description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Specifically referenced is U.S. Pat. No. 7,150,904 issued on Dec. 19, 2006 to D'Urso and Simpson entitled “Composite, Ordered Material Having Sharp Surface Features”, the entire disclosure of which is incorporated herein by reference; the application is available to the public as U.S. Patent Publication No. US 2006/0024478. Also specifically referenced is U.S. patent application Ser. No. 11/460,658 filed on Jul. 28, 2006 by D'Urso and Simpson entitled “Method of Producing Microchannels in Drawn Material”, the entire disclosure of which is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] . The United States Government has rights in this invention pursuant to contract no. DE-AC05-00OR22725 between the United States Department of Energy and UT-Battelle, LLC.
BACKGROUND OF THE INVENTION
[0003] Two methods of making “structured” drawn glass, having microchannels or nanochannels in the direction of the draw are commonly known and used. The first method is to start with a preform that contains two kinds of glass. A core glass is easily etched in acid, while a cladding glass is not etchable. The preform is drawn into fiber, cut perpendicularly to the drawing direction into segments, and the segments are bundled together in parallel. The drawing and bundling process can be repeated many times. Finally, the last bundle is fused, sliced perpendicularly to the drawing direction into segments of a desired thickness, and the core glass is etched out from both sides leaving an array of holes. The difficulty is that in cases where a segment is more than a few millimeters thick, the etching process can take a prohibitively long time, since the core glass is etched out through increasingly long, narrow channels. The article produced is known as microchannel or nanochannel glass.
[0004] The second method is used to make structured optical fiber (also known as photonic crystal fiber or holey fiber). In this case, the preform has holes (macro-channels) through it which can be produced by bundling solid and hollow rods or by bundling two kinds of glass, fusing and etching out one glass before drawing (Falkenstein, et al, Optics Letters vol. 29, p. 1858, 2004). In either case, the preform has holes through it when it is ready for drawing. The preform is then drawn once or repeatedly to make the fiber. The difficulty is that the holes tend to collapse and/or distort during the final fusing process.
BRIEF SUMMARY OF THE INVENTION
[0005] In accordance with one aspect of the present invention, the foregoing and other objects are achieved by a method of making an article having channels therethrough includes the steps of: providing a ductile structure defining at least one macro-channel, the macro-channel containing a salt; drawing the ductile structure in the axial direction of the at least one macro-channel to reduce diameter of the macro-channel; and contacting the salt with a solvent to dissolve the salt to produce an article having at least one microchannel.
[0006] In accordance with another aspect of the present invention, a method of making an article having microchannels therethrough includes the steps of: providing a ductile structure defining at least one macro-channel therethrough; depositing a salt composition into the at least one macro-channel; heating the ductile structure to a sufficient temperature so that the ductile structure can be drawn and so that the salt melts; drawing the ductile structure so that the diameters of the at least one macro-channel is reduced; cooling the drawn ductile structure; and contacting the salt with a solvent to dissolve the salt to produce an article having at least one microchannel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic oblique view of a bundle of glass tubes having salt-filled macro-channels in accordance with an embodiment of the present invention.
[0008] FIG. 2 is a schematic oblique view of the bundle of glass tubes shown in FIG. 1 after drawing and fusing into a glass monolith, showing salt-filled microchannels in accordance with an embodiment of the present invention.
[0009] FIG. 3 is a schematic oblique view of the drawn, fused glass monolith shown in FIG. 2 following removal of salt to produce a microchannel glass article in accordance with an embodiment of the present invention.
[0010] FIG. 4 is a schematic oblique view of a sheathed bundle of glass tubes having salt-filled macro-channels in accordance with an embodiment of the present invention.
[0011] FIG. 5 is a schematic oblique view of the sheathed bundle of glass tubes shown in FIG. 4 after drawing and fusing into a glass monolith, showing salt-filled microchannels in accordance with an embodiment of the present invention.
[0012] FIG. 6 is a schematic oblique view of the drawn, fused glass monolith shown in FIG. 5 following removal of salt to produce a microchannel glass article in accordance with an embodiment of the present invention.
[0013] Several elements that are essentially the same across multiple figs. are assigned like call-out numerals.
[0014] For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above-described drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The process of the present invention begins with the selection of an appropriate structural composition through which microchannels or nanochannels are desired. The well known terms microchannel and nanochannel are considered to be interchangeable for the purposes of describing the present invention, with the general understanding that nanochannels are generally considered to be smaller in diameter than microchannels.
[0016] A ductile structure (i.e., body) should be selected which is appropriate for the intended use in accordance with known criteria. Glass and glassy compositions are especially suitable for making ductile structures such as tubes, for example. Moreover, other amorphous and/or semi-crystalline compositions, such as certain polymers, may also be used. Ductility—the property of being permanently deformed by tension without rupture—is a critical property of an appropriate structural composition in accordance with the present invention. The ductile structure must have the ability to be drawn from a given cross sectional size to a smaller cross sectional size.
[0017] The appropriate ductile structure can be formed into one or more tubes, the interiors of which are referred to herein as macro-channels. Inside and outside surfaces of the tube(s) can be, in terms of cross-sectional shape, the same or different, and can be annular, round (circular), triangular, rectangular, hexagonal, other polygonal, or any other shape that is suitable for holding or forming a desired shape during a drawing process. Cross-sectional shape of the tube(s) is not critical to the invention, but may be significant for some particular end-use of the article.
[0018] Once appropriate ductile structure is selected, an appropriate salt composition (hereinafter often referred to simply as salt) is selected. An appropriate salt composition may include a single salt compound or a mixture of different salt compounds. It is preferable (but not always necessary) that a salt be selected such that the following four conditions are met:
a. The melting temperature of the salt should be lower than the drawing temperature of the ductile structure. Thus, when the ductile structure is drawn, the salt will flow with the ductile structure. b. The melting temperature of the salt should be higher than the fusing temperature of the ductile structure. Thus, when the final bundle is fused, the salt maintains the shape of the channels and prevents collapse thereof. c. The ions in the salt should match the ions in the ductile structure or be inert with respect thereto so that any ion exchange between the ductile structure and the salt either does not alter the composition of the ductile structure, or any such alteration is not deleterious to the application for which the microchannel article is intended. d. The salt should be soluble in water or another solvent that does not dissolve or etch the ductile structure to any significant extent. e. Any possible toxicity or other hazard of the salt or salt solution should be considered and mitigated in cases where such minimization would be prudent for safety and/or environmental purposes.
[0024] At least one tube made of an appropriate ductile structure is loaded with an appropriate salt composition. The tube may be loaded with powdered or crystalline salt grains or the inside of the tube may be coated with a layer of salt which does not necessarily completely fill the tube.
[0025] One can proceed with a bundle of salt-filled tubes. FIG. 1 shows, as an example, bundle 10 of glass tubes 12 having hexagonal outside surfaces 14 and round inside surfaces defining macro-channels 16 , the invention not being limited to those particular shapes. The macro-channels 16 contain an appropriate salt composition 18 .
[0026] Drawing, bundling, and slicing preferably proceed as taught in the published patent applications referenced above. In the drawing process, the glass tubes are heated to the softening point and fused into a monolith. The salt is melted and the melted salt fills the tube, preventing collapse and minimizing the formation of collapsed and/or misshapen microchannels. Drawing, bundling, and slicing can be repeated to produce a preform having the desired dimensions of the desired article are obtained. There are no limitations associated with dimensions of the article, including, for example, size, aspect ratio, number of channels, size of channels, and spacing of channels.
[0027] FIG. 2 shows the bundle of glass tubes after drawing and fusing into a preform 20 . The glass monolith 22 has well-formed, salt-filled microchannels 24 .
[0028] The salt composition is subsequently dissolved by a solvent and removed from the preform. The preform can be simply immersed in water to dissolve the salt, leaving behind well-preserved channels having little or no collapsing or other distortion. The water may be heated and/or agitated (by circulating, stirring or ultrasonication, for example) to further promote the dissolution and removal of the salt. The water may also be forced through the channels in cases where the salt simply coats the inside of each channel. The resulting microchannel or nanochannel glass may be rinsed by forcing water through the channels to remove any remaining salt. FIG. 3 shows an example of a microchannel glass 30 article made from a preform such as that shown in FIG. 2 . The microchannel glass article 30 comprises a glass monolith 22 which defines a plurality of microchannels 26 .
[0029] Referring to FIG. 4 , bundling can be accomplished by inserting a plurality of tubes 12 into a larger tube (sheath) 32 to form a sheathed bundle 40 . This can be especially beneficial for the final bundling step because it will generally result in an article having a thicker, more robust outer surface. Glass tubes 12 have hexagonal outside surfaces 14 and round inside surfaces defining macro-channels 16 , the invention not being limited to those particular shapes. The macro-channels 16 contain an appropriate salt composition 18 . The sheath 32 can be comprised of the same ductile structure as the tubes 12 or a different composition. Voids 42 created by shape mismatches can optionally be filled with filler rods 44 , can be comprised of the same ductile structure as the tubes 12 or a different composition.
[0030] Referring to FIG. 5 , final bundling is generally followed by fusing to produce a monolithic preform 50 . The preform 50 comprises a monolith 34 with well- formed, salt-filled microchannels 24 . FIG. 6 shows the microchannel glass article 60 after the salt has been removed. The microchannel glass article 60 comprises a glass monolith 34 which defines a plurality of microchannels 26 .
EXAMPLE I
[0031] A glass tube comprised of Schott 8330© glass (similar to Corning Pyrex©) was provided. The tube had a length of 1000 mm, an outside diameter of 25 mm, and an inside diameter of 3 mm. The tube was filled with powdered KCl and drawn at about 860° C. to form a fiber having an outside diameter of 0.7 mm.
[0032] The fiber was cut into 650 mm lengths, bundled into a hexagonal bundle, and drawn again at 870° C. to form a second fiber having an outside diameter of 0.7 mm. The second fiber was cut into 200 mm lengths, bundled into a Shott 8330© tube (sheath) having a length of 600 mm, an outside diameter of 24.5 mm, and an inside diameter of 22 mm, and heated at 700° C. under vacuum to fuse the bundled tubes and sheath together to form a fused bundle.
[0033] The fused bundle was allowed to cool and cut transversely to the drawing direction into to form a plurality of preforms of various lengths ranging from 0.1 cm to 5 cm. The preforms were immersed in distilled water to dissolve the salt, rinsed by forcing water through the channels, and dried to form microchannel glass.
EXAMPLE II
[0034] Microchannel glass was made in accordance with Example I with the exception that the salt composition comprised NaCl and KCl such that the ratio of Na to K was the same as that of the glass composition.
[0035] Using the method of the present invention, many advantages and benefits can be realized, including but not limited to the following:
[0036] 1. Microchannel and/or nanochannel glass may be produced from commercial off the shelf materials, minimizing costs.
[0037] 2. The glass composition can be a chemically durable, lead free glass for which a matching, easily etched glass is not commercially available.
[0038] 3. The aspect ratio of the microchannels or nanochannels can be much higher because the dissolution rate of the salt can be high and the contrast in dissolution rate of the salt and glass can be extremely high.
[0039] 4. The preferred dissolution process utilizes water, a non-hazardous solvent, instead of hazardous acid required by prior methods. Moreover, the process generates a non-hazardous salt solution that can be recycled and reused.
[0040] 5. The use of salt in accordance with the present invention is feasible at high temperatures that would be pernicious to organic filler materials.
[0041] Microchannel and nanochannel glass have many applications including detectors, filters, catalyst supports.
[0042] While there has been shown and described what are at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications can be prepared therein without departing from the scope of the inventions defined by the appended claims.
|
A method of making an article having channels therethrough includes the steps of: providing a ductile structure defining at least one macro-channel, the macro-channel containing a salt; drawing the ductile structure in the axial direction of the at least one macro-channel to reduce diameter of the macro-channel; and contacting the salt with a solvent to dissolve the salt to produce an article having at least one microchannel.
| 2
|
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/475,109, filed on Jun. 2, 2003, the entire teachings of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the field of usage rights enforcement and management for digitally encoded documents and data.
[0003] The encoding and distributing of audio, video, graphical, and written work in digital formats has become a fundamental part of modern business. However, the ease with which copies may be made that are identical to the original and the speed of distribution enabled by the Internet have caused the owners of such works to adopt technologies that associate and enforce usage rights with digitally encoded data. Examples of those interested in such technologies include: providers of music, movies, or other entertainment content; publishers of electronic newspapers, magazines, or books; and corporations with confidential, proprietary, or otherwise sensitive information. Without loss of generality and for ease of exposition, we will refer to all of these kinds of digitally encoded works as data objects.
[0004] Many approaches exist to associate and enforce usage rights with data objects. One common approach is based on technologies that attempt to prevent the unauthorized copying of data objects from the physical media carrying the objects. U.S. Pat. No. 5,513,260 is an example of one such copy protection scheme.
[0005] Though copy-protection techniques are appropriate for some domains, the types of usage rights that they can enforce are too coarse grained to be a general solution. For example, the owner of a proprietary and confidential document may wish to have one group of individuals be able to only read a protected document and a different group be allowed to read and write it. Copy-prevention technologies are not powerful enough to describe such usage policies.
[0006] More general-purpose approaches exist that protect the data objects so that only authorized users can access and use the objects according to a set of rules specified for each class or group of authorized user. This approach typically relies on encryption technology to guarantee that only authorized users have access to the actual data object. In particular, authorized users are given access to the secret key needed to decrypt the protected object and produce the actual data object. The usage rights typically specify who is authorized to access the secret key and what an authorized user can do with the decrypted data object. This basic approach includes the large body of work in digital rights management (DRM) and related rights management technologies. Though this approach does not prevent copying of the encrypted bits, it achieves the same end result as copy protection since unauthorized users cannot access the protected data objects without the secret key.
[0007] To be effective, a rights management system must tightly couple the usage rights to the encrypted data objects so that the usage rights always appear with the associated object. This coupling should make it very difficult and ideally impossible for someone, who is not the owner of the object or otherwise authorized, to separate the data object from its usage rights.
[0008] We can group attacks that attempt to separate a data object from its usage rights into two categories. The first category comprises attacks on the combination of the usage rights and encrypted data object. Replacing the usage rights of one file with the usage rights of another is an example of an attack in this category. The second category comprises attacks undertaken while the data object is decrypted and being used by an authorized user. The goal here is to obtain an unprotected copy of the decrypted data object by directly circumventing the usage rights. To be effective, a rights management system must contain mechanisms that protect against both categories of attack.
[0009] The second category of attacks highlights the fact that the encrypted data object must eventually be decrypted in order to be accessed by an authorized user. A rights management system may either allow the user to decrypt the data object directly, or it may require the deployment and use of rights-management-aware applications. In many commercial situations, the owner of the protected data object may not want to bother the end user with an explicit encryption and decryption step or may not trust the end user to abide by the usage rights. Thus, the preferred method is to employ rights-management-aware applications that transparently decrypt the data objects for authorized users and enforce the usage rules attached to the objects. Rights-management-aware applications act as trusted agents for the rights management system, enforcing the rules specified by the owners of the protected data objects. Media players that can play music files in encrypted formats are examples of rights-management-aware applications.
[0010] The closeness of the coupling and the reliance on trusted application agents constitute the fundamental differences between rights management systems and technologies like encrypting file systems. In an encrypting file system (e.g., Microsoft's EFS, U.S. Pat. No. 6,249,866), usage rights are associated only with the computer structure holding the data object (e.g., a file) and not with the data object itself. Since applications are not aware of the usage rights enforced by an encrypting file system, it is fairly simple for a user, who is authorized to access the object but not to change its usage rights, to save the data object in a manner that does not propagate the rights. In particular, an authorized user of a protected file in an encrypting file system needs only to save the file to a directory outside the encrypting file system to create an unencumbered copy of the protected file.
[0011] The use of rights-management-aware applications allows a rights management system to enforce a tight coupling between an encrypted data object and its associated usage rights. Some designers have chosen to implement this tight coupling by storing the usage rights together with the encrypted data object, producing a new data object that is often referred to as a secure container (e.g., see U.S. Pat. No. 6,427,140). In this approach, usage rights are explicitly tied to a particular copy of the protected data object. This approach works well, for example, in commercial markets like online music where the owner of the data object publishes read-only content and simply wants to maintain control over the usage and distribution of the content. We refer to such rights management systems as supporting publish-only distribution models.
[0012] A key characteristic of the publish-only distribution model is that the usage rights in the secure container are not expected to change over time. Or if they do change, they change slowly, and the change affects only one end user at a time. To change the usage rights in the publish-only distribution model, the owner must have access to the secure container holding the usage rights. Access to the secure container would enable the rights management system to modify the usage rights stored in the container. If the secure container was not available, the owner can remove the end user's authorization to access the original secure container (e.g., by destroying the decryption key for this container) and re-issue a new secure container to the end user with the same protected data object but new usage rights. This latter approach requires the rights management system to notify the end user of the new secure container, and it requires that the rights management system has a copy of the data object to put into the new secure container.
[0013] Though these requirements are not an imposition in a domain like online music, they are a serious impediment to dynamic environments, i.e., ones where the usage rights protecting data objects may change frequently and in possibly significant ways. These requirements are also a serious impediment to distributed environments, where multiple users may have individual copies of a protected data object on diverse computer devices and storage media, some of which may not be online or otherwise accessible to the owner of the protected object. Clearly, it is not possible in such environments for the rights management system to have access to all of the copies of the protected object when the owner wishes to make a change to the usage rights of that protected object. It is also not desirable to re-issue a new protected data object to a group of users, since the change in usage rights may affect only a few users and should be unnoticed (transparent) to the rest. Furthermore, it may not even be possible to re-issue the protected data object in a distributed environment where the owner controls the usage rights but does not have a copy of the latest version of the object.
[0014] In a truly collaborative environment, it's often difficult and sometimes impossible to identify a single “publisher” of collaborative material. For corporate data, it is possible however to identify the “owner” of collaborative material produced for the purposes of a corporation's business. The owner is the company that employs the author or authors of the collaborative works. For collaborative environments then, there is a clear need to distinguish between those who produce sensitive material and those that determine the usage rights of the same material.
[0015] Authentica has patented a partial solution to the enforcement and management of usage rights for digital data objects in dynamic and distributed environments (U.S. Pat. No. 6,449,721). This approach allows the owner of a digital data object to maintain control over the usage rights even after the protected objects have been distributed to end users. In particular, the approach stores the usage rights of protected objects in a single, central location so that an owner of a protected data object can change the usage rights of that object without requiring simultaneous access to any of the (possibly numerous) copies of the data object. Ideally, this approach allows multiple, distributed copies of the data object to exist while maintaining only a single, authoritative copy of the object's usage rights. Having a single, authoritative copy of the object's usage rights simplifies management of the usage rights.
[0016] Authentica's approach creates a unique identifier for each segment of protected information. The Authentica key server maintains an association between unique segment identifiers, the usage rights for those segments, and the encryption keys used to protect and access each segment. To access a protected segment, an end user must authenticate to the server and provide the identifier of the protected segment he or she wishes to access. Assuming that the user is authorized to access the protected segment, the server responds with a decryption key for that segment and the usage rights for that segment and user combination. A rights-management-aware application on the end-user's machine uses the server's response to provide the end user with the owner-designated level of access to the protected segment.
[0017] Though an approach like Authentica's allows the owners of protected data objects to control usage of distributed information and dynamically change that usage information without the need to collect or redistribute the protected data objects, it is not a complete solution to the problems associated with the enforcement and management of usage rights in collaborative environments. In particular, a solution for collaborative environments needs to focus on protecting the products of collaboration in a manner that fits naturally into existing collaborative models. For example, in commercial enterprises, collaboration often produces multiple documents all protected by the same usage rights, and thus a truly collaborative solution should allow for the easy grouping of multiple documents under a single set of usage rights. In addition, it is also often expected that derivative works created during collaboration would also be protected by the usage rights of the collaboration and that changes to these rights would coincide with existing processes for moving a work into a new collaborative setting. Finally, all of the current rights management systems, especially those focused on publish-only distribution models, too tightly control the creation, modification, and distribution of protected documents to be appropriate for protecting the data objects comprising collaborative interactions. An appropriate solution should clearly distinguish between the rights held by “authors” and those held by “owners.”
SUMMARY OF THE INVENTION
[0018] Various technologies and inventions in this field, including models of discretionary, mandatory, or role-based access control, and DRM (Digital Rights Management) related technologies have addressed one or another of the requirements mentioned above. The embodiments of the present invention, however, offer a unique approach that addresses all of the necessary features for a rights management system targeting dynamic, distributed, collaborative contexts.
[0019] Aspects of the invention include a method and a system for maintaining and managing control over data objects authored, accessed, and altered by users in dynamic, distributed, and collaborative contexts.
[0020] A data object is any audio, graphical, video, or written work encoded in digital form and encapsulated in a computer structure, such as a file, message, or shared memory object, that a software program can access and manipulate.
[0021] A distributed and collaborative context is one in which groups of one or more users work individually or collaboratively on collections of one or more data objects on a network of computers with at least intermittent connectivity to achieve some common purpose. In the present invention, we refer to this common purpose as a business process.
[0022] Within a business process, there can be classes of users with different sets of rights and responsibilities. In the present invention, we refer to these classes as roles.
[0023] The present invention considers a context to be dynamic if properties of the system can change during the lifetime of a business process. For example, the system might allow the set of users belonging to a role to change during a business process, or it might allow the type of control imposed on a data object to change. The invention separates the publication and modification of protected data objects from the ownership and manipulation of the policies controlling the usage of those data objects.
[0024] Control over a data object is specified by a set of rules describing how software programs run by a computer user in a particular role may access and manipulate the object. In the present invention, we refer to these rules as usage rights.
[0025] Control policies are signed assertions that describe the conditions under which usage rights are authorized. A control policy comprises at least a list of users who may access the data object, the privileges of those users with access, and an additional list of users who may define or edit the control policy. Policies in the present invention may also define supplemental properties that apply to the objects under its control, to assure authenticity, integrity, and confidentiality of those objects.
[0026] As stated in the previous paragraph, the term ‘control’ as used in the present invention typically implies protection against access by unauthorized users and their applications.
[0027] A further objective of the present invention is to provide a system and method for obtaining visibility into a business process. Such visibility may be achieved without committing to the risks of securing data objects by encrypting or otherwise changing the actual digital representation of their data objects. When control does not include protection, we obviously cannot ensure that we maintain control against malicious adversaries, i.e. ones that manipulate the protected data objects outside of our protected environment. However, this level of control is still desirable in business situations where an enterprise might want visibility into a business process while their data objects remain in plain text.
[0028] A further objective of the present invention is to provide a method and system for storing control policies on one or more central servers.
[0029] A further objective of the present invention is to provide a method and system for editing control policies, based on an indication of the users that may edit the control policies and the types of changes that those users can perform. Changes to a control policy would be enacted on the server storing that control policy.
[0030] A further objective of the present invention is to provide a method and system for temporarily changing one or more control policies and then reverting back automatically to the original settings at some point in the future.
[0031] A further objective of the present invention is to provide a method and system for having one or more preset temporary changes that can be enacted by the click of one button and then rolled back on the click of another button.
[0032] A further objective of the present invention is to provide a method and system for attaching to each data object an identification of one (i.e., a respective) control policy. In the present invention, we refer to the control policy whose identification is attached to a data object as the control policy protecting that data object. We also refer to such a data object as a protected data object.
[0033] A further objective of the present invention is to allow multiple data objects to reference the same control policy.
[0034] A further objective of the present invention is to provide a method and system wherein the identification of a control policy specifies the server in whose name space the actual control policy identifier is defined. In the preferred embodiment, the policy reference attached to a data object comprises a server URL and a numerical value known to that server.
