route into for example a dosing device such as a dosing syringe or a collapsible capsule.
The female socket preferably corresponds internally closely in shape and dimensions to the external shape of at least part of the teat nozzle of the first aspect of the invention.
The connection means may comprise various constructions, and some suitable constructions are discussed below.
One suitable construction of the connection means comprises a substantially bell-shaped structure of internal size, shape and dimensions enabling it to fit closely over the closure, including a puncturable seal, of a pharmaceutical vial, and the bell being optionally provided with clip means to enable the bell-shaped structure to be retained upon the vial closure, the hollow puncturing spike extending downwardly internally within the bell, preferably co-axially with the longitudinal axis of the cylindrical bell, a female internally threaded socket being provided externally on the base of the bell and in communication with the hollow channel of the puncturing spike.
Another suitable construction of the connection means comprises a tubular body which can be attached to the vial (e.g. by known means) and which when in place on the vial extends upwardly from the mouth of the vial to define internally a tubular chamber having the puncturable seal at a lower end, a piston, provided in an first upper position relatively more distanced from the seal and being moveable within the tubular body to a second lower position relatively less distanced from the seal, the piston having a connection port comprising the female socket, and a tubular puncture member extending downwardly from the piston, the puncture member having a cannula therethrough communicating with the connection port, movement of the piston from its first position to its second position causing the puncture member to puncture the seal so that in the second position the connection port and the interior of the vial are in communication with each other via the cannula.
In this embodiment the piston may be initially provided mounted on and extending at least partially inside the tubular sleeve (preferably with its puncturing spike within the sleeve). The piston may be mounted in the tubular body by means of a link which may be easily broken, for example by a downward force on the piston. The piston and the tubular body in such a construction may include co-operating guides which encourage the piston to move in a downward direction, i.e. toward the vial seal, and which may prevent relative rotation of the piston and the tubular body. The piston and the tubular body may also include co-operating locking means such that the piston may be locked in place in the tubular body at the lowest end of its downward movement.
Connection means of the general type described above, but without the above-mentioned internally threaded female socket, are known for example being disclosed in EP 0351643A, EP 0587347, EP 0126718A, U.S. Pat. No. 4,564,054, GB 1452418, U.S. Pat. No. 3,977,555 and U.S. Pat. No. 5,350,372.
In use such a connection means may be provided attached to the vial by known means, positioned relative to a pharmaceutical vial provided with a puncturable seal such that the puncturing spike is above and aimed at the seal. The piston may then be moved downwardly toward the vial such that the puncturing spike punctures the seal and thereby provides communication between the interior of the vial and the female socket. The teat nozzle may then be inserted into the female socket and its engagement part(s) engaged with the internal thread of the socket to thereby provide communication between the channel and the interior of the vial, and between the latter and a container in communication with the teat nozzle, e.g. a dosing syringe or collapsible capsule.
Alternatively a teat nozzle comprising part of a dosing device such as a syringe or a collapsible capsule may be engaged with the female socket and force may be applied to the dosing device to move the piston downwards analogously to the above-described manner. This mode of use has the advantage that contact between the user""s fingers and the socket is minimised
In one mode of use a dosing device such as a syringe or collapsible capsule may contain a reconstitution liquid and the vial may contain a solid, e.g. lyophilised, medicament for reconstitution. When the communication between the dosing device and the interior of the vial has been established as described above the reconstitution liquid may be transferred through the teat nozzle, socket and spike into the vial, and the medicament reconstituted in the vial. The reconstituted medicament, e.g. as a solution, may then be withdrawn into the dosing device.
All of the above-mentioned parts of the device and connection means of the invention may be made of plastics materials by a process of injection or blow moulding. Such plastics materials should be acceptable for contact with pharmaceutical substances, particularly liquid medicaments. In a further aspect the invention therefore provides a mould suitable for the manufacture therein of a device or connection means as described above.
The teat nozzle and/or dosing devices described above, and the connecting means of the invention may be provided together as a kit comprising one or more such teat nozzles and/or dosing devices and one or more connection means. Such a kit comprises a further aspect of this invention. The connection means described above may also be provided attached to a vial, and the combination of the connector and a vial are a further aspect of this invention.

Teat nozzle for dosing device with connection means


An air intake scoop for a motorcycle carburetor inserts into the carburetor mouth while also fitting within the air filter housing. The air scoop being designed with a cutout in front, a ridge along the interior and a 90-degree angle for the ability to draw a strong airflow into the carburetor, preventing gas mist from escaping from the carburetor. This air intake scoop would be molded preferably of polyurethane or other gas and oil resistant plastic or rubber, and would be easily adapted to fit a variety of different sizes of carburetors and air filter housings. An air filter cover with a forward air opening admits a strong current of air into the air filter and air intake scoop on clear days and has a closeable lid to prevent water from entering the carburetor on rainy days.