[0035] A further objective of the present invention is to provide a method and system for checking by a client connected possibly intermittently to a policy server that a user attempting to create, access, or alter a data object protected by a control policy has the right to perform that action on that data object. If the user has the right, the client allows the requested action to proceed. If the user does not have the right, the client responds with an appropriate error message. In other words, the protection provided by the business process approach does not just protect proprietary, confidential, or otherwise sensitive data objects while they're stored on disk or transmitted over a communication link, but it also protects them while they are operated on by the software applications of authorized users and during inter-application communication (e.g., clipboard operations in the Microsoft Windows operating system).
[0036] A further objective of the present invention is to provide a method and system with control policies that may contain conditions that specify device, location, time-of-access, or network connectivity constraints.
[0037] A further objective of the present invention is to provide a method and system wherein users authorized to edit a control policy can change that policy without physical or electronic access to all data objects protected by the policy.
[0038] A further objective of the present invention is to provide a method and system allowing the only authoritative copy (or copies) of a protected data object to be located on computing machines or media of users without the rights to change the control policy protecting the data object.
[0039] In one embodiment of the invention, there is no notion of registering a protected data object with the policy server before distributing it to other users. This is a key aspect of the system required to support collaborative work that involves creation and modification of data objects on machines of authorized users that may be off-line.
[0040] A further objective of the present invention is to provide a method and system for allowing authorized users to create new protected data objects even when the client that they are working on has lost connectivity with the server of the specified control policy. Authorized users in this circumstance are those users that have the right to create data objects under the control policy. In the preferred embodiment, the user must have had some recent access to the policy server, where “recent” means within the cache timeout period as specified for that policy.
[0041] A further objective of the present invention is to provide a method and system for two or more authorized users to view protected data objects and work collaboratively on new and existing protected data objects even when one or more of these users' clients may have lost connectivity with the server (or servers) of the control policies protecting the collaborative data objects. The protected data objects may never have been viewed while connected to the server (or servers). The shared data objects may be new, that is, created while the users did not have connectivity with the server.
[0042] A further objective of the present invention is to provide a method and system in which the storage of the policy server scales in proportion to the number of control policies defined. The storage should not scale in proportion to the number of unique protected data objects nor with the number of copies of these protected data objects.
[0043] A further objective of the present invention is to provide a method and system for grouping control policies into business processes.
[0044] A further objective of the present invention is to provide a method and system for constructing a control policy by identifying one or more roles involved in that control policy. Each role comprises a respective set of usage rights and a list of users.
[0045] A further objective of the present invention is to provide a method and system for aggregating the usage rights of a user appearing in multiple roles contained in a single control policy.
[0046] A further objective of the present invention is to provide a method and system for differentiating between users with the privilege to administer (create, edit, and delete) business processes and their encompassing control policies from those users with the privilege to modify only the list of users in one or more roles of a control policy.
[0047] A further objective of the present invention is to provide a method and system in which the identification of a control policy on a data object can change. This change might cause the data object to be no longer managed by the system.
[0048] A further objective of the present invention is to provide a method and system allowing users with appropriate usage rights to change the control policy identifications on data objects. A user may be granted the right to unprotect data objects by changing the objects control policy identifier to “unmanaged” or equivalent status.
[0049] A further objective of the present invention is to provide a method and system with control policies that further define a list of users who may transfer data objects out of the control policy and a separate list of users who may assign the policy to data objects. Both of these actions involve changing the control policy identifier attached to a data object. There may be times when these lists contain no users.
[0050] A further objective of the present invention is to provide a method and system for automating the transfer of data objects between control policies for those users with the privilege to do the transfer and assign manually. The preferred embodiment of this aspect involves integrating a tool into the software component of an existing electronic business process.
[0051] A further objective of the present invention is to provide a method and system for allowing the administrators of business processes to determine the events that cause the automatic transfer of data objects between control policies.
[0052] A further objective of the present invention is to provide a method and system for organizing business processes in a hierarchical manner. Such a hierarchy may be used to limit the scope of transfers of data objects between control policies. It may also be used to define control policies or other properties that are common to several business processes in a single location.
[0053] A further objective of the present invention is to provide a method and system (e.g., graphical user interface) for displaying and changing the control policy of a protected data object. In one embodiment this is implemented as a drop-down window located in the title bar of the window displaying the data object. This drop-down window is referred to as the droplet control. When a user clicks on the droplet control, a window may open up with several policies and options for selection by the user.
[0054] A further objective of the present invention is to provide a method and system for displaying the list of possible control policies that a user can transfer the current data object to when the user activates the droplet control.
[0055] A further objective of the present invention is to provide a method and system for changing a data object's control policy when a user selects a new control policy in the activated droplet control window of the data object.
[0056] A further objective of the present invention is to provide a method and system for illustrating the hierarchy of control policies within business processes within an activated droplet control window.
[0057] A further objective of the present invention is to provide a method and system for encrypting data objects with a content encryption key (CEK), which is then encrypted with a key encryption key (KEK) of the control policy associated with the data object.
[0058] A further objective of the present invention is to provide a method and system for indicating whether the data objects protected by a control policy should be treated as ephemeral or permanent objects. An ephemeral data object is accessible until some designated future time; after that time, the object becomes inaccessible and unrecoverable. A permanent data object is always accessible or recoverable when presented to the rights management system or its agents.
[0059] A further objective of the present invention is to provide a method and system for forcing all data objects protected by a control policy to become inaccessible and unrecoverable before the designated future time. The business process's administrator can permanently revoke access earlier than planned.
[0060] A further objective of the present invention is to provide a method and system for recording the control policy identifier in a data structure stored with the (possibly encrypted) bits of the protected data object. In the preferred embodiment, we refer to this data structure as the Control Policy Tag (CPT).
[0061] A further objective of the present invention is to provide a method and system for attaching the CPT to the beginning or end of the protected data object.
[0062] A further objective of the present invention is to provide a method and system for constructing the CPT of a protected data object on either a client or a server machine.
[0063] A further objective of the present invention is to provide a method and system for storing the CEK safely in the CPT. The client can access protected data objects off-line with only cached policy and key (KEK) information because the CPT contains the CEK.
[0064] A further objective of the present invention is to provide a method and system for automatically replacing an expired CPT on a protected data object. Expiration of a CPT may occur because the CPT format has changed or the control policy KEK for the CPT has expired (i.e., gone beyond its validity period).
[0065] A further objective of the present invention is to provide a method and system where the trustworthy clients of the rights management system do not need code to interpret old CPT formats.
[0066] A further objective of the present invention is to provide a method and system for indicating that a control policy protects data objects that are read-only or stored on read-only computer media.
[0067] A further objective of the present invention is to provide a method and system for informing an unauthorized user of the system protecting the data object accessed. The preferred embodiment includes a text message in the CPT.
[0068] A further objective of the present invention is to provide a method and system for protecting the integrity of the CPT against tampering. The preferred embodiment uses a secure hash over the CPT fields.
[0069] A further objective of the present invention is to provide a method and system for protecting the confidentiality of a data object's CEK while stored in the CPT. The preferred embodiment encrypts the CEK with the control policy's KEK. The encrypted CEK is protected against known plaintext attacks (i.e. attacks based on the knowledge of identical pieces of two similar documents) by using random seed values and changing the CEK whenever the data object is changed.
[0070] A further objective of the present invention is to provide a method and system for protecting the server and client communication against network-based attacks. The preferred embodiment uses a Hypertext Transfer Protocol over Secure Socket Layer (HTTPS) connection for communications between the client and server.
[0071] A further objective of the present invention is to provide a method and system for enabling an audit or forensic analysis of a business process based on activities granted and denied within one or more of the control policies of that business process.
[0072] A further objective of the present invention is to provide a method and system for identifying the data objects in an activity log based on unique document identifiers maintained in the CPT.
[0073] A further objective of the present invention is to provide a method and system for allowing the client to access the server at user login time to obtain and cache the control policies in which the user is mentioned. This feature addresses issues arising in collaborative and distributed environments, including intermittent connectivity, off-line usage of protected data objects, and off-line collaboration with others mentioned in the control policy.
[0074] A further objective of the present invention is to provide a method and system for varying the polling frequency at which clients verify cached policies with the server. The frequency may be set so that the client must always verify the cache policy before permitting access.
[0075] A further objective of the present invention is to provide a method and system for having clients verify and refresh cached policies when network access is restored.
[0076] A further objective of the present invention is to provide a method and system for the server to prompt clients to refresh their cached policies.
[0077] A further objective of the present invention is to provide a method and system for specifying the expiration time of a cached control policy.
[0078] A further objective of the present invention is to provide a method and system for specifying the validity period of the KEK of a control policy.
[0079] A further objective of the present invention is to provide a method and system for allowing the server to supply a client with a limited history of KEKs for a control policy. The use of an expired policy KEK in a protected data object does not force the client to have to contact the server before accessing the object. Even though a user never accesses a protected data object while online, as long as his or her off-line access occurs within the cache timeout period of the control policy of the data object, the user will not be denied access due to an out-of-date KEK.
BRIEF DESCRIPTION OF THE DRAWINGS
[0080] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0081] FIG. 1 is a schematic diagram of an organization structure for rights management policies;
[0082] FIGS. 2-5 are illustrations of various applications of business processes and control policies;
[0083] FIG. 6 is an architectural block diagram of main components of one embodiment of the invention;
[0084] FIG. 7 is a flow diagram describing logic of policy administration;
[0085] FIG. 8 is a schematic illustration of a control policy tag;
[0086] FIG. 9 is a flow diagram of accessing a protected data object;
[0087] FIG. 10 is an architectural block diagram of the client agent in another embodiment of the present invention;
[0088] FIG. 11 is a flow diagram of client handler processing;
[0089] FIG. 12 is an illustration of key encryption, key distribution and expiry;
[0090] FIG. 13 is a second flow diagram of accessing a protected data object;
[0091] FIG. 14 is a third flow diagram of accessing a protected data object;
[0092] FIG. 15 is an illustration of control policy display;
[0093] FIG. 16 is a flow diagram of policy transfer logic;
[0094] FIG. 17 is a flow diagram of off-line collaboration between two users.
DETAILED DESCRIPTION OF THE INVENTION
[0095] A description of preferred embodiments of the invention follows.
[0096] The present invention starts with centralized management of usage rights organized in a structure that mirrors the important processes of the business. FIG. 1 illustrates the organizing structure 10 for policies employed in one embodiment of the present invention. A business process 12 represents progressively continuing procedures based on controlled phases or activities that are systematically directed at achieving specific business results. Business processes 12 within the hierarchical organizing structure 10 act as containers that hold one or more control policies 14 . A control policy 14 specifies usage rules that govern how the protected data objects may be used and by whom. Policies typically represent the phases or activities within a business process and are flexible enough to support data classifications (e.g. company confidential, executive only, etc.). Each protected data object (illustrated as a document) is associated with and under the control of a single control policy 14 within a business process 12 . Each control policy 14 specifies one or more roles 16 . A role 16 describes the set of users (or groups) and their privileges on the data managed by a policy 14 .
[0097] Using the organizing structure 10 in FIG. 1 , the following embodiment of the present invention will allow an organization to retain control of usage and flow of its data objects in a manner that separates rights management actions from physical access to the copies of data objects. For example, assume that we are given a set of data objects, all of which are protected by a single control policy; note that this set may contain only a single data object. The invention and its preferred embodiments guarantee that changes to the control policy will be propagated to end users and ultimately experienced by those users when they next access the data objects protected by that changed policy. This guarantee holds even though access by the owner of the protected data objects to any or all copies of those objects may be impractical or impossible at the time of the change.
[0098] The preferred embodiments will illustrate how the present invention supports the transparent use of protected data objects in a dynamic, distributed, and collaborative environment, where multiple users are modifying individual copies of protected data objects on diverse computer devices and storage media, some of which may not be online or otherwise accessible to the owner of the protected data objects. The discussion will clearly show that the invention supports the distinction between an information author and owner. It will also illustrate that the invention includes protections against adversaries that would try to attack the association between policies and data objects.
[0099] As an example of a dynamic, distributed, collaborative environment where we need to protect data objects while simultaneously providing the ability to create, modify, and distribute these protected data objects within the constrains of a policy model, consider a company that wishes to control and protect data objects in compliance with NASD 2711, a regulation that requires a clear and auditable separation of information between the bankers and research analysts in investment banks. FIGS. 2-5 enumerate hypothetical steps in such a dynamic, distributed, and collaborative process.
[0100] The “NASD 2711” business process 150 comprises three control policies 14 : “Background Research” 152 ( FIG. 2 ); “Industry Review” 154 ( FIGS. 3 and 4 ); and “Publish” 156 ( FIG. 5 ). The “VP Compliance” owns the business process and administers all aspects of it. For the “Background Research” policy 152 in FIG. 2 , she creates two roles: “Analyst” and “Director”. Each person listed in the “Analyst” role is able to create, read, and write reports within the “Background Research” policy. Each person listed in the “Director” role can read (but not write) the report and transfer a copy of such reports to the “Industry Review” policy 154 .
[0101] The example illustrated in FIG. 2 describes the creation of an analyst report for “Big Motor Co.”, which is protected and controlled by the “NASD 2711” business process 150 . As the figure illustrates, analysts can draft and collaborate on reports (a data object) in this policy 152 , and when they have completed a report, they can forward it to the “Director of Research”, who is a member of the “Director” role, for review and ultimately transfer to compliance. Individuals not listed in one of the roles under the “Background Research” policy 152 are unable to access the reports protected by this policy.
[0102] FIG. 3 describes the first part of the dynamic “Industry Review” piece 154 of this business process 150 . “Industry Review” comprises a policy with three roles: the “Director” role can read protected data objects in this policy 154 and transfer data objects into the policy 154 ; the “Compliance” role can read the protected data objects, transfer copies of data objects to the “Publish” policy 156 ( FIG. 5 ), and administer membership in the “External Reviewer” role; and the “External Reviewer” role can edit the protected data objects. When the “VP Compliance”, who is a member of the “Compliance” role, receives a protected data object from the “Director of Research”, who is a member of the “Director” role of the “Industry Review” policy 154 , the “VP Compliance” edits the membership of the “External Reviewer” role to allow the “BMCo CFO” and the “Automotive I-Banker” to review and edit the protected analyst report. When the members of the “External Reviewer” role are done with their collaborative interaction, they will send the updated data object back to the “VP Compliance”. The “VP Compliance” can now remove the “BMCo CFO” and the “Automotive I-Banker” from the membership of the “External Reviewer” role (and thus from the “Industry Review” policy 154 ) so that they are no longer able to view reports (subject data object) protected under the “Industry Review” policy, as illustrated in FIG. 4 . Such removal illustrates one aspect of the dynamic nature of the present invention.
[0103] FIG. 5 completes the progression of the analyst report through the phases of a Big Motor Co. analyst review constrained by the “NASD 2711” business process 150 . FIG. 5 illustrates the three roles within the “Publish” policy 156 , all of which can read but not write the protected data objects. In addition, the “Compliance” role can transfer data objects into the policy 156 , and the “Director” role can administer membership in the “Reader” role. When the “VP Compliance” in the “Compliance” role transfers a copy of an analyst's report to the “Publish” policy 156 , the “Director of Research” in the “Director” role adds the necessary parties (e.g., the sales group and the BMCo CFO) to the “Reader” role and makes the protected analyst report available to the outside world.
[0104] The block diagram in FIG. 6 illustrates the main architectural components of an embodiment of the present invention and the primary interactions between these architectural components. A user 20 uses a rights-management-aware application 21 to operate on a protected data object 32 . The protected data object 32 comprises an encrypted data object 22 and a tag 23 . In some embodiments, the data object 32 may not be encrypted.
[0105] The reference monitor 24 in the client agent 26 intercepts operation requests on the data of the protected data object 32 by the rights-management-aware application 21 . This monitor uses the tag 23 on the protected data object 32 to obtain the usage rights in the policy protecting this data object 22 for the user 20 . The client agent 26 may have to communicate with the policy manager 27 on the policy server 29 to obtain the details of the control policy identified by the tag 23 . Assuming the user 20 has the right to perform the requested operation, the crypto engine 25 in the client agent 26 will perform the appropriate encryption operation for the requested operation on the data object 22 . The encryption key required to perform this operation was originally obtained from the key manager 28 on the policy server 29 as part of control policy request and reply actions.
[0106] The control policies stored on the policy server 29 may be created and edited by an appropriately authorized user 30 using a policy administration application 31 , which interacts with the policy manager 27 on the policy server 29 .
[0107] A particular embodiment may use multiple policy servers. Multiple servers may be used for the purpose of improved reliability or load balancing.
[0108] In a particular embodiment, the client agent 26 may have only intermittent connectivity with the policy server 29 . Though the invention supports the propagation of modified usage rights to the copies of the effected data objects in a timely manner, the definition of “timely” is set by the users 30 authorized to manage policies. For example, in some commercial situations, timely might mean that all accesses to a data object after modification of its usage rights would be governed by the new rights. In other situations where the commercial environment calls for limited “off-line” access to protected data objects, timely might mean that the usage rights are updated once the local agent for the rights management system comes back online.
[heading-0109] Rights-management-aware Applications
[0110] The client application 21 in FIG. 6 is described as a rights-management-aware application that cooperates with the client agent 26 of the rights management system to enforce the policies stored on the policy server 29 . There exist numerous methods for creating such a rights-management-aware application. We might code the application 21 to interact directly with the client agent 26 . Alternatively, we might code an application 21 to load and use a set of rights management libraries with standard interfaces. We would then implement a version of these rights management libraries that would manage all interactions with the client agent 26 . Finally, the system on which the application 21 runs might inject the client agent 26 into applications to create rights-management-aware applications, as described in U.S. patent application Ser. No. 10/194,655, filed on Jul. 11, 2002 by Bala and Smith, entitled “METHOD FOR PROTECTING DIGITAL CONTENT FROM UNAUTHORIZED USE BY AUTOMATICALLY AND DYNAMICALLY INTEGRATING A CONTENT-PROTECTION AGENT” herein incorporated by reference.
[0111] In general, client-centric processing based on reference monitoring, as illustrated in FIG. 6 , enables applications to become trusted agents of the rights management system and thus provide for local enforcement of the specified usage rights, even when the client machines are disconnected from the rest of the rights management system. Embodiments employing dynamic injection enable existing as well as new applications to become immediate participants in the rights management system.
[heading-0112] Policies and Policy Administration
[0113] In the embodiment explained below, a control policy 14 comprises at least a list of the users authorized to access the data objects protected by that policy, a digest of the privileges granted to each user in the authorization list, a current Key Encryption Key (KEK), and a unique identifier (i.e., the Policy ID used in tags 23 ). Control policies 14 may also contain conditions on those privileges; these conditions may specify additional device, location, time-of-access, or network-connectivity constraints.
[0114] The present invention differentiates between the set of users 20 authorized to access data objects protected by a policy (mentioned above) and the set of users 30 to administer (i.e. create, edit, and delete) control policies and the encompassing business processes. Notice that a user might be a member of both sets of users 20 , 30 .
[0115] To better address business process needs of enterprises, the preferred embodiment supports three explicit types of administrative users: information technology (IT) administrators; business process owners; and business role administrators. IT administrators are those users that have administrative access to the policy server 29 in FIG. 6 . Their task is to maintain the computing infrastructure required by the policy server; the IT administrators are not needed to perform the business-related administrative aspects of policy management. A business process owner is a user with the right to administer a specified business process. A business process owner may edit all aspects of the control policies 14 within the owned business process, but he or she cannot modify other business processes (unless the user is also the business process owner of those other business processes as well). A business role administrator is a user that may modify the user lists within the roles of a specified control policy 14 . A business role administrator has a subset of the privileges granted to the business process owner of the business process in which the business role administrator is named.
[0116] To facilitate further categorization of an enterprise's business processes and directly reflect the hierarchical nature of business process management, one preferred embodiment supports the organizing of defined business processes in a hierarchical manner. For example, consider a collection of business processes that are organized as a tree. The business process at the root of the tree represents the topmost context, and the business processes at the leaves of the tree are the individual components of the business process at the root. Additional interior tree nodes may be used to represent major categories within the overall business process.
[0117] Such a hierarchy organized as a tree may be used to indicate the user or users that are able to administer all of the business processes within a subtree of the hierarchy. Similarly, the indicated users might be able to administer only the roles within that subtree.
[0118] FIG. 7 describes the logic of the policy administration application 31 in FIG. 6 . The process begins in step 40 with a user starting the policy administration application 31 and connecting to a policy server 29 . In one embodiment, the policy administration application 31 is a J2EE web application. At step 41 , the system verifies that the user is an authorized administrator, identifies the type of administrator that the user is, and determines the types of operations that the user can perform on the policy database. If the user is not authorized to perform any actions or even view the database, an error message is displayed in Step 42 . Step 43 presents a view of the business processes, their control policies, and associated roles that the authorized user can administer; the view depends upon the rights of the authorized user. Step 43 then waits for the user to select an action that modifies the database of business processes.
[0119] An authorized user may choose to create or edit a business process, control policy 14 , or role list, as illustrated in step 44 . All changes performed by the user are logged and committed in step 46 . The changes are then displayed to the user in Step 43 .
[0120] By logging the changes, the system may allow authorized users to undo an earlier change to the database on the policy server 29 . In particular, Step 43 also allows the user to rollback a set of committed changes, as illustrated in step 45 . This action is also logged and committed in step 46 . Steps 43 through 46 are repeated until the user exits the policy administration application 31 . All of these steps can occur without any access to or knowledge of the exact data objects protected by the changed business processes and policies on the policy server 29 .
[heading-0121] Security Knob
[0122] One preferred embodiment of the invention uses the rollback feature mentioned above to implement a one-click security setting that can be enabled or disabled in a dynamic manner. We colloquially call the one-click security setting the security knob.
[0123] In the simplest case, consider a business process with two security alert states: normal and lock-down. “Normal” is the default security state; the enterprise proceeds without any special considerations beyond the policies enforced in the normal day-to-day workflow of this business process. The security officers and business process owners have together also defined a set of changes to this business process that should go into effect whenever the business process is “under attack” or otherwise vulnerable (e.g., vulnerable to an identified and determined adversary, or vulnerable to potential violations of a governmental regulation during some critical time period). When applied to the appropriate pieces of the business process, these set of changes comprise the “lock-down” security state.
[0124] A key aspect of this feature is that an enterprise or business process owner may want to enter this “lock-down” security state quickly and only for a temporary time period. Once the threat or vulnerability has passed, the system should revert to the policy characteristics defined for the “normal” security state. It would be too slow, error-prone, and tedious to edit each of the pieces of a business process every time the enterprise or business process owner wanted to enter or exit the “lock-down” security state.
[0125] To implement this capability, one embodiment would create a set of log events that would automatically be applied when the security knob was set to a pre-defined setting. The log events for the “lock-down” security state described above could be captured by simply having the authorized administrator perform the changes to the current business process (i.e. “normal” security state), having the system log and store those changes under the appropriate security setting identifier (i.e., “lock-down”), and not having those changes actually applied to the database at the time of definition. The log events for the transition from “lock-down” to “normal” are simply those used to revert from the “lock-down” change.
[0126] To keep the security setting coherent, the system would ask the user if he or she also wanted to change, for example, the “lock-down” security state while the authorized user was making changes to the business process under the “normal” security state.
[0127] Those of ordinary skill in the art should recognize the methods of extending this two-setting security knob example and implementation to one that implements an n-setting security knob, for any specific n greater than 2.
[heading-0128] Policy Deletion
[0129] Since the system does not have access to all of the data objects 32 protected by a control policy 14 when that policy is modified, we must be careful when “deleting” a control policy. First, we cannot reuse a control policy identifier from a “deleted” control policy for a new policy, since any data object 32 protected by the “deleted” policy would then appear to be part of the new control policy. We might also want some privileged user to be able to recover data objects from “deleted” control policies.
[0130] In the preferred embodiment, we use a globally unique identifier (GUID) as the identifier on a control policy 14 , ensuring that no two control policies 14 ever get the same identifier. When an authorized administrative user deletes a control policy, the system removes the control policy from the system (possibly logging the action and the deleted information) so that data objects protected by the “deleted” control policy will appear as data objects that users are not authorized to access. Recovering a protected data object is handled through the “disaster recovery” mechanism described later.
[heading-0131] Encryption and the Control Policy Tag (CPT)
[0132] To ensure continuous protection of and control over a data object 22 , a preferred embodiment of the current invention encrypts the data object 22 when it is not being accessed by rights-management-aware application. To each encrypted data object 22 , the system attaches a Control Policy Tag (CPT). FIG. 8 is an abstract representation of the control policy tag 23 of the protected data object 32 in FIG. 6 . The CPT contains the content encryption key (CEK) used to encrypt the data object 22 . (We describe all of the fields of the CPT below.) The CPT is also the mechanism by which policies in the rights management system are associated with data objects. The combination of an encrypted (or encryptable) data object 22 and its CPT is called a protected data object 32 .
[0133] For each data object 22 , the rights management system generates a pseudo-random number that it uses as a symmetric key for encrypting and decrypting the data object 22 . This process effectively produces a unique CEK for each data object. The control policy tag 23 in FIG. 8 is a data structure with fields that provide identity information, encryption information, and integrity information. Though the fields may appear in any order, a client agent 26 must always be able to find and interpret the CPT version 51 and length 52 fields.
[0134] The version field 51 identifies the version of the CPT structure being used. This field allows the system designers to change the format or contents of the CPT in the future and yet still be able to access content protected by old as well as new CPT structures (see FIG. 14 and its associated explanation below).
[0135] The version field 51 may begin with a “magic number” that content filtering applications can use to identify the data object 32 as one encrypted and protected under the current invention. This “magic number” could, for example, be used by anti-virus scanning applications to know that the protected data object 32 is encrypted (and presumably free of viruses due to a scan before encryption).
[0136] The length field 52 specifies the size of the CPT in bytes.
[0137] The text message field 53 is an optional field that explains to an unauthorized user (or users executing programs not under control of the rights management system) that the attached data object 32 is protected and where to go to get more information. This field is optional; some deployments may choose greater secrecy (no information provided to unauthorized users) over ease-of-use concerns (informing users how they can become part of the rights management system).
[0138] The control policy id field 54 identifies the control policy 14 that protects the attached data object. This field contains a globally unique identifier (GUID). The control policy id field 54 may also specify (e.g., via a URL) the policy server 29 in whose name space the GUID is known.
[0139] The object id field 55 is another optional field; it specifies a unique identifier for each data object 22 .
[0140] Each protected data object 32 is encrypted with a secret key, called the Content Encryption Key (CEK), and this key is stored in at least two places in the CPT structure 23 , labeled Encrypted CEK 56 and 57 . One of these two fields 56 , 57 contains the CEK encrypted with the policy server's KEK. The other field contains the CEK encrypted with the Key Encryption Key (KEK) of the policy identified in the control policy id field 54 . The KEKs may be either symmetric or asymmetric keys. For the rest of the description of the preferred embodiment, we will assume that a KEK comprises a public/private key pair.
[0141] Another embodiment may include additional KEK fields that support role-based KEKs. In this manner, an administrator could specify unique key properties (e.g., shorter off-line access) for certain roles.
[0142] Since an embodiment of the present invention may use one or more different content encryption algorithms, the encryption algorithm id field 58 identifies the actual algorithm and other definable properties (e.g., key length) used to encrypt the data object with the CEK.
[0143] The final field, the integrity check field 59 , is used to ensure that no one has tampered with the fields in the CPT 23 . It may contain, for example, a secure hash of the entire CPT.
[0144] If the data object is tagged but not encrypted, the two encrypted CEK fields 56 and 57 and the encryption algorithm id field 58 are zeroed.
[0145] Control policies 14 are considered an integral part of a protected data object 32 , accompanying the data object even as it moves among computers and their internal structures (e.g., file systems and memory buffers). The CPT, which references the governing control policy through the control policy id field 54 and contains the CEK secured by the control policy's KEK, is propagated with the encrypted data object 22 until explicitly removed by an authorized user through an embodiment of the rights management system of the present invention.
[0146] An explicit decision of the present invention is to allow multiple data objects 32 to refer to and be protected by a single control policy 14 . The CPT structure described above clearly supports this decision. The embodiment also emphasizes the fact that the value in the control policy id field 54 of the CPT does not uniquely identify a document (as a unique document identifier would do).
[0147] The policy server 29 of FIG. 6 stores only the details of control policies 14 and not the association between data objects 32 and control policies 14 . The association between data objects and control policies is stored only in the CPT 23 of the protected data objects 32 . This design implies that the storage of the policy server 29 dedicated to policies 14 scales in proportion to the number of control policies 14 defined. The storage of the policy server is not affected by the number of unique protected data objects 32 . It is also not affected by the number of copies of these protected data objects.
[0148] The preferred embodiment of the present invention has the CPT 23 located in front of the data object 32 (i.e. the CPT is encountered before the data object when scanning a protected data object 32 starting with the first byte of the protected data object). A different embodiment could place the CPT at the end or at any other explicit location within the protected data object 32 .
[0149] The preferred embodiment allows both the policy server 29 and the client agent 26 of FIG. 6 to construct CPTs 23 .
[heading-0150] Reference Monitoring
[0151] FIG. 9 describes the logic followed by the reference monitor 24 of FIG. 6 on an operation that accesses a protected data object 32 . Given a particular operation, the reference monitor 24 in step 61 first determines if the operation accesses a protected data object 32 . This check involves looking for a CPT 23 on the data object. If no CPT exists, the reference monitor 24 allows the application 21 to continue at step 62 . If a CPT 23 exists, the monitor 24 in step 63 checks the CPT's version field 51 and determines if the version of the CPT is the current version. If it is not, the reference monitor proceeds to step 64 , which is explained in FIG. 14 .
[0152] If the monitor 24 can interpret the CPT 23 , the monitor in step 65 proceeds to check the integrity of the CPT via field 59 ( FIG. 8 ). If the CPT has been tampered with, the monitor 24 displays an error message in step 66 ; otherwise, in step 67 it uses the control policy id (field 54 , FIG. 8 ) in the CPT along with the user's authentication credentials to determine the user's usage rights for this protected data object 32 . Given a set of usage rights, the monitor in step 68 determines if the user is authorized to perform the requested operation. If not, the monitor 24 in step 69 inhibits the application 21 from performing the requested operation and displays an appropriate error message.
[0153] If the user appears in multiple roles under the corresponding (associated) control policy 14 , the preferred embodiment aggregates the usage rights for each of the roles containing the user. This aggregation yields a set of usage rights that contains all of the positive rights of that user's individual roles. Clearly, another embodiment might use a different aggregation method.
[0154] If the operation is authorized, the monitor 24 in step 70 uses the KEK of the control policy 14 identified in the CPT to decrypt the CEK used to encrypt and decrypt the contents of the subject protected data object 32 . The sections on CPT update and disaster recovery below describe some exceptional conditions that may occur during the processing of step 70 in some embodiments.
[0155] Finally, given a decrypted CEK, the monitor 24 in step 72 uses the CEK to either decrypt the encrypted contents on a read operation or encrypt new contents on a write operation.
[heading-0156] Architecture of Client Agent 26
[0157] FIG. 10 illustrates the details of the preferred embodiment of the client architecture of the present invention. This embodiment splits the client agent 26 of FIG. 6 into a client handler process 82 and an integration bundle 84 . There is one client handler process 82 per user machine. The integration bundle 84 could be implemented as a single dynamically linked library that would be loaded into each process running on the user machine. The integration bundle 84 contains the reference monitor 83 and crypto engine 85 analogous to those 24 , 25 described in FIG. 6 .
[0158] The client handler process 82 acts as a local proxy for the policy server 29 of FIG. 6 . The client handler process 82 contains a policy service and cache 86 for caching and managing control policies 14 received from the policy manager 27 of FIG. 6 , and it contains a key service and cache 87 for securely caching and managing KEKs from the key manager 28 of FIG. 6 .
[0159] Under this embodiment, the reference monitor 83 requests the policy KEK from the key service and cache 87 in the client handler process 82 in order to extract the CEK for a protected document from its CPT (step 70 of FIG. 9 ). Once the CEK is obtained, the integration bundle 84 scrubs the KEK from its memory and passes the CEK to the crypto engine 85 .
[0160] The client handler process 82 also includes a logging service 88 for collecting log information from each integration bundle 84 and eventually passing that log information back to the policy server 29 of FIG. 6 .
[0161] FIG. 11 describes the logic followed by the client handler process 82 of FIG. 10 . The handler sits in an event loop waiting for one of the several events labeled on the outgoing edges of step 90 . When a new user logs in and authenticates to the client machine, the client handler process 82 will request all policies 14 on the policy server 29 related to the user, as stated in step 91 . On a regular polling interval, the handler process 82 in step 92 checks the policy server 29 for new policies 14 related to the logged-in user or changes to the cached policies 14 .
[0162] Some control policies 14 state how long they can be cached and used off-line. When such policies timeout, the handler process 82 in step 93 will re-fetch expired policies 14 from the policy server 29 . The control policy KEK can also expire; the embodiment's handling of this time out condition is described below in the section labeled “Expired KEKs and CPT Update.”
[0163] The preferred embodiment currently implements a three-way toggle (labeled Basic, Standard, and High) for setting control policy KEK expiry periods and cache timeout values. The policy KEK validity period and length of time before cached policy timeout are longer in the “Low” setting than the “Medium” setting, providing more potential exposure if a KEK is compromised or a control policy changed. The “High” setting provides the highest level of security and thus lowest level of exposure; however, it also implies that users can work off-line for shorter periods of time. Each deployment of the embodiment of the present invention will select control policy KEK expiry periods and cache timeout values according to their level of risk tolerance and need for off-line use of protected data objects 32 .
[0164] Finally, the policy server 29 can prompt the handler processes 82 of online clients to flush and refresh their cached policies, as stated in step 94 . Off-line clients will synchronize their cached policy stores with the policy server 29 when again connected.
[0165] For steps 91 - 94 , the client handler process 82 in step 95 will check to make sure that the necessary network communication occurred. If everything was successful, the handler process 82 in step 96 will cache the received control policies 14 in secure storage. If the client had no network connectivity with the policy server 29 , the handler process 82 in step 97 will record the missed event for replay later in steps 98 and 99 , after network connectivity is restored.
[heading-0166] Expired KEKs and CPT Update
[0167] The CPT 23 of a protected data object 32 is the only structure in the present invention that contains the CEK used to encrypt the data object 32 . As explained earlier, the CEK is encrypted with the KEK of the control policy 14 identified in the control policy id field 54 of FIG. 8 . To limit the risks associated with a compromised KEK, the system limits the lifetime of such encryption keys. This means however that a protected data object 32 in the field may be no longer accessible once its control policy KEK expires. Since the system does not have access to all data objects protected by a control policy 14 when the policy's KEK expires, the system must have a mechanism for allowing access to data objects protected with an expired KEK and eventually lazily updating the CPT 23 of those data objects with the control policy's current KEK.
[0168] The policy server 29 of FIG. 6 is responsible for defining and managing the lifetime of each control policy KEK.
[0169] The preferred embodiment of the present invention assigns a unique identifier to each KEK within a control policy 14 . Using key manager 28 , the policy server 29 stores the current KEK and maintains a history of KEKs for each active control policy 14 . This history may contain all KEKs ever generated for a control policy 14 , or it may contain only a limited number of the most recent expired KEKs for that policy.
[0170] To let the client agent 26 of FIG. 6 determine if it has the correct KEK for decrypting the CEK of a protected data object 32 , the encrypted CEK fields 56 and 57 of FIG. 8 include the (plaintext) value of the KEK unique identifier used to encrypt the CEK. To increase the probability that the client of an authorized user has the KEK necessary to decrypt the CEK of a protected data object 32 , the preferred embodiment of the present invention (e.g., policy server 29 ) distributes to the client agent 26 not only the current KEK for a control policy 14 but also some portion of the most recent stored history of KEKs for the control policy. The length of the distributed history is less than or equal to the length of the history maintained on the policy server 29 by key manager 28 .
[0171] We will consider two cases associated with an attempt to access a protected data object 32 with a CEK encrypted with an expired control policy KEK; we consider further cases in the later section entitled “Disaster Recovery and CPT Version Control.” Both of the current cases assume that the policy server 29 maintains a complete history of expired KEKs and distributes only a limited number of the most recently expired keys to the client agent 26 . We assume that it is not practical for the policy server 29 to distribute a complete history of expired KEKs to every client agent 26 . FIG. 12 illustrates the scenario for an embodiment that distributes the current and past three expired KEKs 125 to the client agent 26 ; the figure assumes that a KEK comprises a key pair 121 a,b.
[0172] In the first case, if the expired control policy KEK is one of the ones sent by the server 29 in the distributed history, the client agent 26 is able to decrypt the CEK, use this CEK to access the protected data object 32 , and create a new CPT for the protected data object 32 that uses the control policy's current KEK. All of this occurs without any involvement of the user or further communication with the policy server 29 , i.e. it could occur even while the client was off-line.
[0173] The second case solves the problem that the expired KEK is not part of the history distributed to the client agent 26 . To recover from this situation, the client agent 26 must be online and able to communicate with the policy server 29 , since the policy server maintains a complete history expired KEKs for the control policy 14 of the protected data objects 32 . The preferred embodiment simply has the client agent 26 request the particular expired KEK of the control policy 14 of interest. When the policy server 29 responds with the appropriate archived KEK, the client proceeds as above (as if it found the expired KEK in the distributed history).
[0174] FIG. 12 also illustrates that there may exist times when a control policy 14 has no current KEK, due to the expiration of the current KEK. The preferred embodiment of the current invention generates a new KEK for a policy only when a client agent 26 asks for the user-specific usage rules and current KEK of a control policy (step 91 of FIG. 11 ). To guarantee that the client agent 26 does not have to wait an excessive amount of time for step 91 of FIG. 11 to complete, the policy server 29 does cache a set of pre-generated KEKs. This cache of KEKs is used to satisfy demands for a new current KEK in response to a client agent's 26 request for a control policy 14 without a current KEK. The cache of pre-generated KEKs is managed using a simple low and high watermark scheme well known to those practiced in the art. This approach in the preferred embodiment guarantees that the policy server 29 does not generate a large number of unused KEKs that it would need to archive for control policies 14 with protected data objects 32 that experience long periods of inactivity.
[heading-0175] Persistence Models for Protected Data Objects
[0176] The present invention supports two explicit persistence models for protected data objects 32 . In general, the protected data objects 32 of a control policy 14 are either considered permanent or ephemeral assets.
[0177] In the “permanent” model, protected data objects 32 within a control policy 14 are considered permanent assets that should be protected and never lost. The preferred embodiment implements this model by encrypting the CEK of each protected data object 32 with the public master KEK of the policy server 29 . This encrypted value is stored in the one of the encrypted CEK fields (e.g., field 56 of FIG. 8 ); the other field (field 57 of FIG. 8 ) contains the CEK encrypted with the current KEK of the control policy identified in field 54 of FIG. 8 .
[0178] The next section, entitled “Disaster Recovery and CPT Version Control”, describes how the preferred embodiment uses the private master KEK to be always able to recover the CEK of a protected data object 32 . For now, we simply state that the master KEK of the policy server 29 also has a validity period, except that the validity period of the master KEK is typically longer than those assigned to control policy KEKs. The validity period can be longer because, as explained in the next section, the private portion of the master KEK is never distributed to the client agents 26 (i.e., it is used only on the policy server 29 ). Since the master KEK has a validity period, the preferred embodiment also associates a unique identifier with each generated master KEK of the policy server 29 , and this identifier is stored with the encrypted CEK in field 56 of FIG. 8 . Thus, contents stored in the storage for fields 56 and 57 in FIG. 8 are identical.
[0179] In the “ephemeral” model, protected data objects 32 within a control policy 14 are considered ephemeral assets that should be protected for some pre-determined period of time and then destroyed. By “destroyed” we mean that it is theoretically impossible to recover the plaintext of the protected data object 32 .
[0180] The preferred embodiment implements the “ephemeral” model by encrypting the CEK in the CPT 23 not with the policy server's master KEK but with a “policy master” KEK (field 56 of FIG. 8 ). The system never encrypts the CEK of the protected data object 32 with the server's master KEK. The policy master KEK has all of the same attributes as the server master KEK (e.g., it has a very long expiration time, never leaves the server 29 , and supports recovery of the CEK as long as it is archived).
[0181] When the owner of an ephemeral policy decides that it is time to permanently destroy all data objects associated with that policy 14 , he or she simply requests that all archived copies of the policy master KEKs for that policy be deleted on the policy server 29 .
[heading-0182] Disaster Recovery and CPT Version Control
[0183] There are many types of disasters that an embodiment of the present invention must protect against and recover from (e.g., loss of the policy store and restoration of that store from backups). In this section, we focus on two unique aspects of the present invention's disaster recovery mechanisms. The first concerns embodiments that maintain only a limited history of control policy KEKs (or have through some catastrophic event lost all of the archived KEKs for one or more control policies 14 ). The second describes support within the present invention for forward and backward compatibility of CPT formats. This feature is again necessary to address the dynamic nature of the enterprise security space and to ensure that the system is always able to recover the CEK stored in the CPT 23 of a protected data object 32 that may not have been referenced for years.
[0184] FIG. 13 expands upon the logic followed by the reference monitor 24 of FIG. 6 in step 70 of FIG. 9 . At this point, the monitor 24 attempts to extract the CEK of the protected data object 32 from the CPT 23 (both of FIG. 6 ). The client agent 26 already has the current KEK and some number (possibly zero) expired KEKs of the subject control policy 14 . The monitor 24 compares (step 110 ) the unique identifier of the current KEK with the unique identifier (stored in field 57 of FIG. 8 ) of the KEK used to encrypt the CEK. If the identifiers match, the monitor 24 proceeds with decryption of the encrypted CEK, as stated in step 115 of FIG. 13 .
[0185] As described above, the KEK for the control policy can expire; the embodiment identifies such an occurrence by noticing that none of the unique identifiers of the stored KEKs match the unique identifier of the KEK used to encrypt the CEK. To recover, in step 111 , the monitor 24 extracts the CPT 23 and sends it to the policy server 29 with a request for the server to encrypt the CEK with the current policy KEK. The server 29 in step 112 recovers the CEK by using the appropriate master KEK (server or policy), as indicated by the unique identifier stored with the encrypted CEK. The server 29 in step 113 returns the updated CPT to client agent 26 . The client agent 26 in step 114 retrieves the CEK from the received CPT, generates a new CEK, wraps it into an updated CPT, and replaces the original CPT 23 if the protected data object 32 is not marked read-only or stored on read-only media, and proceeds to step 115 using the updated CPT. The client may cache the received CPT in the case where the data object 32 is marked read-only.
[0186] The preferred embodiment treats the versioning of CPT formats as a disaster recovery problem. This approach allows the embodiment to distribute client agents 26 with code that only knows how to interpret the current CPT format and how to recover from disasters.
[0187] FIG. 14 describes the logic followed by the reference monitor 24 of FIG. 6 when it gets to step 64 of FIG. 9 . The monitor 24 reaches this logic when the version of the CPT 23 of a protected data object 32 (both of FIG. 6 ) does not match the CPT version supported by the monitor 24 . The reference monitor 24 in the client agent 26 in step 100 extracts the entire CPT from the protected data object 32 . In step 101 , the client agent 26 sends the extracted CPT to the policy server 29 with a request to convert the CPT to the specified version that the client agent 26 supports. The server 29 in step 102 uses the version field 51 of the CPT to select the correct converter routine, which simply maps the fields in the given version of the CPT data structure to the fields in the specified version (possibly using a canonical intermediate form). Notice that only the server 29 needs to have the entire set of converter codes. During this conversion, the server 29 in step 103 decrypts the CEK using either the indicated control policy KEK or the master KEK, and re-encrypts the CEK with the current control policy KEK and master KEK. The server 29 in step 104 returns the updated CPT to client agent 26 . The client in step 105 extracts the current CEK, renews the CEK, updates the received CPT, caches the updated CPT, replaces the original CPT if the protected data object 32 is not marked read-only or stored on read-only media, and proceeds to step 65 of FIG. 9 using the updated CPT.
[heading-0188] Read-Only Protected Data Objects
[0189] So far, the description has generally assumed a collaborative environment involving the creation and modification of protected data objects 32 . The preferred embodiment also supports a publish-only model of document generation and distribution. In particular, the preferred embodiment allows the business process administrator to indicate that the KEK for a control policy 14 should always remain valid. This option is desirable when the administrator knows that the data objects protected by the control policy 14 are read-only or are stored on read-only computer media. Even though the system cannot update the CPT 23 of a read-only data object 32 , it may still want to expire the policies 14 associated with read-only documents in the client's policy cache 86 to restrict the length of time allowed for off-line viewing of read-only data objects.
[heading-0190] Policy Identification and Data Object Transfer
[0191] FIG. 15 illustrates how the preferred embodiment displays the name for the control policy 14 currently protecting the data object displayed in a computer window. The subject control policy name is displayed in a drop-down window object called the droplet control 120 . When activated, the drop-down window displays the name of the business process 122 containing the active control policy 124 , and the other business processes 12 and control policies 14 that the user may transfer the protected data object to.
[0192] In one embodiment, an ActiveX Window supports droplet control 120 . Contents and hierarchy of same are obtained from policy server 29 via cache 86 , tag 23 and/or client handler 82 as further explained below.
[0193] FIG. 16 describes the logic involved in transferring a data object (represented by a document) between control policies 14 . The transferring of a protected data object 32 from one control policy 14 to another is an important aspect of a dynamic, distributed, and collaborative environment, as described earlier in reference to FIGS. 2-5 . In particular, the preferred embodiment allows business process owners (i.e. business administrators) to specify the flow of information between control policies 14 within or between business processes 12 . The business process owners define the flows while authorized users perform the actual transferring of protected data objects. Often a transfer will occur as part of normal workflow.
[0194] An authorized user in step 130 opens a document in a rights-management-aware application 21 . This might be a new document 22 (data object), in which case the client agent 26 in step 132 displays the default “Unmanaged” control policy in droplet control 120 . Alternatively, this might be an existing protected document, in which case the agent 26 in step 132 displays the name of the control policy protecting the document 22 in the droplet control 120 . The user in step 134 edits and further manipulates open document within the usage rights specified by the control policy 14 for that user. The logic flow from step 134 back to itself represents the fact that such editing may continue for some unspecified and extended period of time.
[0195] At some point, the user in step 136 may decide to activate the droplet control 120 and select a new control policy 14 to which he would like to transfer the protected document. After selection, the agent 26 in step 138 creates a new CPT 23 with the selected control policy identifier in it and tags the document 22 with it. If specified in the control policy 14 , an authorized user may in step 136 select the “Unmanaged” control policy, in which case the agent 26 in step 138 does not create a new CPT, deletes the existing CPT, and decrypts the document 22 . After step 138 , the user can continue to edit the document 22 under the constraints of the new control policy 14 .
[0196] Each control policy 14 in the system records a list of users with the authority to transfer data objects 22 out of the protection provided by that control policy. The control policy 14 also contains a list of users with the authority to assign new data objects 22 to the control policy. In order for a user to transfer a data object 22 from its current control policy 14 to a new control policy, the user must be a member of the “transfer-out” list of the current control policy 14 and a member of the “assign-to” list of the new control policy 14 .
[0197] “Transfer” rights are not necessary, i.e. the “transfer-out” and “assign-to” lists of a control policy 14 can be empty. However, in the preferred embodiment of the present invention, at least one of the roles in a control policy 14 will allow users to assign data objects 22 to the policy 14 . If none of the roles has assign privileges, the policy 14 would not have any meaning (i.e., it would never have objects associated with it). The “assign-to” list may become empty because the privilege was needed only initially to assign data objects to the control policy 14 . For instance, a member may have “assign-to” privileges during the initial creation of the policy and assignment of data objects to the policy. After this initialization, the “assign-to” privilege is removed and the policy 14 controls a fixed set of objects.