1. Field of the Invention
The present invention relates to air intake for carburetors, and more particularly, to an air intake scoop for a motorcycle carburetor which inserts into the carburetor and fits within the air filter housing.
2. Description of the Prior Art
In motorcycle carburetors mounted with a horizontal opening, such as Harley Davidson models of 883 cc, 1400 cc, and 80 ci depending on which motor combination, pipes, cam with valve overlap, a problem that can occur in some instances is that a gas mist comes out of the carburetor when accelerating allowing gas to saturate the air filter with a gas mist and then the gas will drip down the side of the motorcycle causing gasoline odors, possible paint damage, stains, and a potential fire hazard.
Prior art air intakes in most instances do not address the problem of gas misting from the carburetor.
Prior art intakes do not direct the airflow into the carburetor from inside the air filter area with an enclosed shroud forcing the air into the carburetor improving the performance of the motor.
U.S. Pat. No. 4,592,316, issued Jun. 3, 1986 to Shiratsuchi, et al., describes an air funnel assembly extending between an air inlet assembly and one or more carburetors on a two-wheeled vehicle. The air funnel assembly includes an elastic air funnel and an air funnel cover. The funnel and funnel cover are affixed to the carburetor or carburetors and extend in spaced relation towards the air inlet assembly. The components may be fixed to the carburetors by means of one or more clamp rings, may be additionally joined together by projections from the elastic funnel which are retained in holes in the rigid cover. A radially interlocking arrangement may be employed at the inlet from the air inlet assembly to retain the funnel thereto.
U.S. Pat. No. 5,868,808, issued Jan. 9, 1999 to Henderson, shows a carburetor air intake velocity stack engagable with a carburetor inlet, that has a cylindrical throat section having first and second ends. The first end is adapted to be coupled to the carburetor, while the second end is open to the air. A shaped, mesh filter having an effective open area which exceeds the open area of the velocity stack by at least about 50%, is located within said air intake velocity stack. The filter has a cylindrically formed flange member which is trapped between said air intake velocity stack and the carburetor.
U.S. Pat. No. 6,371,068, issued Apr. 16, 2002 to Taylor, claims a modified air intake mechanism for an internal combustion engine. The air intake mechanism includes an air passageway that contains a fixed vane located in a plane that is parallel to the air flow within the passageway. More specifically, the vane is stationary and is located in the air horn or the air intake passageway of the cylinder head.
U.S. Pat. No. 4,066,720, issued Jan. 3, 1978 to Carter, provides an improved carburetor air intake velocity stack for maximizing the quantity of air delivered to a carburetor. An air intake velocity stack is adapted to be coupled to the air inlet of a carburetor, the surface of the air intake stack substantially eliminating turbulence at the air intake velocity stack as well as increasing the density of air being input to the carburetor. The curvature of the intake stack provides for substantially laminar flow of the input air, the laminar flow being undisturbed by the shape of the input path.
U.S. Pat. No. 5,549,085, issued Aug. 27, 1996 to Endrigo, discloses an insert device for smoothing air flow from air filters to carburetors. The device is suitable for turning an air stream from an intake air passageway, which is directed inwardly along a plane from a periphery towards a center to a fuel/air mixing chamber having an annular downwardly flowing mixing passageway with a longitudinal axis at the center. The insert device includes a first end adapted to be operably located concentrically with the annular fuel/air passageway, and a second end opposite the first end. The first and second ends have a central axis extending therebetween. The second end has a center and an upper wall extending outwardly therefrom. A peripheral wall of diminishing outside diameter begins at a point spaced outwardly near the center of the second end and extends smoothly to a point of minimum diameter. From the point of minimum diameter, concave shaped subwalls of slightly increasing size extend downward to the first end. In an alternate embodiment, from the point of minimum diameter, a single peripheral wall of increasing diameter extends to and connects with the first end.
What is needed is a means for preventing gas from misting out of horizontally oriented motorcycle carburetor openings.
What is also needed is a means to prevent the air from flowing past the carburetor inlet. Air needs to be funneled directly into the carburetor, which improves performance.
An object of the present invention is to provide an air intake scoop to draw a strong flow of air into a motorcycle carburetor having a horizontal opening to force the flow of air into the carburetor and prevent the gas mist from exiting the carburetor.
Another object of the present invention is to provide a small-sized air flow scoop to fit onto the motorcycle carburetor and under the air filter.
One more object of the present invention is to provide an inexpensive air intake scoop molded preferably of polyurethane or other gas and oil resistant plastic or rubber.
An additional object of the present invention is to provide an air intake scoop which has 90 degree airflow movement to take in air from the forward direction of travel of the motorcycle and send it 90 degrees into the side mounted mouth of the carburetor.
A further object of the present invention is to provide a rubber or plastic air intake scoop which may be easily adapted to fit a variety of different sizes of carburetors and filters.
Yet one more object of the present invention is to provide a cover for the air filter with a movable lid over a forward opening in the cover to admit a substantial flow of air into the air scoop with the lid open on days when it is not raining and with the lid closed to prevent water from entering the carburetor on rainy days.
In brief, a sleeve elbow with a 90 degree bend is molded of polyurethane or other gas and oil resistant plastic or rubber. A circular opening fits with a tight friction fit inside the mouth of the carburetor which opens to the side of the motorcycle. A rim recessed from the circular opening acts as a stop and contacts the rim around the mouth of the carburetor.
The other end of the elbow faces in the forward direction of travel of the motorcycle to scoop in the air. The front facing portion of the elbow is cut away to create a larger scoop area extending from the rim to the outer tip of the elbow. A ridge protrudes along the inside centerline of the back surface of the elbow from the circular opening to the front edge of the scoop, the ridge acting as a vortex generator to assist in directing air flow into the mouth of the carburetor.
The air filter fits over the air intake scoop and bolts onto the carburetor backing plate in a normal fashion. A cover for the air filter is preferably bowl shaped and attractively chrome coated and fits onto the air filter with a single center bolt. A sliding lid in a front portion of the cover opens to admit air through a front opening in the cover in a strong current into the air scoop on clear days and closes to prevent water from entering the carburetor on rainy days.
An advantage of the present invention is that it funnels air directly into the carburetor, which improves performance while the vehicle is in motion.
Another advantage of the present invention is to provide a means to maintain a gasoline free air filter.
Another advantage of the present invention is to provide a means to prevent gas from dripping down from the carburetor.