[0198] In general, the preferred embodiment supports three kinds of “transfers” within the hierarchy of business processes 12 ( FIG. 1 ):
(a) An authorized user may be granted the privilege of changing the association between a data object 22 and its control policy 14 within a single business process 12 . (b) A user may also be granted the privilege of moving data objects 22 between business processes 12 . (c) A user may also be granted the privilege of moving data objects 22 out of the rights management system, i.e. the data object 22 resulting from the transfer is no longer managed or protected.
[0202] The types of transfers described above can be explicitly initiated by an authorized user through the droplet control 120 described earlier, or transfers can be implicitly initiated as a byproduct of some other electronic action undertaken by the authorized user. We refer to this latter category as “automatic transfers.”
[0203] The policy 14 associated with a data object 22 may be changed automatically via merge operations (e.g., cut/paste operations). The preferred embodiment of the present invention implements the following kinds of automatic transfers on merge operations: If a protected data object 32 is pasted into an unmanaged data object, the targeted data object assumes the policy 14 of the pasted object. If the protected data object is pasted into a protected data object with a different policy 14 , the target object maintains its policy and the paste is allowed to complete only if the source data object's policy allows transfer and the target data object's policy allows assign.
[0204] The preferred embodiment of the present invention implements “automatic transfers” by integrating a standalone transfer tool into a software component of an existing electronic business process. For example, a report generator for a large database system might be modified to use the standalone transfer tool to produce reports as protected data objects 32 under a pre-configured control policy 14 . As another example, an email server might be configured to use the standalone transfer tool as a type of filter (i.e. exploiting those interfaces used by anti-virus filters) to transfer automatically data objects from one control policy 14 to another based on the people or groups in the “to” and “from” fields of an email message. An automatic transfer would take place only if the sender of the email message had the appropriate transfer rights. Such an embodiment would also want to employ digital signatures to ensure that the email message actually came from the person specified in the “from” field.
[heading-0205] Off-line Collaboration
[0206] Collaboration in a dynamic and distributed environment implies that the only authoritative copy of a protected data object 32 may reside in the field, away from the policy server 29 , and in locations not accessible by the business process owner. A system in support of dynamic, distributed, and collaborate environments must make it easy for two (or more) authorized users to generate and share protected data objects 32 both on and off-line. The preferred embodiment of the present invention supports such a goal with the only criterion that the authorized users must have had some recent access to the policy server 29 , where “recent” means within the cache timeout for the control policy 14 under which they wish to collaborate. In other words, collaboration is driven by pre-defined business processes 12 and not by pre-registered data objects 32 .
[0207] FIG. 17 presents a flow diagram illustrating collaboration between two users within a rights management system 200 based on the present invention, where the collaboration occurs through a document (data object 22 ) that was never known to the policy server 29 . Step 140 begins with an administrator creating a control policy P that includes both users A and B in roles. Users A and B in step 141 are logged in to their laptops connected to the corporate network where the policy server 29 is located. In step 142 , the client handler processes 82 on the users' laptops cache the control policy P and its KEK. Users of A and B in step 143 then disconnect from the corporate network and take their laptops to an off-site meeting. At this point, the client handler processes 82 are prepared to permit any collaborative activity within the bounds of the cached control policies 14 ; the client handler processes 82 act as trusted agents of the rights management system 200 .
[0208] While off-line, user A in step 144 creates a sensitive data object D (in the example, a document) and protects it with control policy P. This action takes place while user A is disconnected from the policy server 29 . Since control policy P is cached on user A's laptop, he or she is able to create and protect document D. User A in step 145 gives a copy of document D to user B. User B in step 146 is able to edit protected document D on his or her laptop while also disconnected from the policy server 29 . The collaboration of users A and B around document D (or any other document protected by control policy P) continues in step 147 , as long as no expiry periods occur.
[heading-0209] Audits, Forensics, and Compliance
[0210] The preferred embodiment of the present invention supports logging of the activities (granted and denied) monitored and controlled by the client agent 26 of FIG. 6 . The logging service 88 in FIG. 10 collects the log data from the individual rights-management-aware applications 21 and communicates the data back to the policy server 29 . The collected information can then be reviewed and mined by the business process owner to support business needs, such as audits, forensics, and compliance.
[0211] Auditing the activities associated with the data objects 32 of a business process 12 does not necessarily require encryption of the identified data objects 32 . In one embodiment of the invention, the identified data objects 32 may be simply “managed” and not “protected.” In other words, auditing requires only that an identified data object 32 have a CPT 23 ; it does not require that the contents 22 of that data object 32 be encrypted.
[0212] The object id field 55 in the CPT 23 ( FIG. 8 ) aids in audits, forensics, and compliance. It is a globally unique identifier generated when the client agent 26 first creates a protected data object 32 . If the new data object 22 was generated from an existing protected data object (e.g., via a “Save As” command), a log record is written linking the new and existing data objects using their object identifier 55 values. Otherwise, the system 200 records that the new protected data object 32 was generated from scratch or from an unmanaged data object 22 .
[0213] This example emphasizes the fact that the preferred embodiment of the present invention uses object identifiers only for audits, forensics, and compliance purposes. The embodiment does not use the object identifier 55 of a protected data object 32 for determining the control policy 14 or associated usage rules.
[0214] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
|
In a network of intermittently-connected computers, a method and apparatus for maintaining and managing control over data objects authored, accessed, and altered by users in dynamic, distributed, and collaborative contexts. The invention method and apparatus attach to each data object an identification of a respective control policy. Each control policy comprises at least an indication of a subset of the users who may access the data object, an indication of the privileges granted to each subset of users able to access the data object, and an indication of a subset of users who may define or edit the control policy. The invention method and apparatus separate the management of the control policies of data objects from the creation and use of the data objects. The invention method and apparatus automate common policy changes, distribution of policy changes to the enforcement agents, and propagation of control policies to derivative works.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 10/053,103 filed Jan. 17, 2002, now U.S. Pat. No. 6,862,542 incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates generally to the field of devices for detecting the health status of the pulp tissue within a tooth, and more particularly to a device and method for using a combination of light and acoustics to measure the degree of erythema in a tooth.
BACKGROUND OF THE INVENTION
Erythema refers to redness, or inflammation of vascularized areas of the body, which can increase as a result of various causes including diseases and disorders of the mucosa and skin, and of the dental pulp (“tooth nerve”) tissue. There is a long-standing problem of determining the health status of the contents of the dental pulp chamber within teeth. The pulp consists of different tissues, including a dense network of small blood vessels. In the healthy state, the pulp tissue is red in color due to a rich blood supply. When a tooth becomes diseased from caries (decay), or injured from trauma, the dental pulp becomes inflamed, and in the case of caries, the degree of erythema might increase, first near the area of disease (caries) in the crown portion of the tooth, and ultimately progressing throughout the pulp chamber and root canal(s) to the apex of the tooth, where the pulp tissue joins the systemic circulation in the surrounding alveolar bone. This increased erythema eventually disappears as the pulp becomes overwhelmed by the inflammatory process, loses its blood supply, and becomes necrotic. This can be painful, but in many cases it is a silent process. The resulting infection can ultimately spread to the soft tissues of the face, involving vital structures of the head and neck, and on rare occasions can result in death.
Methods to determine the health status of the dental pulp are crude, often highly subjective, and have not progressed significantly in the last three decades. Part of the problem stems from the two different layers of calcified tissue, dentin and enamel, that surround the pulp tissue. The standard method for visualizing the dental pulp is to use the intraoral dental radiograph, which only gives a two-dimensional view, or shadow, of the pulp chamber. Radiographs do not allow for differentiation between the extremes of entirely healthy versus completely necrotic pulp tissue.
The determination of the degree of erythema, and therefore the degree of disease of pulp tissue, has always been of interest to dentists in clinical practice and in research, as it would allow for early diagnosis, less invasive treatment, and less costly treatment. It would also allow for the development of medications to prevent or treat pulpal inflammation. This would provide for early intervention in situations where the inflammatory process could be altered, and provide a research tool for studies concerning disorders where tooth vascularity may be altered by changes in the blood supply. There are no practical or commercial methods for quantifying erythema within teeth, and existing methods of determining the health status of the pulp are highly subjective, poorly reproducible, and often do not detect disease at an early stage when treatment and preventative strategies are most effective.
SUMMARY OF THE INVENTION
Briefly stated, an erythema meter includes a probe, a light source of one or more specific probing and reference wavelengths, and an acoustic detector which determines the level of erythema present in the dental pulp chamber of a tooth. The probing and reference wavelengths are delivered in pulsed or amplitude modulated fashion through the probe, thereby permitting electronic identification and filtering of the received data. The absorption of the light wave raises the temperature of the material in the tooth and causes it to expand, thus creating tiny shockwaves which are picked up with the acoustic detector, revealing information on the location of blood and the quantity of blood inside the tooth. The erythema meter accurately measures the erythema, or inflammation, within the tooth in a qualitative and quantitative manner.
According to an embodiment of the invention, a system for measuring erythema in a tooth includes means for generating light of a first frequency; means for transmitting the light of the first frequency into the tooth; means for detecting shock waves induced in the tooth by the transmitted light of the first frequency; and means for processing the detected shock waves induced by the transmitted light of the first frequency to measure the erythema in the tooth.
According to a feature of the invention, the system further includes means for generating light of a second frequency; means for modulating the light of the first frequency; means for modulating the light of the second frequency, wherein the modulation of the second frequency is different from the modulation of the first frequency; the means for transmitting the light of the first frequency into the tooth being effective for transmitting the light of the second frequency into the tooth; the means for detecting shock waves induced in the tooth by the transmitted light of the first frequency being effective for detecting shock waves induced in the tooth by the transmitted light of the second frequency; and the means for processing the detected shock waves induced by the transmitted light of the first frequency being effective for processing the detected shock waves induced in the tooth by the transmitted light of the second frequency to measure the erythema in the tooth.
According to an embodiment of the invention, a system for measuring erythema in a tooth includes a generator for generating light of a first frequency; a probe which transmits the light of the first frequency into the tooth; a detector which detects shock waves induced in the tooth by the transmitted light of the first frequency; and a processor which processes the detected shock waves induced by the transmitted light of the first frequency to measure the erythema in the tooth.
According to a feature of the invention, the system further includes a generator for generating light of a second frequency; a modulator for modulating the light of the first frequency; a modulator for modulating the light of the second frequency; wherein the probe transmits the modulated light of the first and second frequencies into the tooth; the detector detects shock waves induced in the tooth by the transmitted modulated light of the first and second frequencies; and the processor processes the detected shock waves induced by the transmitted modulated light of the first and second frequencies to measure the erythema in the tooth.
According to an embodiment of the invention, a method for measuring erythema in a tooth includes the steps of generating light of a first frequency; transmitting the light of the first frequency into the tooth; detecting shock waves induced in the tooth by the transmitted light of the first frequency; and processing the detected shock waves induced by the transmitted light of the first frequency to measure the erythema in the tooth.
According to a feature of the invention, the method further includes the steps of generating light of a second frequency; modulating the light of the first frequency; modulating the light of the second frequency, wherein the modulation of the second frequency is different from the modulation of the first frequency; transmitting the light of the first and second frequencies into the tooth; detecting shock waves induced in the tooth by the transmitted light of the first and second frequencies; and processing the detected shock waves induced by the transmitted light of the first and second frequencies to measure the erythema in the tooth.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a diagram of the delivery and detection protocol of the present invention, i.e., a system for measuring tooth erythema and for measuring the blood supply to the tooth; and
FIG. 2 shows a flow chart of a method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , a tooth 30 is shown. A layer of dentin 32 protects an inner layer of pulp 34 . Tooth 30 includes an outer protective layer of enamel 36 which protects that part of dentin 32 which is not protected by the gums. A layer of cementum 38 covers that part of dentin 32 which is protected by the gums. Tooth 30 is embedded in a layer of alveolar bone 40 in the mouth. The systemic circulation system has a portion 42 which interconnects with a root canal 44 inside tooth 30 to provide blood to pulp 34 .
The degree to which the pulp in a tooth is healthy can be determined by knowing the state of its vascularity, or blood supply. The areas of interest are the root canal 44 and pulp 34 areas. These areas are screened from observation by enamel 36 , cementum 38 , and dentin 32 , hereinafter referred to as the “opaque” areas. The method of the present invention is implemented by using frequencies of light which penetrate the opaque areas and interact with the media present in the areas of interest. The various media in the areas of interest preferably consist of blood, both oxygenated and deoxygenated, no blood, and infection. The wavelengths of the light are therefore selected so they pass through the opaque areas without too much interference and without causing unwanted side effects, such as cracking the tooth. The near infrared range of light is preferred, although the mid and far infrared ranges might also work. The visible wavelengths are to be avoided because there is too much scattering caused by the opaque areas. The preferred embodiment of the method of the present invention involves determining those frequencies of light which permit detection of (1) oxygenated blood, (2) deoxygenated blood, (3) no blood, and (4) infection. In addition, a frequency which doesn't react with any of the media present in the areas of interest is preferably used to detect the boundaries between the different areas of the tooth. Determination of the best frequencies to use for each of these purposes is believed to be possible through routine experimentation. The light frequencies need to penetrate 5-6 mm in tooth 30 , and also preferably need to penetrate artificial crowns.
A detection and delivery system is shown generally at 5. A detector/probe 10 includes a light transmitting/carrying device, such as an optical fiber 12 , and a sensor 11 which detects an acoustic shock wave. A generator 19 is electrically coupled to a light source 13 such as a laser or LED. Several light sources are preferable so that different wavelengths of light can be transmitted simultaneously through detector/probe 10 , although a tunable light source would work with the different frequencies transmitted sequentially instead of simultaneously. Because sensor 11 has no way to determine which frequency of light activated the area of the tooth being studied, a unique identifier has to be imposed on each light frequency. In addition, a shock wave has to be induced in the area of interest by the light after the light penetrates the opaque areas. Both of these considerations are solved by modulating the light frequency with a pulse frequency, and using a different pulse frequency for each light frequency. The pulse frequency is preferably in the ultrasound range to take advantage of the known ultrasound imaging techniques which exist in the art. The pulse frequency also determines the resolution. Because blood vessels are on the order of microns, a range of 500 to 50,000 KHz should work for the pulse frequencies. The optimal pulse frequencies to use should be discoverable through routine experimentation. Amplitude modulation instead of pulse modulation of the light frequencies is also possible.
Generator 19 preferably houses at least two individual frequency generators for delivering a pulsed voltage to light source 13 , which in turn delivers at least one light wave pulse train through optical fiber 12 . As previously described, one of the light wavelengths preferably interacts with the blood content of the pulp to provide a measure of blood absorption, whether oxygenated or reduced. Alternately, a second wavelength in the spectral range of preferential absorption in blood may be used. An additional third wavelength light source may be chosen to determine the background, with no specific absorption difference between oxygenated or reduced blood, or dentin.
The qualitative and quantitative detection of blood inside tooth 30 is accomplished by delivery of femtosecond laser pulses in a repetition delivery protocol. The absorption of the light wave raises the temperature of the material and causes it to expand. As a consequence, a shock wave is created which can be detected by means of piezo-acoustic detectors such as sensor 11 . Shockwave detection itself is known in art, being used in ultrasound imaging, for example. Fiber 12 inside probe 10 delivers the femtosecond light pulses to tooth 30 . There are preferably two separate wavelengths from two separate pulsed lasers, one operating at a wavelength that penetrates enamel 36 and bone 40 , while having greater than twice the absorption in Hb and/or HbO 2 , thus creating sonic sources at the point of blood content. The wavelength of the laser light is varied to evaluate the best sensitivity point, which is the wavelength at which the blood and the surrounding media have the greatest difference in the absorption coefficient. A minimum of two separate wavelengths may be used to distinguish between oxygenated (HbO2) and deoxygenated (Hb) blood. Optionally, an additional third wavelength is at a wavelength range where Hb/HbO2 and other structures are overlapping in the absorption spectrum, thus providing a background check to be used for subtraction of the signal and contrast enhancement. Wavelengths are preferably selected based on their contrast in absorption with enamel and dentin, as well as various popular artificial dental crown materials, such as metals and alloys, ceramics, and combinations of these materials. The laser sources may have a variety of degrees of polarization, or be unpolarized, linearly polarized, or elliptically polarized. Fiber 12 maintains this state of polarization for additional discrimination potential of the delivery of the light to the target area inside tooth 30 .
Generator 19 is preferably electrically connected to a calculating circuit or computer 20 via a standardized connection such as a parallel cable, RS232 cable, or USB cable. A wire 18 carries an electric signal generated in probe 10 by detector 11 to an ultrasound detector signal processing device 14 . A second detector 16 , or even a third detector (not shown), is optionally connected to a secondary ultrasound signal detection processing device 15 through a lead 17 , to provide additional information on the location of sound wave generation. Thus, the shock waves generated by the absorption of these light pulses are detected with one or more detectors 11 , 16 on either side of tooth 30 , revealing three-dimensional information on the location of the absorption of laser pulses in blood as probe 10 is moved around different areas of tooth 30 . Shock wave detectors 11 , 16 can be any device that measures displacement, such as piezo-electric detectors or fiberoptic Fabry-Perot ultrasound sensor such as are known in the art. The pulsed wave of laser light is modulated with a frequency train, or by adding one extra pulse at specific intervals, thus providing a means to obtain time of travel and therefore information on depth. Structural detail can also be derived by analyzing the second harmonic of the ultrasound signal. The magnitude of the signal provides information on the amount of blood content. To be able to quantify the amount of blood present in the volume of observation and set criteria for normal or abnormal condition of the tooth pulp, data is processed preferably using image and pattern recognition techniques. These techniques allow the three dimensional picture of the volume to be reconstructed. In addition, the invention can be used to obtain images of healthy teeth for reference purposes, whether to compare the same tooth in a patient at regular intervals, or to obtain accepted data, stored in a database, on what healthy teeth should look like as obtained from measurements taken on a random group of test subjects.
Referring to FIG. 2 , a method according to an embodiment of the invention is shown. The probe is aimed at the tooth in step 50 . Light of several frequencies is generated in step 52 and each frequency is modulated with a unique pulse frequency in step 54 , after which the light pulses are sent in step 56 . The time is measured in step 58 to obtain distance information. Mechanical activity of the tooth in response to the frequencies is measured in step 60 . The results are processed in step 62 , so that the determinations of oxygenated blood, deoxygenated blood, infection, no blood, and boundary area are made. The location(s) are stored in step 64 , with the interim results preferably displayed in step 66 . If the tooth is mapped in step 68 , the mapped tooth is displayed in step 70 . Otherwise, the probe is aimed at a different part of the tooth in step 72 and the process reverts to step 52 .
While the present invention has been described with reference to a particular preferred embodiment and the accompanying drawings, it will be understood by those skilled in the art that the invention is not limited to the preferred embodiment and that various modifications and the like could be made thereto without departing from the scope of the invention as defined in the following claims.
|
An erythema meter includes a probe, a light source of one or more specific probing and reference wavelengths, and an acoustic detector which determines the level of erythema present in the dental pulp chamber of a tooth. The probing and reference wavelengths are delivered in pulsed or amplitude modulated fashion through the probe, thereby permitting electronic identification and filtering of the received data. The absorption of the light wave raises the temperature of the material in the tooth and causes it to expand, thus creating tiny shockwaves which are picked up with the acoustic detector, revealing information on the location of blood and the quantity of blood inside the tooth. The erythema meter accurately measures the erythema, or inflammation, within the tooth in a qualitative and quantitative manner.
| 0
|
The U.S. Government has rights in this invention pursuant to contract no. F33657-83-C-0281 awarded by the United States Air Force.
The following commonly assigned applications are directed to related subject matter and are being concurrently filed with the present application, the disclosures of which are hereby incorporated herein by reference:
U.S. Patent application Ser. No. 07/805,136, filed on Dec. 11, 1991.
U.S. Patent application Ser. No. 07/805,134, filed on Dec. 11, 1991.
The present invention relates, in general, to connectors for electrical cables and, more particularly, to an improved backshell structure for electrical cable connectors.
BACKGROUND OF THE INVENTION
Electric cables for modern aircraft engines normally include a number of individually shielded wires surrounded by a conduit which is itself surrounded by a shield. Since most discontinuities in such cables occur at the cable connectors, it would be advantageous to design a cable termination wherein the individual wires would be easily accessible and repairable. It would further be advantageous if the cable termination or connector were designed such that repairs to individual wires did not destroy the EMI shielding or the environmental seal of the connector. Finally, it would be advantageous to eliminate the potting material normally used to protect individual wires between the cable end and the connector.
SUMMARY OF THE INVENTION
The present invention is directed to an electrical cable assembly comprising an improved backshell. The backshell assembly comprises an outer backshell cable shield connected between two backshell nuts such that the backshell may be disengaged from the connector and/or the cable termination piece to access the signal wires in the cable. The improved backshell further includes a cable termination piece adapted to mate with a first of the backshell nuts providing electrical continuity between the outer cable shield and the outer backshell shield. In addition, an inner shield termination is provided to provide electrical continuity for the inner cable shield at the junction between the connector and the second backshell nut.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a cutaway view of a backshell connector according to the present invention.
FIG. 2 is a cutaway view of a portion of a backshell connector according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a cut away view of a backshell connector 11 according to one embodiment of the present invention. In FIG. 1, backshell coupling nut 10 includes threads 15 which engage threads 41 of cable termination 40. Backshell nut 10 is rotatably connected to backshell termination 12 by washer 14. As used herein, the term washer (e.g. washer 14) may include, for example, snap rings, split washers, true arcs or helical washers The function of these washers is to rotatably engage the backshell nuts to the backshell terminations such that the nuts may be tightened or loosened without turning the backshell shield 20. Band clamp 18 holds outer backshell shield 20 in position around backshell termination 12. Backshell shield 20 may be, for example, an electrically conductive mesh or solid material Shrink tubing 16 surrounds band clamp 18 and a portion of shield 20 and a portion of termination 12.
Cable termination 40 includes teeth 41 adapted to engage teeth 15 of backshell nut 10. Band clamps 46 and 48 hold outer cable shield 44 to cable termination 40. Outer cable shield 40 may be, for example, an electrically conductive outer layer of cable 45. Shrink tubing 42 surrounds band clamp 46, band clamp 48, a portion of cable termination 40 and a portion of outer cable shield 44.
Inner cable shield 36, which may be, for example, the ordinance braids of wires 38, is clamped to inner shield termination 34 by band clamp 32. Inner shield termination 34 is adapted to fit over a portion of connector body 50. Inner shield termination 34 is adapted to be held in place by backshell termination 26.
Outer backshell shield 20 is attached to backshell termination 26 by band clamp 24. Backshell termination 26 is rotatably attached to backshell nut 30 by washer 28. Shrink tubing 22 surrounds band clamp 24, a portion of backshell termination 26 and a portion of outer backshell shield 20.
Backshell nut 30 includes teeth 58 adapted to engage teeth 56 of connector body 50. In FIG. 1, a portion of connector body 50 is not shown since the present invention is directed to the improved backshell.
Wires 38 terminate at connector body 50 in "pokehome" pins 52. Poke-home sockets 52 may be connected to pokehome pin connectors 54 which, in turn, are connected to other connectors when connector body 50 is attached to a Line Replaceable Unit (LRU) or other electronic device.
Improved backshell 11 of FIG. 1 is adapted to provide substantial Electro-Magnetic Radiation (EMI) shielding for wires 38 in cable 45. In addition, backshell 11 enhances access to wires 38 and connector body 52 for repairing wires 38 or sockets 52 or any other electrical problems at the connector.
In order to provide EMI shielding, there must be electrical continuity from outer cable shield 44 to connector body 50. In addition, it would be advantageous to seal wires 38 from environmental hazards such as water or fuel. Finally, it would be advantageous to provide a second shield which improves the EMI shielding beyond that provided by outer backshell shield 20.
In the embodiment of FIG. 1, band clamps 46 and 48 bind outer cable shield 44 to electrically conductive cable termination 40 which may be manufactured from, for example nickel, shrink tubing 42 provides an environmental barrier at the interface between shield 44 and termination 40. Conductive backshell nut 10 is screwed onto cable termination 40 and threads 15 and 41 provide an electrical path between nut 10 and termination 40. An environmental barrier shielding might be provided by, for example, covering backshell 11 with shrink fit tubing or by other suitable means.
Electrical continuity is provided between nut 10 and outer backshell shield 40 by electrically conductive backshell termination 12. Backshell termination 12 is rotatably connected to nut 10 by electrically conductive washer 14 which allows nut 10 to rotate without rotating termination 12. Termination 12 is connected to electrically conductive backshell shield 20 by band clamp 18 which is covered by shrink tubing 16.
Electrical continuity between shield 20 and backshell nut 30 is provided by electrically conductive backshell termination 26 which is attached to shield 20 by band clamp 24 and covered by shrink tubing 22. Electrically conductive washer 28 rotatably connects termination 26 to nut 30.
Additional EMI shielding and/or an environmental barrier may be provided by inner cable shield 36. Inner cable shield 36 is connected to electrically conductive inner shield termination 34 by band clamp 32. Termination 34 slides over a portion of connector body 50 and is positioned between connector body 50 and backshell termination 26 such that, when backshell nut 30 is tightened, termination 34 is forced against connector 50.
In FIG. 2, cable termination 140 includes a portion 142 which extends beyond backshell nut 10. By extending termination 140, it may be attached to, for example, a gas turbine engine by a clamp 170. Clamp 170 may be, for example, a band clamp, saddle and band clamp or other suitable device. Clamp 170 is also advantageous in that it prevents nut 10 from backing off termination 140 due to, for example, vibration.
While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.
|
The present invention is directed to an electrical cable assembly comprising a cable termination piece adapted to engage a backshell nut. The cable outer shield is terminated at the termination piece. The backshell assembly comprises an outer backshell cable shield connected between two backshell nuts such that the backshell may be disengaged from the connector and, or the cable termination piece to access the signal wires in the cable.
| 8
|
BACKGROUND
This invention relates generally to heat exchangers, and more particularly to counter flow microchannel heat exchangers.
There are many industrial devices and processes wherein a component has to be maintained at a precise and uniform temperature. Examples of such devices and processes include optical devices and components, such as precision telescopes, solid-state lasers, and semiconductor laser diodes; wafer processing equipment in the semiconductor industry; and bio-processing containers in the pharmaceutical industry.
A suitable heat exchanger for these applications can be either of the microchannel type or the impingement type. Microchannel heat exchangers typically use unidirectional liquid coolant flow in a single layer of channels. While a microchannel heat exchanger is conducive to maintaining a very uniform temperature in a component in a direction perpendicular to the coolant flow, the lateral temperature parallel to the direction of coolant flow exhibits an increase as the liquid coolant receives heat. The temperature rise can be limited by increasing the coolant flow rate, but this results in a high pressure drop and poor coolant utilization. A 2-layer, 2-pass microchannel heat exchanger is described in U.S. Pat. No. 5,005,640, the contents of which are hereby incorporated by reference in their entirety. The 2-pass heat exchanger improves lateral temperature uniformity and coolant utilization. However, to achieve the second pass, the direction of coolant flow is reversed, which leads to a very high pressure drop.
Impingement type heat exchangers can provide uniform cooling, but exhibit very high pressure drop and poor coolant utilization.
For the foregoing reasons, there is a need for a microchannel heat exchanger which can provide substantially uniform cooling over a large area. The new microchannel heat exchanger should also handle high heat flux with a low pressure drop.
SUMMARY
According to the present invention, a heat exchanger is provided for transferring heat to a working fluid. The heat exchanger comprises a housing having a plurality of grooves formed in a surface of the housing. The grooves have a first end and a second end, and define fluid flow channels. Each channel has a fluid flow inlet and a fluid flow outlet. The fluid flow inlets of an alternating first set of channels are adjacent to the first end of the grooves, and the fluid flow inlets of a second set of alternating channels are adjacent to the second end of the grooves. The first set of channels and the second set of channels are arranged such that fluid in immediately adjacent channels flows in opposite directions.
Also according to the present invention, a system is provided for controlling the temperature of a heat source. The system comprises a heat generating component having a surface and a heat exchanger having a surface adapted for thermal communication with the surface of the heat generating component. The heat exchanger includes a housing having a plurality of grooves formed in a surface of the housing. The grooves have a first end and a second end, and define fluid flow channels. Each channel has a fluid flow inlet and a fluid flow outlet. The fluid flow inlets of an alternating first set of channels are adjacent to the first end of the grooves, and the fluid flow inlets of a second set of alternating channels are adjacent to the second end of the grooves. The first set of channels and the second set of channels are arranged such that a working fluid in immediately adjacent channels flows in opposite directions.
Further according to the present invention, a method is provided for controlling temperature of a heat source having a surface. The method comprises the steps of providing a heat exchanger having a surface adapted for thermal communication with a surface of the heat source. The heat exchanger includes a housing having a plurality of grooves formed in a surface of the housing. The grooves have a first end and a second end, and define fluid flow channels. Each channel has a fluid flow inlet and a fluid flow outlet. The fluid flow inlets of an alternating first set of channels are adjacent to the first end of the grooves, and the fluid flow inlets of a second set of alternating channels are adjacent to the second end of the grooves. The method further comprises the steps of providing a working fluid, and supplying the working fluid to the channels such that the working fluid in immediately adjacent channels flows in opposite directions for transferring heat from the heat source to the working fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference should now be had to the embodiments shown in the accompanying drawings and described below. In the drawings:
FIG. 1 is a perspective view of an embodiment of a microchannel heat exchanger according to the present invention.
FIG. 2 is a close up cross-section view of an upper peripheral portion of the heat exchanger of FIG. 1 showing a supply manifold and a return manifold.
FIG. 3 is a close up perspective view of a portion of the upper surface of the heat exchanger of FIG. 1 showing an open microchannel array.
FIG. 4 is a cross-section view taken along line 4 - 4 of FIG. 1 .
FIG. 5 is a cross-section view taken along line 5 - 5 of FIG. 1 .
FIG. 6 is a graph showing the temperature rise in a cooled component as a function of position downstream from the supply manifold in a prior art unidirectional flow microchannel heat exchanger.
FIG. 7 is a graph showing the temperature rise in a cooled component as a function of position downstream from the supply manifold in a counter-flow microchannel heat exchanger according to the present invention.
DESCRIPTION
As used herein, the term “microchannel” refers to a channel having a maximum depth of up to about 10 mm, a maximum width of up to about 2 mm, and any length.
Certain terminology is used herein for convenience only and is not to be taken as a limitation on the invention. For example, words such as “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” and “downward” merely describe the configuration shown in the FIGs. Indeed, the components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise.
Referring now to the drawings, wherein like reference numerals designate corresponding or similar elements throughout the several views, a counter flow microchannel heat exchanger according to the present invention is shown in FIG. 1 and generally designated at 20 . The heat exchanger 20 comprises a housing 22 having a single layer of a plurality of parallel microchannels 24 . As will be described below, the heat exchanger 20 is designed such that a fluid coolant flows through adjacent alternating microchannels in opposite directions. This counter-flow configuration reduces the lateral temperature variation as compared to a unidirectional flow heat exchanger, while maintaining low pressure drop and high coolant utilization.
The housing 22 of the heat exchanger 20 comprises two separate portions, a base portion 26 and a surface portion 28 . The surface portion 28 of the housing 22 has a plurality of slots which define the microchannels 24 . The housing 22 shown in the FIGs. is generally cylindrical. A cylindrically-shaped housing 22 represents a compact design and minimizes coolant flow thereby reducing power requirements for a liquid coolant pump. However, it is understood that the housing 22 of the heat exchanger 20 can be any shape, including rectilinear. Opposed holes 30 are formed in the housing 22 of the heat exchanger 20 for receiving pins on the component to be cooled (not shown) in order to provide proper angular alignment of the housing 22 relative to the component.
The base portion 26 and the surface portion 28 of the heat exchanger 20 are preferably formed from single crystal silicon and bonded together to form an integral unit. The heat exchanger 20 may also be constructed of a material comprising a metal (e.g, aluminum, nickel, copper, stainless steel or other steel alloys), ceramics, glass, graphite, single crystal diamond, polycrystalline diamond, a polymer (e.g., a thermoset resin), or a combination thereof. These materials possess thermal conductivities that are sufficient to provide the necessary requirements for overall heat transfer coefficients. It is understood that the scope of the invention is not intended to be limited by the materials listed here, but may be carried out using any material which allows the construction and operation of the heat exchanger described herein.
The microchannels 24 are defined by the walls of the slots extending from the surface portion 28 of the housing 22 . The number of microchannels 24 may be any desired number, for example, two, three, four, five, six, eight, tens, hundreds, thousands, tens of thousands, hundreds of thousands, millions, etc. The microchannels 24 may have a cross-section having any shape, for example, a square, a rectangle or a circle. Each of the microchannels 24 may have an internal width ranging from about 50 μm up to about 2 mm. As shown in FIG. 1 , the microchannel array 24 is circular, and the microchannels extend in parallel substantially across the surface portion 28 of the housing 22 . In this configuration, the depth of the microchannels 24 varies in order to match flow impedance and thus achieve the same heat transfer conditions in spite of the different microchannel lengths. Alternatively, the microchannel array 24 may be rectangular, square, polygonal, or any other suitable shape. The microchannels 24 can be straight or curved, and the depth of the microchannels can be constant or variable.
A suitable supply manifold 32 provides for the flow of the fluid coolant into the microchannels 24 . A suitable return manifold 34 provides for the coolant return. In the embodiment of the present invention shown in the FIGs., the supply manifold 32 and the return manifold 34 are each a pair of radially opposed crescent-shaped openings formed in the housing 22 . As seen in FIGS. 1 and 2 , each of the supply manifold 32 openings penetrates the surface portion 28 of the housing 22 and extends nearly one half of the circumference of the housing 22 . The supply manifold 32 openings open onto the ends of the microchannels 24 . Each of the opposed supply manifold 32 openings communicates with alternate microchannels 24 , whereby one supply manifold 32 opening passes fluid coolant to alternating microchannels 24 extending in one direction, and the other supply manifold 32 passes fluid coolant to the adjacent alternating microchannels 24 extending in the other direction. As shown in FIG. 3 , inlets 36 to the corresponding return manifold 34 are formed in the bottom of alternating slots at the opposite end of the microchannels 24 from the supply manifold 32 .
The microchannel heat exchanger 20 of the present invention can be used with either open channels or closed channels. In the open channel configuration, shown in FIGS. 1-3 , the heat generating component (not shown) is positioned against the upper surface 28 of the housing 22 and is in direct contact with the fluid coolant. In the closed channel configuration, shown schematically in FIGS. 4 and 5 , a wall 38 defines the upper surface of the heat exchanger 20 . The wall 38 seals in the fluid coolant by closing the top of the microchannels 24 and forms an outside surface of the heat exchanger 20 . The use of open microchannels versus closed microchannels depends upon the heat generating component to be cooled. While the wall 38 between the fluid coolant and the heat generating component can be made very small, heat transfer will nevertheless depend upon conduction through the boundary layers between the heat exchanger 20 and the heat generating component. If the contact heat transfer coefficients are low, heat exchange is inefficient. A much higher heat flux is possible with open channels because the component to be cooled is in direct contact with the fluid coolant.
A suitable fluid coolant for use according to the present invention is deionized water. It is understood that the coolant may be any fluid, gas or liquid, for use in a heat exchanger, and is not limited to water or other liquid coolants. Other suitable coolants include alcohol, liquid propane, antifreeze, gaseous or liquid nitrogen, freons, air, and mixtures thereof. Preferably, the coolant has low viscosity.
Operation of the heat exchanger 20 according to the present invention is shown in the schematic cross-sectional views of the housing 22 shown in FIGS. 4 and 5 , which depict microchannels 24 a , 24 b having opposite fluid flow directions. The arrows denote the direction of fluid flow. Referring to FIG. 4 , fluid coolant is pumped into the supply manifold 32 as indicated by arrow 40 . Fluid passes from the supply manifold 32 through the supply manifold opening from which the fluid coolant enters the microchannel 24 a . Fluid flows across the plane of the heat exchanger 20 via the microchannel 24 a as indicated by arrow 42 . Fluid falls through the inlet opening 36 of the return manifold 34 at the end of the microchannel 24 a and through the return manifold 34 as indicated by arrow 44 . The walls of the slots define a closed end ( 45 ) of the microchannels adjacent the inlet openings ( 36 ) of the return manifold ( 34 ) ( FIG. 3 ).
Referring to FIG. 5 , fluid coolant is pumped into the supply manifold 32 as indicated by arrow 46 . Fluid passes from the supply manifold 32 through the supply manifold opening from which the fluid coolant enters the microchannel 24 b . Fluid flows across the plane of the heat exchanger 20 via the microchannel 24 b as indicated by arrow 48 , which is in a direction opposite to the direction indicated by arrow 42 . Fluid falls through the inlet opening 36 of the return manifold 34 at the end of the microchannel 24 b and through the return manifold 34 as indicated by arrow 50 . Although it is not shown, the supply manifold 32 and the return manifold 34 transition into a round cross-section and continue in a downward direction as seen in the FIGs. Once the fluid enters the return manifold 34 , the ΔP is low because the cross-section of the flow member is large. The fluid coolant then returns to the pump where the cycle starts again.
The heat exchanger 20 according to the present invention may be used with any heat generating component. The heat exchanger 20 is particularly suitable for use with optical components. In this application, the upper surface portion 28 of the heat exchanger 20 is formed to be optically flat. This feature allows the heat exchanger 20 to seal against an optically flat heat generating component upon contact, which is sufficient to provide a fluid tight seal. As seen in FIG. 2 , an o-ring 52 may be provided in a circumferential groove in the surface portion 28 of the housing 22 to provide a fluid tight seal. A seal may also be accomplished for other applications by soldering or other means.
The counter-flow microchannel heat exchanger 20 according to the present invention has many advantages, including reducing the temperature variation provided by a unidirectional flow heat exchanger by a factor of about 5, while maintaining low pressure drop and low fluid coolant utilization. By flowing fluid coolant in opposite directions in adjacent microchannels, the increase in coolant temperature in a direction parallel to the coolant flow is minimized. The heat exchanger can also provide substantially uniform cooling over a large area, typically about 100 cm 2 to about 1000 cm 2 , and can handle high heat flux (10-1000 W/cm 2 ) with a low pressure drop.
Example
Table 1 lists parameters of an exemplary unidirectional microchannel heat exchanger and an exemplary counter-flow open microchannel heat exchanger according to the present invention.
TABLE 1
HEX10A
HEX10A
Parallel
Counter
flow
flow
Channel width [μm]
610
610
Land width [μm]
406
406
Channel depth [μm]
1525
1525
Water film coef. [w/cm 2 -
3.3
3.3
K]
Contact film coef.
1.9
1.9
[w/cm 2 -K]
Channel water flow rate
5.5
5.5
[gm/s]
Channel water ΔT [° K]
3.35
3.35
Channel ΔP [psid]
15 psid
15 psid
Model ΔT(max) [K]
107.0
105.6
ΔOPD [μm] due to water
0.22 (~1/5 λ)
0.022 (~1/48 λ)
temperature rise
The results of a computer simulation of the two heat exchangers used to cool an optical component, a second surface mirror, are shown in FIGS. 6 and 7 . The counter-flow open microchannel heat exchanger according to the present invention reduced the optical path difference (OPD) in the optical component from 0.22 um in the unidirectional microchannel heat exchanger to 0.022 um.
Although the present invention has been shown and described in considerable detail with respect to only a few exemplary embodiments thereof, it should be understood by those skilled in the art that I do not intend to limit the invention to the embodiments since various modifications, omissions and additions may be made to the disclosed embodiments without materially departing from the novel teachings and advantages of the invention, particularly in light of the foregoing teachings. Accordingly, I intend to cover all such modifications, omission, additions and equivalents as may be included within the spirit and scope of the invention as defined by the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures.
|
A heat exchanger is provided for transferring heat to a working fluid. The heat exchanger comprises a housing having a plurality of grooves formed in a surface of the housing. The grooves have a first end and a second end, and define fluid flow channels. Each channel has a fluid flow inlet and a fluid flow outlet. The fluid flow inlets of an alternating first set of channels are adjacent to the first end of the grooves, and the fluid flow inlets of a second set of alternating channels are adjacent to the second end of the grooves. The first set of channels and the second set of channels are arranged such that fluid in immediately adjacent channels flows in opposite directions.
| 5
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application Ser. No. 60/178,421, filed Jan. 27, 2000, entitled “Apparatus for Regulating Power to an Integrated Circuit” and is a continuation application of U.S. application Ser. No. 10/136,209, filed May 1, 2002 now U.S. Pat. No. 6,703,814, entitled “Apparatus for Providing Regulated Power to an Integrated Circuit,” which is a continuation of application of U.S. application Ser. No. 09/771,756, filed Jan. 29, 2001, entitled “Apparatus for Providing Regulated Power to an Integrated Circuit.”
TECHNICAL FIELD
The present invention generally relates to microelectronic devices. More particularly, the present invention relates to microelectronic devices suitable for regulating power.
BACKGROUND OF THE INVENTION
Regulators are often employed to provide a desired, regulated power to microelectronic devices such as microprocessors. For example, switching regulators such as buck regulators are often used to step down a voltage (e.g., from about 3.3 volts) and provide suitable power to a microprocessor (e.g., about 10-30 amps and about 2-3 volts).
To increase speed and reduce costs associated with microprocessors, microprocessor gate counts and integration generally increase, while the size of the microprocessor per gate generally decreases. As gate counts, speed, and integration of microprocessors increase, supplying requisite power to microprocessors becomes increasingly problematic. For example, a current required to drive the processors generally increases as the number of processor gates increases. Moreover, as the gate count increases per surface area of a processor, the operating voltage of the processor must typically decrease to, among other reasons, reduce overall power consumption of the processor. Furthermore, as the microprocessor speed increases, the microprocessors demand the higher current at faster speeds.
Although buck regulators are generally suitable for controlling power to some microprocessors, such regulators are not well suited to supply relatively high current (e.g., greater than about 30 amps) at relatively high speed (e.g., greater than about 500 MHz.). One. reason that buck regulators have difficulty supplying high current at high speed to the microprocessor is that the current supplied from the regulator to the processor has to travel a conductive path that generally includes a portion of a printed circuit board that couples the processor to the regulator. The relatively long conductive path between the processor and the regulator slows a speed at which the regulator is able to supply current to the processor. In addition, as microprocessor speed and current demands increase, the buck controller simply cannot provide the desired amount of current at the desired rate.
Yet another problem with buck regulators is that they are generally configured to supply power to within about ±5% of a desired value. While this range may be acceptable for processors running at relatively low currents, this range becomes decreasingly acceptable as the current requirements of microprocessors increase. Thus, as microprocessor gate counts and clock speeds increase, improved methods and apparatus for supplying high current at high speed and low voltage are desired. Furthermore, methods and apparatus for supplying the relatively high current within a relatively tight tolerance is desired.
SUMMARY OF THE INVENTION
The present invention provides improved apparatus and techniques for providing regulated power to a microelectronic device. More particularly, the invention provides improved devices and methods suitable for supplying electronic devices with relatively high, regulated current at relatively high speed.
The way in which the present invention addresses the deficiencies of now-known regulators and power supply systems is discussed in greater detail below. However, in general, the present invention provides an array of power regulators that provides power to a single microelectronic device.
In accordance with one exemplary embodiment of the present invention, an array of regulators is configured to provide power to a microprocessor. In accordance with one aspect of this embodiment, the array is formed as an integrated circuit on a semiconductor substrate. In accordance with a further aspect of this embodiment, the circuit is coupled to the microprocessor through a relatively short conductive path (e.g., by coupling the circuit to the device via bump interconnects). In accordance with yet a further aspect of this embodiment, the array circuit is formed on a silicon germanium (SiGe) substrate to facilitate faster current supply to the device. In accordance with a further exemplary embodiment of the present invention, a tiered power regulation system is configured to provide power to a microelectronic device. The tiered system includes at least two levels of power regulation. In accordance with an exemplary aspect of this embodiment, a first level of power regulation includes a switching regulator and a second level of regulation includes a linear regulator. In accordance with a further aspect of this embodiment, the second level of regulation includes an array of linear regulators.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a power regulation system in accordance with an exemplary embodiment of the present invention;
FIG. 2 illustrates a power regulation system in accordance with alternative embodiment of the present invention; and
FIG. 3 schematically illustrates a portion of a regulator array in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The present invention generally relates to microelectronic power regulators. More particularly, the invention relates to regulators suitable for providing high current, high speed power to microelectronic devices and to electronic systems including the regulators. Although the present invention may be used to provide power to a variety of microelectronic devices, the invention is conveniently described below in connection with providing power to microprocessors.
An exemplary power supply system 100 in accordance with the present invention is schematically illustrated in FIG. 1 . As illustrated, system 100 includes an intermediate regulator 110 , a regulator array 120 , including regulators 120 ( a )- 120 ( n ), and a microprocessor 130 . System 100 may also suitably include a power converter 140 and one or more discrete electronic components, collectively represented as components 150 .
In general, system 100 is configured to provide relatively high current (e.g., 30 to more than 100 amps) at relatively low voltage (e.g., down to about 1 volt or less) with a relatively short response time. As discussed in greater detail below, in accordance with the present invention, system 100 provides the high current power to microprocessor 130 by distributing the power regulating duty to a plurality of regulators (e.g. regulator 110 and/or regulators 120 ( a )- 120 ( n )).
Converter 140 of system 100 is generally configured to convert alternating current (AC) power obtained from a typical AC power outlet to direct current (DC) power to, for example, provide suitable DC power for a motherboard of a computer. For example, in accordance with one exemplary embodiment of the present invention, converter 140 is configured to convert 110 volt AC power to about 3.3 volts to about 15 volts DC power at about 1 amp to about 20 amps. In accordance with one aspect of this embodiment, converter 140 includes multiple DC power outputs-e.g., about 12 volts at about 1 amp, about 5 volts at about 5 amps, at about 3.3 volts at about 30 amps to supply the power to, for example, various types of microelectronic devices which may be coupled to the motherboard. In accordance with alternative embodiments of the present invention, converter 140 may include any number of DC power outputs, and the amount of power associated with each output may vary in accordance with a type of device coupled to the output of converter 140 .
Intermediate regulator 110 is a DC-to-DC converter, which is designed to convert output from converter 140 to higher current, lower voltage power. In accordance with one exemplary embodiment of the present invention, regulator 110 receives power (e.g. 3.3 volts at 30 amps) from converter 140 and converts the power to about 1.15 volts at about 100 amps. Regulator 110 may be a linear regulator, a switching regulator, or any other suitable type of power controller; however, in accordance with one exemplary embodiment of the present invention, regulator 110 comprises a switching regulator such as a buck regulator.
System 100 may also optionally include discrete components 150 to facilitate rapid response power transfer from regulator 110 to array 120 . In particular, components 150 may include capacitors to store an appropriate charge and discharge the energy as array 120 calls for power from regulator 110 .
Regulator 120 is generally configured to provide high current (e.g., up to 100 amps or more) power at a relatively low response time (e.g., at speeds of 500 MHz and above) to microprocessor 130 . In accordance with an exemplary embodiment of the present invention, array 120 includes one or more power regulators (e.g., regulators 120 ( a )- 120 ( n )) configured to transform power received from regulator 110 and/or components 150 and convert the power into higher current, lower voltage power suitable for microprocessor 130 .
Array 120 may include any number of regulators, which may be configured and coupled to processor 130 in a variety of ways. For example, array 120 may include a number (n) of substantially identical regulators, wherein each regulator is configured to provide processor 130 with 1/n the operation power of processor 130 . However, in accordance with alternate embodiments of the invention, array 120 may be configured with regulators of various sizes that are configured to provide power to various portions of processor 130 . For example, array 120 may include relatively high current regulators to provide power to input/output buffers and relatively low current regulators to supply power to logic units of the microprocessor.
FIG. 2 illustrates a power supply system 200 in accordance with an alternative embodiment of the invention. Similar to system 100 , system 200 generally includes an intermediate regulator 210 , a regulator array 220 , including regulators 220 ( a )- 220 ( n ), a microprocessor 230 , and optionally a power converter 240 and components 250 .
System 200 is configured such that a portion of power supplied to microprocessor 230 may be derived from regulator 210 . For example, in accordance with one aspect of this embodiment, regulator 210 supplies power to input/output contacts of microprocessor 230 and/or a floating point contact of microprocessor 230 . However, the invention is not so limited; system 200 may suitably be configured such that regulator 110 provides power to any portion of microprocessor 230 .
FIG. 3 is a schematic illustration of an array 300 , showing regulators 310 , 320 , 330 , and 340 coupled to a common voltage reference 350 in accordance with an exemplary embodiment of the present invention. In accordance with the embodiment illustrated in FIG. 3 , each regulator 310 - 340 is configured to supply substantially the same power (at the reference voltage) to a microprocessor—e.g., microprocessor 130 .
Regulators 310 - 340 may include switching regulators, linear regulators, combinations thereof, or other suitable devices for controlling power. In accordance with one exemplary embodiment of the present invention, regulators 310 - 340 are linear regulators and each regulator 310 - 340 suitably includes a transistor (e.g., bipolar transistors 312 , 322 , 332 , and 342 ), an error amplifier (e.g., error amplifier 314 , 324 , 334 , and 344 ), and a voltage source (e.g., sources 316 , 326 , 336 , and 346 ).
As noted above, regulators 310 - 340 are generally configured to provide output power to processor 130 at a voltage substantially equivalent to voltage reference 350 . However, regulators 310 - 340 may suitably be trimmed such that the output voltage can be set to about ±1% of the reference voltage. In accordance with alternative embodiments of the present invention, array 300 may include multiple voltage references at various voltages, with one or more regulators tied to each reference. Use of multiple voltage references allows for power regulation at the various voltage levels to various portions of microprocessor 130 .
In accordance with one exemplary embodiment of the invention, all regulators (e.g., regulators 310 , 320 , 330 , and 340 ) are suitably coupled together in parallel such that, in addition to each regulator being tied to a common reference voltage, each regulator array 300 is tied to a common collector structure. The parallel coupling of regulators within an array allows for a total current output of array 300 which is equal to the sum of current outputs from each regulator within array 300 . Thus, time delays associated with larger regulators are mitigated because smaller regulators within an array are used to provide current to a portion or portions of microprocessor 130 . In other words, microprocessor 130 does not depend on a single, large regulator to supply requisite current.
A conductive path between array 120 and microprocessor 130 , or a portion thereof, is preferably relatively short to reduce the effects of parasitic inductance between an array (e.g., array 120 ) and microprocessor 130 . Providing a relatively short conductive path between array 120 and microprocessor 130 is additionally advantageous because parasitic inductance between array 120 and processor 130 is generally reduced as the distance between the components is reduced. One technique for providing a relatively short conductive path between array 120 and microprocessor 130 in accordance with the present invention is to couple array 120 to processor 130 using conductive bumps such as C4 (Controlled Collapse Chip Connection) bumps. In accordance with various aspects of this embodiment, array 120 may be coupled directly to microprocessor 130 , or array 120 may suitably be coupled to a package containing microprocessor 130 .
To facilitate fast power delivery from regulators 120 ( a )- 120 ( n ) of array 120 to processor 130 , regulators 120 ( a )- 120 ( n ) are formed on a semiconductor substrate having relatively high electron mobility such as silicon germanium (SiGe), Gallium Arsenide (GaAs), or the like. Forming regulators on SiGe or similar substrates that have relatively high electron mobility allows relatively quick power transfer (e.g., on the order of GHz speed) between regulator 120 and microprocessor 130 . In addition, semiconductive substrates such as SiGe exhibit a relatively high current density, compared to conventional semiconductor materials, which allows for formation of more transistors per surface area of SiGe compared to substrates having lower current density such as silicon.
In accordance with an alternative embodiment of the present invention, a regulator array and microprocessor 130 are formed on a single semiconductive substrate formed of, for example, SiGe, or other suitable semiconductive materials. Integrating an array and a microprocessor on a single substrate allows for even faster power supply from the array to the microprocessor. The integral array may provide power to all or a portion of the microprocessor and may be in addition to or in lieu of an array, such as array 120 illustrated in FIG. 1 .
Although the present invention is set forth herein in the context of the appended drawing figures, it should be appreciated that the invention is not limited to the specific form shown. For example, while the invention is conveniently described above in connection with providing power to a discrete microprocessor, the present invention may suitably be used provide power to a plurality of microelectronic devices. Various other modifications, variations, and enhancements in the design and arrangement of the method and apparatus set forth herein may be made without departing from the spirit and scope of the present invention as set forth in the appended claims.
|
A regulator system for supplying power to a microelectronic device is disclosed. The system includes an array of a plurality of regulators, where each regulator provides a portion of power required to operate the device. The system may further include an intermediate power regulator that supplies power to the array of regulators.
| 7
|
This is a division, of application Ser. No. 863,804, filed Dec. 23, 1977, now U.S. Pat. No. 4,166,150.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to coatings for paper or other sheets or substrates, which are generally classified in the art as release coatings and are characterized by their ability to separate intact from a surface or material which is normally adherent or adhesive in nature. There are many applications for such release coatings ranging from packaging materials for tacky products, such as asphalt, to release papers for such uses as preparing heat and pressure consolidated decorative laminates.
2. Description of the Prior Art
The requirements for release coatings and release sheets may vary widely, depending upon the application in which they are to be employed. For example, a release sheet which is adequate for use as a packaging material may not satisfy the requirements necessary for a release sheet used in the casting of a thermoplastic film or sheet; and, similarly, a release sheet which is adequate for a casting application may not be suitable in a platen press application wherein high temperatures and/or pressures are employed to consolidate decorative laminates. This latter application places particularly demanding requirements on the release sheets.
Decorative laminates have found widespread acceptance as marresistant surfaces for wall-coverings, paneling, table tops, counter tops, vanities, and the like. These laminates are conventionally formed by consolidating several laminae under heat and pressure to form a unitary structure which usually carries on at least one of its surfaces a surface decoration which can range from something as simple as a solid color to something as complex as an embossed, simulated woodgrain finish.
Preparation of such laminates generally involves the use of one or more sheets of corestock in combination with a decorative or print sheet and, if desired, a top sheet or overlay. The corestock, if corestock is employed, usually comprises an unbleached kraft paper which has been impregnated with a relatively inexpensive thermosetting resin such as a phenolic resin, a polyester resin, and the like, which is easily crosslinked upon the application of heat and pressure during consolidation.
The decorative or print sheet and the overlay (if used) are both impregnated with a "noble" thermosetting resin (i.e. a resin which is also cross-linkable upon the application of the heat and pressure during consolidation, but which exhibits little or no color deterioration upon the application of such heat and pressure and which prevents any strikethrough or "bleeding" of the thermosetting resin used in the corestock). Two of the most common "noble" thermosetting resins used to impregnate the decorative or print sheet employed in the preparation of such laminates are urea-formaldehyde resin condensates and melamine-formaldehyde resin condensates, although other resins such as polyester resins have also been employed as "noble" thermosetting resins for the impregnation of such sheets.
After consolidation, in those applications where the resulting laminate is intended to be used in a structural application, rather than merely for its decorative effect, the laminate is usually bonded to a substrate material such as plywood, hardboard, particle board, cementasbestos board, and the like, to give it additional strength and rigidity for its intended structural use.
As indicated above, the various laminae employed to form the ultimate laminate are consolidated through the simultaneous application of heat and pressure between heated pressure platens. Such presses generally consist of two heavy, heated platens on the top and bottom of the press, with additional heated platens in between to provide the number of openings desired in the press. Each opening typically includes the following elements in the following order: (a) a heated platen, (b) one or more sheets of caul stock, which are primarily intended to distribute pressure uniformly over the surface of the caul plate, (c) a metal caul plate, (d) the opening itself, (e) another metal caul plate, (f) one or more sheets of caul stock, and (g) another heated platen. The various laminae which will form a laminate are placed together in the opening, sometimes alone and sometimes as a "book" or "pack" of laminates.
In order to prevent the decorative sheet or overlay sheet from adhering to the caul plate, and in some cases to also impart desired gloss or surface texture to the decorative sheet or overlay sheet, it is customary to employ a release sheet or liner between the print sheet or overlay sheet and the caul plate. The laminae material which is placed against the release sheet is typically an uncured amine formaldehyde resin, such as melamine formaldehyde resin condensate or urea formaldehyde resin condensate. Such materials have a strong tendency to react with and/or adhere to the surface of the release sheet, placing tough requirements upon the release sheet, which must resist adhering to the laminate. This difficult requirement is further complicated by the fact that different manufacturers use different laminate materials and different press temperatures and pressures. Furthermore, the variation in heating and cooling cycles occurring from laminate to laminate and edge to center in each laminate, even in a single pressing operation can result in variable release results.
A particularly satisfactory prior art release coating and release sheet for use with platen pressing of decorative laminates is disclosed in U.S. Pat. No. 3,946,135, issued to John O. H. Peterson on Mar. 23, 1976. This patent, which is herein incorporated by reference, discloses a release coating formulation comprising a release agent, a monomeric polyhydric alcohol and a cross-linkable thermosetting resin. The monomeric polyhydric alcohol cross-links with the cross-linkable thermosetting resin to form a particularly stable surface having a low level of reactance with and/or adherence to laminates used in panel pressing. However, the release sheets coated from the above-described formula are sometimes not entirely satisfactory from a release standpoint for use with all varieties of laminate materials and press conditions. Also, the release coating formulation, which is coated as an aqueous solution onto a paper substrate, is sometimes difficult to coat because of its low viscosity. Attempts to increase the viscosity by adding conventional thickener materials have generally been unsatisfactory because of their tendency to rapidly cross-link with the other materials in the formulation to increase the coating viscosity very quickly beyond that which is coatable, resulting in an unacceptably short pot life.
SUMMARY OF THE INVENTION
The present invention relates to a coating composition for use in the preparation of a release coating and release sheet which is particularly useful for panel pressing applications wherein decorative laminates are consolidated under heat and pressure. In some embodiments, the invention is an improved form of the release coating described and claimed in U.S. Pat. No. 3,946,135. The coating composition of the present invention comprises a release agent, a cross-linkable thermosetting resin, and a water dispersible organic compound containing polyoxyethylene, polyoxypropylene, or block copolymers of polyoxyethylene and polyoxypropylene. The coating composition is applied to the substrate in an aqueous form, so the organic compound must be water dispersible, and is preferably water soluble. A monomeric polyhydric alcohol is preferably included in the coating composition to cross-link with the thermosetting resin. However, it can be left out in cases where the organic compound provides the same function.
The water dispersible organic compound is preferably chosen from either
Class A.--polyoxyethylenated polyoxypropylenated ethylene diamine, such as the materials sold under the trademark Tetronics; or
Class B.--a compound having the formula: ##STR1## where R 1 is hydrogen or an organic hydrophobe;
R 2 , R 3 , and R 4 are independently selected from H or CH 3 --, and where R 2 , R 3 , and R 4 are all H, more than 50% of the molecular weight of the compound is provided by polyoxyethylene;
X is 0,S, or N;
n=1 where X is 0 or S, n=2 where X is N; and
a, b, and c are zero or integers, and the sum of a, b, and c is greater than 1.
One Class B type of organic compound is the type in which R 1 , R 2 , R 3 , and R 4 is H, and X is 0 (polyoxyethylene), preferably where a+b+c is greater than 14 (mol. wt.=634).
Another Class B type of organic compound is the type in which R 1 is H; R 2 , R 3 , R 4 is CH 3 --(polyoxypropylene), and a+b+c is preferably less than 25 (mol. wt.=1468), and more preferably greater that 4 (mol. wt.=250).
Another Class B type of organic compound is the type in which R 1 , R 2 and R 4 is H; X is 0; R 3 is CH 3 --; and a; b and c are all integers (block copolymers of polyoxyethylene-polyoxypropylene-polyoxyethylene), preferably where 300>a+c>9 and 72>b>17.
Another Class B type of organic compound is the type in which R 1 , R 3 is H; R 2 , R 4 is CH 3 --; X is 0 and a, b, c are all integers (block copolymers of polyoxypropylene-polyoxyethylene-polyoxypropylene), preferably where 55>a+c>17 and 250>b>74.
Another Class B type of organic compound is the type in which R 1 is an organic hydrobe. Examples of such compounds include, but are not limited to, long-chain carboxylic acid esters of glycerol, polyoxyethylenated long-chain carboxylic acid esters of sorbitol or sorbitan, polyoxyethylenated fatty acids, polyoxyethylenated, polyoxypropylenated fatty acids, polyoxyethylenated alkylphenols, and polyoxyethylenated alcohols.
Some of the above named materials will be recognized as conventional surfactants. The addition of surfactants to release coatings does not usually improve release, and in many case is detrimental to release. Furthermore, it will be recognized that the quantities desirable for improving release in the present invention are much higher than those quantities normally used in surfactant applications. When used as surfactants, their function is to cause emulsification, lowering of surface tension and the like of aqueous systems, and they are typically used in an amount of about 1%. When they are used in the present invention to improve release characteristics, they are used in a quantity of about 4% to 30% of the coating compound, and as such comprise a substantial part of the coating structure. It should be recognized that some of the above-named materials are commercially obtainable or can be prepared as mixtures of each other and of the same type in varying molecular weights. Such mixtures are within the scope of the invention.
The resulting release sheet is highly useful in panel pressing release applications wherein decorative laminates are consolidated. They provide significantly improved release under a wide variety of conditions. The coating compositions of the invention exhibit excellent stability and pot life. The release sheets prepared therefrom provide very easy release in the pressing of laminates, including laminates of amine formaldehyde resins, under a wide variety of conditions. These release sheets may be reusable, and they permit excellent control over the gloss and surface texture of the laminates being pressed. Additionally, the water dispersible organic compound provides excellent viscosity control over the coating mixture without excessive build up of viscosity. This is believed to be due to the materials having only a few reactive sites even though they are in polymeric form. The present invention is also useful for release coatings upon which are cast urethanes and polyvinyl chloride resins.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The coating compositions of the invention are aqueous coating compositions comprising a release agent, a cross-linkable thermosetting resin, and a water dispersible organic compound containing polyoxyethylene and/or polyoxypropylene. Illustrative of the types of release agents which have been found useful in the coating compositions of the invention are the Werner type chromium complexes of a fatty acid, such as those sold under the trade name "QUILON" by E. I. duPont de Nemours & Company Inc. of Wilmington, Del. (e.g., QUILON S-the stearic acid complex, QUILON M or H-the myristic acid complex) and those sold under the tradename "KROMPLEX 75" (a myristic acid chrome chloride complex) by Sun Chemical Co.
Illustrative of the types of cross-linkable thermosetting resins which are useful in the coating compositions of this invention are ureaformaldehyde resin condensates, melamine-formaldehyde resin condensates, phenolic resins, and the like. Illustrative of the types of monomeric, polyhydric alcohols which are used in the preferred embodiments of the present invention are pentaerythritol, glycerine (glycerol), 1,6 hexanediol, tris-hydroxymethyl nitromethane, tartaric acid (dihydroxysuccinic acid) and the like, alone or in combination with each other.
The amounts of the various components used in the coating compositions of this invention are not narrowly critical, as long as they are sufficient to effectively provide release, and preferably range from about 3 parts by weight (dry) to about 30 parts by weight (dry) of release agent per 100 parts by weight (dry) of coating, from about 5 parts by weight (dry) to about 50 parts by weight (dry) of monomeric polyhydric alcohol per 100 parts by weight (dry) of coating (if the monomeric polyhydric alcohol is to be included), from about 20 parts by weight (dry) to about 60 parts by weight (dry) of cross-linkable thermosetting resin per 100 parts by weight (dry) of coating, and from about 4 parts, preferably 5 or more, by weight (dry) to about 30 parts by weight (dry) of the water dispersible organic compound per 100 parts by weight (dry) of coating.
In addition to the essential components set forth above, the coating compositions of the present invention may also contain other components such as anti-foam agents, dyes, colorants, and the like.
Release sheets are prepared from the coating compositions of this invention by coating the composition on a suitable base and then heating the resulting coated base until the release coating thereon has been dried and cured. The principal requirement for the substrate or base to be suitable is that it have a relatively smooth surface which resists substantial penetration of the aqueous coating composition into the base. In the case of a cellulosic fibrous substrate such as paper, this requirement is typically met by providing the paper with a base coating which comprises a mineral pigment (e.g. clay) and adhesive (or binder). In the case of a metal foil, no base coating will be necessary.
The following examples are intended to further illustrate the invention disclosed and claimed herein, but they are not intended to limit the scope thereof. The release coating formulation of each example was coated with a Meyer rod on a 83 lbs. per 3,300 square feet ream base paper sheet that had been previously coated on both sides with 5 lbs. per ream of a conventional clay-binder dispersion and further coated on the side upon which the release coating formulation was to be applied with 8 lbs. per ream of another conventional clay-binder dispersion. In each example except where otherwise indicated, the release coating was applied within 15 minutes after mixing and was dried in a circulating air oven for 1 minute at 150°-160° C. to yield a release coating of approximately 3 lbs. per 3,300 square feet ream.
The general formula for each of the examples was:
______________________________________Component Parts by Weight (Wet)______________________________________Pentaerythritol at 5.6% 14.3 g.Resimene 735 (an 80% solution inisopropyl alcohol of a methylatedmelamine-formaldehyde resin condensatesold by Monsanto Company of St. Louis,Missouri) 6.0 g.Quilon H (a 50% solution inisopropyl alcoholof a Werner-type chromicchloride complex with myristic acidsold by E. I. DuPont de Nemours andCompany, Inc. of Wilmington, Delaware) 2.4 g.isopropyl alcohol 0.6 g.2-ethylhexanol 0.6 g.Additive water soluble organiccompound material under test x______________________________________
Each of the coated and dried examples was tested by the following procedure. A 12 by 12 inch platen press at 280° F. and 1200 psi was used for pressing for 10 minutes. The configuration of the stack of materials in the press was, from top to bottom:
1. Hot platen
2. Conventional release sheet, face down
3. 2-phenolic sheets
4. Melamine-formaldehyde pre-preg sheet
5. The release sheet of the example being tested, face up
6. 1/8 inch thick aluminum caul plate
7. 3/4 inch thick pressed board
After pressing, the consolidated laminates were stripped from the release sheet of the example being tested and rated as follows:
______________________________________Release Value Observed______________________________________A Perfect peeling-type releaseB Sticking in small spots one or more cornersC Corner stickingD Severe corner sticking extended along edgesE Total edge and corner stickingF Partial release only in a few spotsG Total bonding, no release whatsoever______________________________________
The test procedure was purposely designed to be sufficiently stringent to result in very low ratings for the prior art release sheet (the control) to enable better evaluation of the improved release sheets. Although the control release sheet performed poorly under this test, it is satisfactory for many commercial applications.
______________________________________Ex- Amt. Re-am- g. leaseple (Wet Val-No. Additive Material Wt.) ue______________________________________1. CONTROL - NO ADDITIVE -- F2. Polyoxyethylene (Polyox WSR-80.sup.1) .8 Amol. wt. = 200,0003. Polyoxyethylene (Polyox WSR N-10.sup.1) .8 Amol. wt. = 100,0004. Polyoxyethylene (Polyox WSR N-10.sup.1) 1.6 Amol. wt. = 100,0005. Polyoxyethylene (Polyox WSR N-10.sup.1) 3.2 Amol. wt. = 100,0006. Polyoxyethylene (POE 200.sup.2) mol. .8 Fwt. = 2007. Polyoxyethylene (POE 200.sup.2) mol. 1.6 Dwt. = 2008. Polyoxyethylene (Carbowax 600.sup.1) .4 Fmol. wt. = 6009. Polyoxyethylene (Carbowax 600.sup.1) .8 Fmol. wt. = 60010. Polyoxyethylene (Carbowax 600.sup.1) 1.6 A-Bmol. wt. = 60011. Polyoxyethylene (Carbowax 4000.sup.1) .4 Fmol. wt. = 400012. Polyoxyethylene (Carbowax 4000.sup.1) .8 Amol. wt. = 400013. Polyoxyethylene (Carbowax 4000.sup.1) 1.6 Amol. wt. = 400014. Polyoxyethylene (Polyox POE 20M.sup.1) .4 Amol. wt. = 20,00015. Polyoxyethylene (Polyox POE 20M.sup.1) .8 Amol. wt. = 20,00016. Tetraethylene glycol, mol. wt. = 176 .4 F17. Tetraethylene glycol, mol. wt. = 176 .8 F18. Polyoxyethylenated polyoxypropylene .4 Aglycol (Pluronic L-35.sup.3) mol. wt. ofPPO = 950, + 20 moles EO19. Polyoxyethylenated polyoxypropylene .8 Aglycol (Pluronic L-35.sup.3) mol. wt. ofPPO = 950, + 20 moles EO20. Polyoxyethylenated polyoxypropylene .4 Aglycol (Pluronic L-31.sup.3) mol. wt. ofPPO = 950, + 3 moles EO21. Polyoxyethylenated polyoxypropylene .8 Cglycol (Pluronic L-31.sup.3) mol. wt. ofPPO = 950, + 3 moles EO22. Polyoxyethylenated polyoxypropylene 1.6 Dglycol (Pluronic L-31.sup.3) mol. wt. ofPPO = 950, + 3 moles EO23. Polyoxyethylenated polyoxypropylene .4 Dglycol (Pluronic F-108.sup.3) mol. wt.of PPO = 3250, + 300 moles EO24. Polyoxyethylenated polyoxypropylene .8 Aglycol (Pluronic F-108.sup.3) mol. wt.of PPO = 3250, + 300 moles EO25. Polyoxypropylenated polyoxyethylene .4 Bglycol (Pluronic 10R5.sup.3) mol. wt.of PPO = 1000, + 23 moles of EO26. Polyoxypropylenated polyoxyethylene .8 Aglycol (Pluronic 10R5.sup.3) mol. wt.of PPO = 1000, + 23 moles of EO27. Polyoxypropylenated polyoxyethylene .4 Dglycol (Pluronic 17R2.sup.3) mol. wt.of PPO = 1700, + 10 moles EO28. Polyoxypropylenated polyoxyethylene .8 Aglycol (Pluronic 17R2.sup.3) mol. wt.of PPO = 1700 + 10 moles EO29. Polyoxypropylenated polyoxyethylene .4 Eglycol (Pluronic 10R8.sup.3) mol. wt.of PPO = 1000, + 91 moles EO30. Polyoxypropylenated polyoxyethylene .8 Aglycol (Pluronic 10R8.sup.3) mol. wt.of PPO = 1000, + 91 moles EO31. Polyoxypropylenated polyoxyethylene .4 Dglycol (Pluronic 25R5.sup.3) mol. wt.2500 PPO, 57 moles EO32. Polyoxypropylenated polyoxyethylene .8 Aglycol (Pluronic 25R5.sup. 3) mol. wt.2500 PPO, 57 moles EO33. N,N'-Polyoxypropylenated .4 Dethylenediamine mol. wt.,2501-3000 + 14-17 moles EO(Tetronic 702.sup.3)34. N,N'-Polyoxypropylenated .8 Aethylenediamine mol. wt.2501-3000 + 14-17 moles EO(Tetronic 702.sup.3)35. N,N'-Polyoxypropylenated .4 Eethylenediamine mol. wt.3501-4000 + 53-61 moles EO(Tetronic 904.sup.3)36. N,N'-Polyoxypropylenated .8 Aethylenediamine mol. wt.3501-4000 + 53-61 moles EO(Tetronic 904.sup.3)37. N,N'-Polyoxypropylenated .4 Cethylenediamine mol. wt.3501-4000 + 318-363 moles EO(Tetronic 908.sup.3)38. N,N'-Polyoxypropylenated .8 Aethylenediamine mol. wt.3501-4000 + 318-363 moles EO(Tetronic 908.sup.3)39. Polyoxypropylene (Polyglycol .4 BP-1200.sup.2) mol. wt. 120040. Polyoxypropylene (Polyglycol 200.sup.2) .8 Fmol. wt. 20041. Polyoxypropylene (Polyglycol 200.sup.2) 1.6 Dmol. wt. 20042. Polyoxyethylenated castor oil .4 C(Emulphor EL-719.sup.4) 40 moles EO43. Polyoxyethylenated sorbitan .4 Amonolaurate (Tween 20.sup.5) 20moles EO44. Polyoxyethylenated sorbitan .8 Amonolaurate (Tween 20.sup.5) 20moles EO45. Polyoxyethylenated sorbitan .4 Bmonopalmitate (Tween 40.sup.5) 20moles EO46. Polyoxyethylenated sorbitan .8 Amonopalmitate (Tween 40.sup.5)20 moles EO47. Polyoxyethylenated sorbitan .4 Amonooleate (Tween 80.sup.5) 20moles EO48. Polyoxyethylenated sorbitan .8 Amonooleate (Tween 80.sup.5)20 moles EO49. Polyoxyethylenated sorbitan .4 Bmonooleate (Tween 81.sup.5)5 moles EO50. Polyoxyethylenated sorbitan .8 Amonooleate (Tween 81.sup.5) 5moles EO51. Polyoxyethylenated sorbitol .4 Dlaurate (G-1045.sup.5)52. Polyoxyethylenated sorbitol .8 A-Blaurate (G-1045.sup.5)53. Polyoxyethylenated sorbitol- .4 Blanolin esters (G-1471.sup.5)54. Polyoxyethylenated sorbitol- .8 Alanolin esters (G-1471.sup.5)55. Polyoxyethylenated sorbitol- .4 Bbeeswax ester (G-1726.sup.5)56. Polyoxyethylenated sorbitol- .8 Bbeeswax ester (G-1726.sup.5)57. Polyoxyethylenated .4 Apolyoxypropylenated stearicacid (G-2162.sup.5)58. Polyoxyethylenated .8 Apolyoxypropylenated stearicacid (G-2162.sup.5)59. Polyoxyethylenated stearic .4 Bacid (Myrj 45.sup.5) 8 moles EO60. Polyoxyethylenated stearic .8 Aacid (Myrj 45.sup.5) 8 moles EO61. Polyoxyethylenated stearic .4 Bacid (Myrj 52.sup.5) 40 moles EO62. Polyoxyethylenated stearic .8 Aacid (Myrj 52.sup.5) 40 moles EO63. Polyoxyethylenated nonylphenol .4 C(Tergitol NP-14.sup.1) 4 moles EO64. Polyoxyethylenated nonylphenol .8 D(Tergitol NP-14.sup.1) 4 moles EO65. Polyoxyethylenated nonylphenol .4 D(Tergitol NP-27.sup.1) 7 moles EO66. Polyoxyethylenated nonylphenol .8 B(Tergitol NP-27.sup.1) 7 moles EO67. Polyoxyethylenated nonylphenol .4 C(Tergitol NP-35.sup.1) 15 moles EO68. Polyoxyethylenated nonylphenol .8 A(Tergitol NP-35.sup.1) 15 moles EO69. Polyoxyethylenated nonylphenol .4 C(Tergitol NP-40.sup.1) 20 moles EO70. Polyoxyethylenated nonylphenol .8 A(Tergitol NP-40.sup.1) 20 moles EO71. Polyoxyethylenated lauryl alcohol .4 A(Brij 35.sup.5) 23 moles EO72. Polyoxyethylenated lauryl alcohol .8 A(Brij 35.sup.5) 23 moles EO73. Polyoxyethylenated stearyl alcohol .8 B(Brij 76.sup.5) 10 moles EO74. Polyoxyethylenated tert-octylphenol .4 A(Triton X-100.sup.5) 9-10 moles EO75. Same as Ex. No. 2, except Quilon H .8 Gwas replaced with 3.0 g. of Volan(a chrome complex of methacrylicacid)76. Same as Ex. No. 2, except Quilon H .8 Gwas replaced with p-toluene sulfonicacid77. Same as Ex. No. 12, except Quilon H .8 Awas replaced with Quilon S.sup.7 (a 30%solution in isopropyl alcohol of aWerner type chromic chloride complexwith stearic acid)78. Same as Ex. No. 2, except Resimene .8 C735 was replaced with Cymel 303.sup.879. Same as Ex. No. 12, except Resimene .8 C735 was replaced with 4.8 g. ofResimene 975.sup.9 (urea formaldehyderesin condensate)80. Same as Ex. No. 12, except Resimene .8 A735 was replaced with 4.8 g. ofResimene X980.sup.9 (urea formaldehyderesin condensate)81. Same as Ex. No. 2, except 2-ethyl .8 Ahexanol was replaced with anadditional 0.9 g. of isopropylalcohol82. Same as Ex. No. 2, except isopropyl .8 Balcohol was replaced with anadditional 0.9 g. of 2-ethylhexanol83. Same as Ex. No. 2, except isopropyl .8 Band 2-ethyl hexanol were left out84. Same as Ex. No. 12, except .8 Apentaerythritol was replaced withtris-hydroxymethyl nitromethane85. Same as Ex. No. 12, except .8 Apentaerythritol was replaced with1.6 gms. of 1,6 hexanediol86. Same as Ex. No. 12, except .8 Apentaerythritol was left out87. Coating of all Polyox WSR-80.sup.1 G88. Same as Ex. No. 1, except Resimene 0 F735 was replaced with Resimene 975.sup.989. Same as Ex. No. 1, except Resimene 0 F735 was replaced with Resimene X980.sup.990. Same as Ex. 85, except carbowax 4000 0 Fwas left out91. Same as Ex. No. 2, except Resimene .8 G735 was left out92. Same as Ex. No. 20, except coated .4 A2 hours after mixing93. Same as Ex. No. 21, except coated .8 A2 hours after mixing94. Same as Ex. No. 22, except coated 1.6 A2 hours after mixing______________________________________ .sup.1 Manufactured by Union Carbide Corp. of N.Y., N.Y. .sup.2 Manufactured by Dow Chemical Co. of Midland, Michigan .sup.3 Manufactured by Wyandotte Chemical Corp. of Wyandotte, Michigan .sup.4 Manufactured by GAF Corp. of N.Y., N.Y. .sup.5 Manufactured by Atlas Chemical Industries, Inc. of Wilmington, Delaware .sup.6 Manufactured by Rohm and Haas Company of Philadelphia, Pennsylvani .sup.7 Manufactured by E. I. duPont de Nemours & Co. of Wilmington, Delaware .sup.8 Manufactured by American Cyanimide .sup.9 Manufactured by Monsanto Company of St. Louis, Missouri
From the above examples it can be seen that a wide variety of compounds containing polyoxyethylene and/or polyoxypropylene significantly improve the release values of the release coating described in U.S. Pat. No. 3,946,135. For illustration, compare Example No. 1 (which represents the release coating of U.S. Pat. No. 3,946,145) with Examples Nos. 2-74. As can be seen from the examples, some materials need be used in a larger quantity than others to provide the most improved release, and some of the materials are more effective at lower concentration (see Exs. 43, 47, 57 and 71). Also, it can be seen that higher molecular weights of polyoxyethylene, for example 600 or more, provide a greater improvement to release than lower molecular weights. See Examples 2-17.) Also, it can be seen that examples of higher molecular weight polyoxypropylene provide greater improvements to release than lower molecular weight examples. However, polyoxypropylene at higher molecular weight becomes water insoluble. Therefore, only a narrow molecular weight range of polyoxypropylene is preferred in the invention, from a molecular weight of about 200 to about 1200, for example. (See Examples 39-41.)
Examples 75-91 illustrate the results from varying other materials in the coating formula. Example 86 indicates the ability to leave out the monomeric polyhydric alcohol of the formula disclosed and claimed in U.S. Pat. No. 3,946,135, when using the additive material of the present invention. Coating formulations of the present invention have varying release characteristics depending upon how long after being mixed they were coated on the paper. Examples 92-94 illustrate the improvement over the coating mixture of examples 20-22 when coating 2 hours after mixing.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it is understood that a number of variations and modifications will occur to a person skilled in the art without departing from the spirit and scope of the invention as defined in the appended claims.
|
Disclosed is a release sheet having on at least one of its outer surfaces a dried and cured coating composition comprising a release agent, a cross-linkable thermoplastic resin, and a water dispersible organic compound containing polyoxyethylene, polyoxypropylene, or a block copolymer of polyoxyethylene and polyoxypropylene.
| 3
|
I claim the benefit under Title 35, United States Code, § 120 to U.S. Provisional Application No. 60/422,492, filed Oct. 31, 2002, entitled METHOD FOR THE ALKYLATION OF SALICYLIC ACID.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the alkylation of salicylic acid with long-chain olefins. These alkylated salicylic acids can be overbased to form useful lubricating oil additives.
2. Description of Related Art
It is known to use alkaline earth metal salts of organic carboxylic acids as additives for lubricating oil compositions. These salts have a dispersant property that helps ensure that the insides of engine cylinders remain clean and that deposition of carbonaceous products on pistons and in piston grooves is counteracted, thus preventing piston-ring sticking.
It is also known to prepare basic (or overbased) alkaline earth metal salts of such acids. The overbasing provides an alkaline reserve which, when applied in lubricating oil compositions, reacts with and neutralizes acidic compounds formed during the operation of the engine in which the composition is applied. Hence, any sludge that may arise is dispersed owing to the dispersant property of the salt, while acids that would enhance sludge formation are neutralized.
Overbased salicylates are prepared by overbasing the corresponding alkylated salicylic acids. The alkyl group is typically a long chain alkyl group of greater than about 14 carbon atoms so as to impart oil solubility. Alkylated salicylic acids are conventionally prepared by the alkylation of a phenol to form an alkylphenol followed by carboxylation of the alkylphenol by the Kolbe-Schmitt reaction to provide the alkylated salicyclic acid. In addition to the adverse economics attributable to the use of high temperatures and/or pressures, the Kolbe-Schmitt route to alkylated salicylic acids suffers from the problem that, when substantially linear alkylation feeds are employed, not all of the long-chain alkylphenol is readily carboxylated. Specifically, conventional alkylation of phenol with a substantially linear alkylation feed provides for approximately a 50:50 mixture of ortho-alkylphenol and para-alkylphenol. While the Kolbe-Schmitt reaction readily carboxylates the resulting long chain para-alkylphenol, the resulting long chain ortho-alkylphenol is less reactive and only about 70 percent of total amount of the alkylphenol derived from a substantially linear alkylation feed is typically converted to alkylated salicylic acid during this reaction.
One method of circumventing this problem is to alkylate an alkyl salicylate (e.g., methyl salicylate) and then subject the resulting alkylated alkyl salicylate to hydrolysis so as to provide for the alkylated salicylic acid. Methods of alkylating alkyl salicylates are disclosed in U.S. Pat. No. 5,434,293.
DD-A-269 619 and DD-A-293 108 both disclose the direct alkylation of salicylic acid with an olefin using an acidic ion exchange resin or polyphosphoric acid respectively as catalyst. Both documents teach that the use of sulfuric acid as a catalyst (in prior art processes not involving alkylation of the acid with an olefin) is undesirable because it has many disadvantages, such as corrosion problems and side reactions.
DE 689 600 discloses the use of perchloric acid as the catalyst.
U.S. Pat. No. 1,998,750 discloses the condensation of salicylic acid with any nonaromatic monohydric alcohol having from 5 to 7 carbon atoms, or with compounds capable of furnishing an amyl-, hexyl-, cyclohexyl-, or heptyl- group, in the presence of sulfuric acid.
U.S. Pat. No. 4,810,398 discloses a basic alkaline earth metal salt of a blend of organic carboxylic acids is prepared by (a) preparing a mixture of one equivalent of the blend of organic carboxylic acids and more than one equivalent of an alkaline earth metal hydroxide and/or oxide in a hydrocarbon solvent; (b) introducing carbon dioxide into the mixture obtained in an amount of at least 0.5 equivalent carbon dioxide per equivalent of excess alkaline earth metal; and (c) removing residual solids, if any, and an aqueous layer, if any, whereby the blend of organic carboxylic acids comprises a C 8-30 alkyl salicylic acid and one or more alkanecarboxylic acids in which the alkyl moiety is branched and has from 4 to 40 carbon atoms. Such a salt has dispersant properties and is said to be suitable for use in lubricating oil and fuel compositions.
U.S. Pat. No. 4,869,837 discloses a process for the preparation of a basic alkaline earth metal salt of a blend of organic carboxylic acids, which comprises (a) preparing a mixture of one equivalent of the blend of organic carboxylic acids and more than one equivalent of an alkaline earth metal hydroxide and/or oxide in a hydrocarbon solvent; (b) introducing carbon dioxide into the mixture obtained in an amount of at least 0.5 equivalent carbon dioxide per equivalent of excess alkaline earth metal; and (c) removing residual solids, if any, and an aqueous layer, if any, whereby the blend of organic carboxylic acids comprises an oil-soluble alkyl salicylic acid and one or more hydrocarbon substituted succinic acids or anhydrides, in which the hydrocarbon radical has a number average molecular weight from 120 to 5000.
U.S. Pat. No. 4,876,020 discloses a lubricating oil composition comprising a lubricating base oil, one or more overbased alkaline earth metal salts of an aromatic carboxylic acid, and a stabilizing agent which has been selected from a polyalkoxylated alcohol having a molecular weight from 150 to 1500.
U.S. Pat. No. 5,049,685 discloses a nuclear substituted salicylic acid represented by the following general formula
wherein R 1 represents a methyl group, an isopropyl group, a tert-butyl group, a tert-amyl group, a tert-hexyl group, a tert-octyl group, an α,α-dialkylbenzyl group or a nuclear substituted α,α-dialkylbenzyl group; and R 2 represents a tert-butyl group, a tert-amyl group, a tert-hexyl group, a tert-octyl group, an α,α-dialkylbenzyl group or a nuclear substituted α,α-dialkylbenzyl group) and a salt thereof. The nuclear substituted salicylic acids and salts thereof are said to have good solubility in water, organic solvents or organic polymeric compounds and that they are very favorable as bactericidal and germicidal agents, stabilizers for polymeric compounds or color developing agents for recording materials.
U.S. Pat. No. 5,415,792 discloses overbased alkyl alkyl salicylates that are said to be useful additives for lubricating oil compositions. In particular, the compositions impart detergency and dispersancy to the lubricating oil composition as well as provide for an alkalinity reserve.
U.S. Pat. No. 5,434,293 discloses a method for alkylating alkyl salicylates using a solid acidic alkylation catalyst and approximately equimolar amounts of alkyl salicylate and alkylating feedstock.
U.S. Pat. No. 5,451,331 discloses a process for the production of a lubricating oil additive concentrate having a TBN greater than 300 that comprises reacting, at elevated temperature, component (A) a defined salicylic acid derivative, component (B) an alkaline earth metal base added either in a single addition or in a plurality of additions at intermediate points during the reaction, component (C) at least one compound which is (i) water, (ii) a polyhydric alcohol having 2 to 4 carbon atoms, (iii) a di-(C 3 or C 4 ) glycol, (iv) a tri-(C 2 –C 4 ) glycol, (iv) a mono- or poly-alkylene glycol alkyl ether of the formula (I) R(OR 1 ) x OR 2 (I) wherein R is a C 1 to C 6 alkyl group, R 1 is an alkylene group R 2 is hydrogen or a C 1 to C 6 alkyl group and x is an integer from 1 to 6, (vi) a C 1 to C 20 monohydric alcohol, (vii) a C 1 to C 20 ketone, (viii) a C 1 to C 10 carboxylic acid ester, or (ix) a C 1 to C 20 ether, component (D) a lubricating oil, component (E) carbon dioxide added subsequent to the, or each, addition of component (B), component (F) a defined carboxylic acid or derivative, and component (G) at least one compound which is (i) an inorganic halide of (ii) an ammonium alkanoate or mono-, di-, tri- or tetra-alkyl ammonium formate or alkanoate provided that, when component (G) is (ii), component (F) is not an acid chloride, the weight ratios of all components being such as to produce a concentrate having a TBN greater than 300.
U.S. Pat. No. 5,734,078 discloses a process for the production of an alkyl salicylic acid in which the alkyl substituent has at least 6 carbon atoms, comprising reacting salicylic acid with an olefin having at least 6 carbon atoms at elevated temperature in the presence of sulfuric acid as a catalyst. Lubricating oil additives comprising a metal salt of such alkylated salicylic acids and a process for making them are also disclosed.
U.S. Pat. No. 5,792,735 discloses a lubricating oil composition said to be suitable for use in low or medium speed diesel engines that comprises a fuel oil with a residual oil content characterized in that the lubricating oil composition further comprises a hydrocarbyl-substituted phenate concentrate having a TBN greater than 300, and at least one of a hydrocarbyl-substituted salicylate and a hydrocarbyl-substitute sulphonate. The hydrocarbyl-substituted phenate is preferably one modified by incorporation of a carboxylic acid of the formula RCH(R 1 )CO 2 H where R is a C 10 –C 24 alkyl group and R 1 is hydrogen or a C 1 to C 4 alkyl group, e.g., stearic acid.
U.S. Pat. No. 6,034,039 discloses complex detergents that are said to provide improved deposit control and corrosion protection in crankcase lubricants.
The disclosures of the foregoing are incorporated herein by reference in their entirety.
SUMMARY OF THE INVENTION
The present invention is directed to the preparation of alkylated salicylic acids from salicylic acid and branched, internal and alpha olefins using a perfluoroalkylsulfonic acid, an alkylsulfonic acid, or an acidic clay, such as Fulcat® 22B or Filtrol® 20X, as the catalyst. It is preferred that the alkyl groups of the sulfonic acids have from 1 to about 30 carbon atoms. Anhydrous methanesulfonic acid (10 to 30 mole % of the moles of salicylic acid) is especially preferred. The conditions are such as to allow a suspension of salicylic acid in the olefin to react at elevated temperatures, preferably from about 120° C. to 160° C., with olefin excesses of up to about 20 mole percent relative to the salicylic acid. The products are mixtures of ortho and para monoalkylated salicylic acids with some dialkylated and trialkylated salicylic acids. The alkyl phenol content is very low and the color of the product is excellent compared to that obtained via the Kolbe-Scmitt synthesis. The alkylated salicylic acids have acid numbers approximately 60–95% of the theoretical value. PDSC and panel coker values of the corresponding overbased calcium salts of the salicylic acids are comparable or superior to control commercial salicylate detergents.
In the preferred case in which methanesulfonic acid is used as the catalyst, the catalyst can be readily removed and recycled by the addition of from about 10 to about 50 weight percent (relative to the reaction mass) of light naphtha to the final reaction product, which precipitates the catalyst. If the catalyst is to be discarded, a water wash can remove the methanesulfonic acid. The solution of alkyl salicylic acid can be used directly for the preparation of overbased alkali or alkaline earth metal salicylates.
More particularly, the present invention is directed to a process for the production of alkyl salicylic acids comprising reacting salicylic acid with an olefin having at least four carbon atoms at elevated temperature in the presence of a perfluoroalkylsulfonic acid, an alkylsulfonic acid, or an acidic clay as a catalyst.
In another aspect, the present invention is directed to composition comprising an alkyl salicylic acid prepared by a process comprising reacting salicylic acid with an olefin having at least four carbon atoms at elevated temperature in the presence of a perfluoroalkylsulfonic acid, an alkylsulfonic acid, or an acidic clay as a catalyst.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The process of the present invention can be represented by the following equation:
wherein:
R is selected from the group consisting of hydrogen, linear alkyl groups of from 4 to 30 carbon atoms, and branched alkyl groups of from 4 to 30 carbon atoms, and
R′ is selected from the group consisting of linear alkyl groups of from 4 to 30 carbon atoms and branched alkyl groups of from 4 to 30 carbon atoms.
Both straight-chain and branched-chain olefins, preferably α-olefins, can be employed in the practice of the present invention. Preferably, the olefin has from 4 to 50, more preferably from 8 to 35, and most preferably from 8 to 25 carbon atoms. Suitable olefins include, but are not limited to, isobutylene, propylene trimer, propylene tetramer, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicosene, 1-docosene, 1-tetracosene, mixtures of the foregoing, and the like.
Commercial salicylic acid can be employed with or without further purification.
The conditions under which the reaction is carried out depend upon the nature of the olefin to be employed. The conditions to be described hereinafter are for 2-methyl-1-undecene, an example of a longer carbon chain branched 1-olefin. Those skilled in the art will realize that, with other olefins, different optimum reaction conditions may, and probably will, be desirable.
The temperature at which the salicylic acid and the olefin are reacted is preferably about 50° C. or more, and may suitably be in the range from about 50° to about 200° C. The optimum temperature within this range is dependent on the carbon chain length of the olefin. Typically, for a C 14 olefin the optimum temperature is from about 100° to about 170° C., preferably, about 120° to about 160° C.
The duration of the reaction is usually not critical. A reaction time of from about 2 to about 36 hours is usually satisfactory.
The reaction can, if desired, be carried out in a solvent, but normally no solvent is employed.
The alkyl salicylic acid can be recovered from the reaction mixture by means known in the art. For C 12 and higher alkyl salicylic acids, solvent extraction, preferably with light naphtha, is typically used.
The alkylated salicylic acids prepared by the process of the present invention are useful as intermediates in the preparation of lubricating oil additives. The method for effecting such use comprises the steps of forming a C 4 or higher alkyl salicylic acid as disclosed above, and then reacting it with a metal base in the presence of a solvent at elevated temperature.
The reaction with the metal base can be carried out in the presence of carbon dioxide and, optionally, a carbonation catalyst. The metal base can be an alkali metal or an alkaline earth metal base, or a mixture of the two. An alkaline earth metal base is preferred. Of the alkaline earth metals, calcium, magnesium, and barium are preferred and calcium is especially preferred. The base may take the form of the oxide or the hydroxide, e.g., slaked lime, which is principally calcium hydroxide.
The amount of base added should be sufficient to provide an overbased salt, i.e., one in which the ratio of the number of equivalents of the metal moiety to the number of equivalents of the alkyl salicylic acid moiety is usually greater than about 1.2, and can be as high as 4.5 or greater.
The metal base may be added either in a single addition or in a plurality of additions at intermediate points during the reaction.
The overbasing reaction mixture suitably further contains a promoter, preferably an oxygen-containing organic solvent and optionally water. Suitable promoters include C 1-6 alcohols, polyhydric alcohols such as glycol, propylene glycol, glycerol, or 1,3-dihydroxypropane, ethers such as C 1-4 monoethers of glycol or propylene glycol, diisopropyl ether, 1,3- or 1,4-dioxane, or 1,3-dioxolane. Preferably, the promoter is a C 1-6 alcohol, in particular, methanol.
The solvent for the reaction of the alkyl salicylic acid with the metal base may be
(1) a polyhydric alcohol having 2 to 4 carbon atoms; (2) a di-(C 2 to C 4 ) glycol; (3) a tri-(C 2 to C 4 ) glycol; (4) a mono- or polyalkylene glycol alkyl ether of the formula:
R 1 (OR 2 ) x OR 3
wherein R 1 is a C 1 to C 6 alkyl group, R 2 is an alkylene group, R 3 is hydrogen or a C 1 to C 6 alkyl group and x is an integer from 1 to 6;
(5) a monohydric alcohol having up to 20 carbon atoms; (6) a ketone having up to 20 carbon atoms; (7) a carboxylic acid ester having up to 10 carbon atoms; (8) a volatile liquid hydrocarbon; or (9) an ether having up to 20 carbon atoms.
The preferred solvent is an inert hydrocarbon, which can be either aliphatic or aromatic. Suitable examples include toluene, xylene, naphtha, and aliphatic paraffins, e.g., hexane, and cycloaliphatic paraffins.
A combination of methanol, which acts as a promoter in the reaction, and naphtha is especially preferred.
In view of the intended use of the overbased product as a lubricating oil additive, it is preferred to incorporate a base oil as a supplemental diluent. The base oil can be an animal oil, a vegetable oil, or a mineral oil. Preferably, it is a petroleum-derived lubricating oil, such as a naphthenic base, a paraffin base, or a mixed base oil. Alternatively, the lubricating oil may be a synthetic oil, for example, a synthetic ester or a polymeric hydrocarbon lubricating oil.
Carbon dioxide is employed in the production of overbased metal salts in the form of a gas or a solid, preferably in the form of a gas, wherein it can be blown through the reaction mixture. Carbon dioxide addition is typically effected after the addition of metal base.
A carbonation catalyst can be used to produce highly overbased metal salts. The catalyst can be either an inorganic compound or an organic compound, preferably an inorganic compound. Suitable inorganic compounds include hydrogen halides, metal halides, ammonium halides, metal alkanoates, ammonium alkanoates or mono-, di-, tri- or tetra-alkyl ammonium formates or alkanoates. Examples of suitable catalysts include calcium chloride, ammonium chloride, calcium acetate, ammonium acetate, zinc acetate, and tetramethyl(ammonium acetate). The catalyst is typically employed at a level of up to about 2% by weight. A more complete description of the production of highly overbased metal alkyl salicylates can be found in EP-A-0351052.
Suitably, the elevated temperature employed in the above reaction may be in the range from about 100° to about 500° F. (about 38° to about 260° C.).
The concentrate of the metal salt in the solvent can be recovered by conventional means, such as distillative stripping. Finally, the concentrate can be filtered, if desired.
The amount of additive concentrate present in the finished lubricating oil will depend on the nature of the final use. For marine lubricating oils, it is typically enough to provide a TBN of from 9 to 100; for automobile engine lubricating oils, enough to provide a TBN of from 4 to 20.
As used herein, the term “Total Base Number” or “TBN” refers to the amount of base equivalent to milligrams of KOH in 1 gram of additive. Thus, higher TBN numbers reflect more alkaline products and therefore a greater alkalinity reserve. The Total Base Number for an additive composition is readily determined by ASTM test method number D2896 or other equivalent methods.
The finished lubricating oil may also contain effective amounts of one or more other types of conventional lubricating oil additives, for example viscosity index improvers, anti-wear agents, antioxidants, dispersants, rust inhibitor, pour-point depressants, and the like.
The advantages and the important features of the present invention will be more apparent from the following examples.
EXAMPLES
Example 1
Alkylation of Salicylic Acid
Salicylic acid (215.0 grams) is added to a 3 liter glass vessel equipped with a stirrer, a thermometer, and a heating mantle. A mixed C 14 –C 18 olefin (367.7 grams) is added next, followed by an alkylation catalyst, preferably 45.1 grams of methanesulfonic acid. The mixture is heated to 120° C. and kept at that temperature for 24 hours. Next, some light naphtha, such as VM&P naphtha, (582.6 grams) is introduced and the clear solution is allowed to settle to remove the spent catalyst. The product recovered is a clear yellowish naphtha diluted alkyl salicylic acid suitable for direct overbasing or for reaction with previously overbased detergent.
Example 2
Salicylic Acid Monoalkylated with a 16.4:47.9:35.6 Wt/Wt % Mixture of C 14 , C 16 , C 18 α-olefins
A three liter resin kettle was charged with salicylic acid powder (828.96 grams, 6.0 moles). The kettle was fitted with five-hole lid, mechanical stirrer (PTFE bearing, polished glass shaft, PTFE axial and radial turbines), reflux condenser (attached to a nitrogen line and mineral oil bubbler for positive pressure) and mantle, Therm-O-Watch®, thermocouple. The kettle was charged with a commercial mixture of C 14 /C 16 /C 18 α-olefins (1414.12 grams, 6.30 moles, assuming an average molecular weight of the alkene mixture of 228.11, composition in wt %: 16.4% 1-tetradecene, 47.9% 1-hexadecene, an 35.6% 1-octadecene) and then stirring at about 250–300 rpm was started. Anhydrous methanesulfonic acid (173.47 grams, 1.8 moles, 30 mole % relative to the salicylic acid) was added all at once to the resulting white suspension. The suspension was then heated under nitrogen and stirred to a target pot temperature of 120° C.
As the reaction progressed, the suspension disappeared and became a dark reddish-orange in color. Crystals of what is presumed to be sublimed salicylic acid were present in cool areas of the reaction apparatus. After a total of 25 hours at 120° C., the heating was stopped and the reaction mixture allowed to cool. Light naphtha (1.5 L total) was used to transfer the reaction product from the kettle to a separatory funnel and the phases separated to afford a large upper phase and a dark colored lower phase of spent catalyst. The upper phase was stripped of solvent in vacuo (rotary evaporator, 90° C. water bath, <10 mbar vacuum) over about 2 hours. A brownish oil (2189.77 grams) was obtained, (97.6 % based on the combined weights of the alkene and salicylic acid). This sample was found to have an acid number that was 92% of the theoretical value of 153.20 for a 16.4:47.9:35.6 wt/wt % mixture of monoalkylated salicylic acids.
Example A
Comparative Example
Salicylic Acid Monoalkylated with 80 V/V Aq. Sulfuric Acid with Propylene Tetramer
A two liter resin kettle was charged with salicylic acid (138.39 grams, 1.00 mole) and 890 mL (25.6 moles) of an 80% v/v aqueous sulfuric acid solution. The suspension was stirred under a nitrogen positive pressure at 43° C., and then propylene tetramer (185.24 grams, 1.1 moles) was added dropwise over about 0.5 hour. During the addition, the reaction temperature cooled slightly to 41° C. Then, the reaction mixture was warmed to a target temperature of 60° C.; however, there was an exotherm to 75° C. The reaction was kept at about 60° C. for a total of three hours. The deep reddish reaction product was diluted with 600 mL of water and an exotherm, owing to the dilution of the sulfuric acid, occurred. The diluted product separated into two phases, which were treated with 200 mL of n-heptane in a separatory funnel. The upper organic phase was kept and the lower aqueous phase extracted with two 100 mL portions of n-heptane. All of the organic phases were combined and washed twice with 300 mL of water, and then twice with 200 mL of saturated aqueous sodium chloride solution. The organic phase was dried over anhydrous sodium sulfate. Then, the drying agent was removed with suction in a Büchner funnel and the filtrate was stripped in vacuo (90° C. water bath, <20 mbar vacuum) to afford 252.53 grams of a viscous dark reddish oil (78.0% based on the combined weights of the alkene and salicylic acid). The product had a sulfurous odor, and an acid number of 136.0, 74.2% of the theoretical value of 183.1.
Example 3
Salicylic Acid Monoalkylated with Propylene Tetramer and Methanesulfonic Acid
Example 2 was repeated in a two liter resin kettle with 414.99 grams of salicylic acid (3.0 moles), 530.61 grams of propylene tetramer (3.15 moles) and 86.52 grams of methanesulfonic acid (0.90 mole). The mixture was stirred and heated under nitrogen at 120° C. for 26 hours. The reaction product was diluted with 500 mL each of water and n-heptane and the resulting organic phase was washed twice with 500 mL portions of water. The aqueous phases were then combined and extracted with 200 mL of n-heptane. All the organic extracts were combined and then stripped in vacuo (90° C. water bath, <20 mbar vacuum) to afford 868.05 grams of a dark colored viscous oil (92.8% based on the combined weight of propylene tetramer and salicylic acid). The resulting product had an acid number of 163.2 (89.1% of the theoretical value of 183.1).
Example 4
Salicylic Acid Monoalkylated with a 10:10:80 (wt %) Mixture of C 14 , C 16 , C 18 α-Olefins
As in Example 2, salicylic acid (414.34 grams, 3.00 moles), 1-tetradecene (87.32 grams, 0.445 mole), 1-hexadecene (87.34 grams, 0.389 mole), 1-octadecene (698.70 grams, 2.73 moles), and methanesulfonic acid (86.61 grams, 0.90 mole) were combined in a two liter resin kettle. The suspension was warmed at 120° C. for 26.5 hrs. The cooled reaction product was diluted with 600 mL of light naphtha and then filtered with suction through a coarse glass fritted funnel. The filter cake was washed with 300 mL of light naphtha. The filtrate was split in a separatory funnel and the lower dark layer was separated off. The upper organic phase was stripped in vacuo (90° C. water bath, <15 mbar vacuum) to afford 1119.11 grams of a yellowish oil (86.9% based on the combined weights of the alkene and salicylic acid). The alkylation product had an acid value of 133.8 (87.3% of the theoretical value of 147.40).
Example 5
Salicylic Acid Monoalkylated with 10:10:80 Wt % Mixture of 1-Tetradecene, 1-Hexadecene, and 1-Octadecene
In a manner similar to Example 2, salicylic acid (829.04 grams, 6.0 moles), 1-tetradecene (152.89 grams, 0.7783 mole), 1-hexadecene (152.81 grams, 0.689 mole), 1-octadecene (1222.60 grams, 5.447 moles), and methanesulfonic acid (173.02 grams, 1.80 moles) were combined in a three liter resin kettle. Under nitrogen, the suspension was brought to 130° C. with stirring and kept at 130° C. for a total of eight hours. The cooled reaction mixture was diluted with 500 mL of n-heptane and the solution was filtered through a coarse glass fritted funnel.
Example 6
Salicylic Acid Monoalkylated with 1-Tetradecene
Example 2 was repeated in a two liter resin kettle with 388.84 grams (2.815 moles) of salicylic acid and 580.49 grams (2.956 moles) of 1-tetradecene with 57.81 grams (0.60 mole) of anhydrous methanesulfonic acid. The suspension was heated and stirred under nitrogen for 24 hours at 120° C. The catalyst was removed by washing the product with one liter of water, followed by stripping at 90° C. under reduced pressure. A dark red-brown oil was obtained (910.66 grams, 93.9% based on the combined weights of alkene and salicylic acid). The resulting product had an acid number of 112.0 (66.8% of the theoretical value of 167.7).
Example 7
Salicylic Acid Monoalkylated with 1-Decene
Example 2 was repeated with 414.72 grams of salicylic acid (3.0 moles), 441.91 grams of 1-decene (3.15 moles) and 86.55 grams of methanesulfonic acid (0.90 mole). The mixture was heated at 120° C. under nitrogen for 24 hours. The resulting product was diluted with 200 mL of light naphtha and then the lower dark colored phase was removed in a separatory funnel. The upper phase was stripped of solvent in vacuo (90° C. water bath, <10 mbar vacuum) to afford 856.6 grams of a dark oil (99.9% based on the combined weights of alkene and salicylic acid). The product had an acid number of 189.8 (94.1% of the theoretical value of 201.5).
Example 8
Salicylic Acid Monoalkylated with 1-Octene
Salicylic acid (414.89 grams, 3.0 moles), 1-octene (353.5 grams, 3.15 moles) and methanesulfonic acid (57.63 grams, 0.60 mole) were combined as in Example 2 in a two liter kettle and warmed to a target temperature of 120° C. under nitrogen positive pressure. The reaction mixture was heated and stirred at 120° C. for a total of 24.5 hours. Light naphtha (200 mL) was added to the reaction product, which was then filtered with suction through a coarse glass fritted funnel. The filtrate split into a larger upper phase and a lower darker phase containing the catalyst. The upper phase was stripped in vacuo (90° C. water bath, <10 mbar vacuum) to provide 755.7 grams of the alkylated salicylic acid as a brown oil (98.4% based on the combined weights of alkene and salicylic acid). The product had an acid number of 211.2 (94.2% of the theoretical value of 224.1).
Example 9
Salicylic Acid Monoalkylated with a Mixture of C 20 , C 22 , and C 24 α-Olefins
Salicylic acid (414.76 grams, 3.0 moles), a blend of C 20 , C 22 , and C 24 α-olefins (908.82 grams, 3.15 moles), and methanesulfonic acid (86.82 grams, 0.90 mole) were combined as in Example 2 in a two liter resin kettle. As the α-olefin was a waxy solid, the blend was warmed to a 120° C. target temperature under nitrogen without stirring until the olefin became molten, then stirring was begun. The reaction mixture was heated for a total of 22.4 hours at 120° C. The reaction product was diluted with 500 mL of water and 200 mL of n-heptane and the phases split in a separatory funnel. The upper organic phase was washed three times with 300 mL portions of water. Then the organic phase was stripped in vacuo (90° C. water bath, <10 mbar vacuum) to provide 1295.85 grams of a dark colored oil, (97.9 % based on the combined weights of alkene and salicylic acid). This material solidified overnight to a cream colored solid. The product had an acid number of 97.0 (77.6% of the theoretical value of 125.0).
Example 10
Salicylic Acid Monoalkylated with Propylene Trimer (Nonenes)
In a manner similar to Example 2, 414.50 grams (3.00 moles) of salicylic acid, 398.32 grams (3.15 moles) of propylene trimer (nonenes) and 86.67 grams (0.90 mole) of methanesulfonic acid were combined in a two liter resin kettle. The suspension was stirred and warmed at 120° C. for 23 hours under nitrogen positive pressure. The reaction product was allowed to cool, diluted with 300 mL light naphtha. Then the reactor contents were filtered with suction through a coarse fritted glass Büchner funnel and the filtrate was diluted with 500 mL of additional light naphtha and 200 mL of water in a separatory funnel. The upper organic phase was then stripped in vacuo (90° C. water bath, <10 mbar vacuum) to afford 774.88 grams of a dark viscous oil (95.3% based on the combined weights of alkene and salicylic acid). The final alkylate had an acid number of 230.4 (87.4% of the theoretical value of 263.6).
Example 11
Salicylic Acid Monoalkylated with Propylene Pentamer
Salicylic acid (414.41 grams, 3.00 moles), propylene pentamer (662.96 grams, 3.15 moles), and methanesulfonic acid (86.48 grams, 0.90 mole) were combined as in Example 2 in a two liter resin kettle. The suspension was warmed at 120° C. for a total of 23 hours under nitrogen. The cooled, dark reaction product was diluted with 500 mL of n-heptane and then filtered through a coarse glass fritted Büchner funnel with suction. The filtrate was a two-phase system. The lower, catalyst, phase was separated off and the upper organic phase stripped in vacuo (90° C. water bath, about 30 mbar vacuum) to afford 1065.74 grams of a viscous dark oil (98.9% yield based on the combined weights of alkene and salicylic acid). The product of the alkylation had an acid number of 158.6 (98.5% of the theoretical value of 161.0).
In view of the many changes and modifications that can be made without departing from principles underlying the invention, reference should be made to the appended claims for an understanding of the scope of the protection to be afforded the invention.
|
A process is disclosed for the production of alkyl salicylic acids wherein the process comprises reacting salicylic acid with an olefin having at least four carbon atoms at elevated temperature in the presence of a perfluoroalkylsulfonic acid, an alkylsulfonic acid, or an acidic clay as a catalyst.
| 2
|
BACKGROUND OF THE INVENTION
The invention relates to a device for guiding daylight comprising a prism plate of synthetic glass which has a base side and an active side. The active side has embankments which form trenches thereat.
Since large-area (for example 40×40 cm) and relatively thick (for example 5 mm) prismatic panes of synthetic glass (for example of polymethylmethacrylate-PMMA) have not yet been successfully manufactured in planar and warp-free fashion with adequate precision, such prism plates had to be composed of small sub-plates. For this purpose, the sub-plates were flued to one another at their narrow edge sides at their end faces. This, however, results in high manufacturing expense. Furthermore, the glue causes disturbing deposits and deteriorates the mechanical stability over the long term (crack formation) when such prism plates are situated in a closed interior between panes of glass.
SUMMARY OF THE INVENTION
It is an object of the invention to design the sub-plates and/or additional joining means such that the sub-plates can be combined to form a large-area prism plate in a simple way without employing an adhesive.
According to the invention, sub-plates are connected to one another so as to form a large-area prism plate. At least one positive lock plug-type connection connects the two plates to one another. The connection comprises a locking projection and a mating locking projection receptacle. The plug-type connection includes a latching means for securing the plug-type connection in a dimension perpendicular to a plane of the prism plate. According thereto, simple positively locking plug-type connections with dovetailing locking projections or tenons and projection receptacles or mortises mating thereto first insure an adhesion of the sub-plates in two dimensions, preferably within the plate plane. The plug-type connections are prevented from falling apart in the direction of the third dimension--at right angles to the plate plane--by latching devices.
The projections or tenons are preferably dove-tailed in shape and fashioned as one piece with a sub-plate. Within the framework of the invention, however, every locking projection can also be a separate part and can plug into adjoining projection receptacles of the sub-plates to be joined. In this case, the projection is fashioned symmetrically relative to a center plane, and are particularly fashioned in a dove-tailed manner at both sides of the center plane. The sub-plates then only have the identically shaped projection receptacles. These can be situated parallel or at right angles to the plate plane.
Every latching device is fundamentally composed of a latch shoulder at one sub-plate and of a latch stop face at the neighboring sub-plate such that the latching stop face overlaps the latching shoulder of the other sub-plate when the sub-plates are joined.
In the simplest case, the latching stop face of every latching means can be situated at the end of a spring arm. The spring arm can be situated in the region of an edge side of a sub-plate such that, thanks to an oblique guiding surface, the spring arm is first pushed back into a recess when the sub-plates are joined. In the final position of the hooked together sub-plates, the latching stop face springs into a recess of the other sub-plate and overlaps the latching shoulder of the other sub-plate. The spring arm can be situated at the edge side with the projection or at the edge side with the projection receptacles. In the former case, the free end of the spring arm with the latching stop face faces the active side. In the latter case, it faces the base side of the sub-plates. The spring arm and latching stop face can also be situated at a projection or at the walls of a projection receptacle. The spring arm, latching stop face, and sub-plate preferably form a single-piece part in every case.
In a preferred embodiment of the invention, the latching stop face of every latching device is situated at the upper part of a retainer which is inserted into a recess in the active side of the joined sub-plates. Thus, this recess is bounded by sub-recesses and by the latching shoulders at the joined sub-plates. The upper part of the retainer can have a planar surface at the outside or can continue the profile of the active side in the region of the recess. A retaining member of the retainer extends through a latching opening surrounded by the latching shoulders and is held in the latching opening by a latch hook at the end of the retaining member.
The retaining member and upper part of the retainer can be two separate parts which are plugged through the latching opening from both sides of the joined sub-plates and are connected to one another in a positively locking fashion.
It is more advantageous to provide the upper part and the retaining member as a one-piece assembly and to employ two resilient holding arms as a retaining member. These comprise a latch hook at the end.
The recess for the upper part of the retainer is situated in the region of the edge side of the joined sub-plates and is bounded by sub-recesses of identical size in the adjoining sub-plates. When a retainer is situated in the region of an edge side between the corners of the sub-plates, then the recess for the retainer is formed by two sub-recesses, half of each of these lying in each of the sub-plates abutting at this location.
Insofar as four sub-plates abut in one corner, it is particularly advantageous to situate the retainer in this corner. In this case thus the recess for the retainer is formed by four sub-recesses, whereby each sub-recess forms one-fourth of the contour of the recess for the upper part of the retainer.
As a rule, a prism plate composed of sub-plates is situated in floating fashion between the glass panes of a composite pane. A plurality of prism plates can also be situated above one another in the interior between the glass panes. In this case, the prism plates are preferably supported with their retainers since these retainers lie on one another with supporting faces. A defined spacing between the prism plates can thus be achieved since one of the two retainers lying on top of one another has a spacer formed of the supporting surface. The supporting surfaces of the two retainers lying on top of one another can proceed parallel to the base surface of one of the prism plates, or can continue the profile of the active sides in the region of the recess.
Over and above this, a retainer at the side lying opposite the active side can also have a spacer which projects beyond the base side of the prism plate. A defined spacing, for example from a neighboring glass pane, can thus also be achieved at this side.
In view of the great, temperature-dependent changes (up to 8 mm) in the distance between the glass panes of a composite pane, it has proven particularly expedient to equip the retainers with a receptacle for a resiliently seated spacer pin.
The mutually parallel wall or trenches at the active side of every sub-plate which are limited by oblique surfaces can proceed at an arbitrary angle relative to an edge side. When, on the other hand, one wishes to use identical sub-plates (only one injection molding die), then the number and arrangement of locking projections and projection receptacles must be based on this angle. Particularly simple relationships result with a quadratic sub-plate having a side length of 20 to 40 cm and n walls or trenches proceeding parallel to an edge side, and where n is a whole number. At least two respective projections are provided at each of two neighboring edge sides, and a corresponding number of projection receptacles are provided at the two other edge sides. A sub-recess is provided at every corner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a sub-plate;
FIG. 2 illustrates by a perspective view the corner region of four such sub-plates before being joined;
FIG. 3 is a magnified sub-view along line III--III in FIGS. 2 and 4 given joined sub-plates;
FIG. 4 is a view in the direction of the arrow IV in FIG. 3;
FIG. 5 is a sectional view through a composite pane comprising two prism plates;
FIG. 6 is a section through the edge region in FIG. 5 comprising a spacer, shown in magnified form;
FIG. 7 is a section through a region in FIG. 5 comprising two retainers, likewise shown in magnified scale; and
FIG. 8 is a section like FIG. 6 comprising a different spacer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The quadratic sub-plate 1.1 is shown in plan view in FIG. 1, so that its active side 10 can be seen. Embankments and trenches (peaks and valleys) are alternatingly situated thereon next to one another. The embankments are defined by two oblique surfaces which describe an acute angle. The embankments thus have the form of prismatic rods and proceed parallel to one another and to two edge sides 11, 14. Between these edge sides, n embankments or trenches having a respectively identical contour are situated, where n is a whole number. The angle between the oblique surfaces is preferably 90° and the respective oblique surfaces of every embankment facing the same edge side are mirrored with vapor-deposited aluminum. With such a prism plate, sunlight below a critical angle can be kept out of a room and bright zenith light above this critical angle can be guided into the room.
Four locking projections 112 or 111 having a dove-tail profile are situated at the one edge side 11 and at a neighboring edge side 13 of the sub-plate which proceeds at a right angle relative to side edge 11. They are at a respective distance from the corners of the sub-plate, are flush with the base side 15 thereof at the bottom, and do not extend up to the active side 10 (see FIG. 2, for example).
At the two other edge sides 12 and 14, the sub-plate has four respective projection receptacles 121 or 122 open toward the edge side and toward the base side 15. They are of such a shape and arrangement that a plurality of identical sub-plates of FIG. 1 can be joined in gap-free fashion and flush to form a large-area prism plate, as shown in FIG. 2. The distance a or b between two projections 111 or 112 as well as the corresponding distance between the respectively corresponding projection receptacles is somewhat different at the edge sides 13 and 11. Incorrect joining of the sub-plates is thus impossible.
At every corner, the sub-plate 1.1 of FIG. 1 has a sub-recess 101, 102, 103, 104 which extends from the active side 10 to a latching shoulder 105, 106, 107, 108, and is respectively limited by two boundary surfaces 1011, 1021 of identical length which proceed parallel or perpendicular to the edge sides 11 through 14. When, as shown in FIGS. 2 and 4, four sub-plates 1.1 are joined to form a prism plate, the sub-recesses 101 through 104 of the four meeting corners of the four sub-plates form a quadratic recess 100 (shown in FIG. 4) which extends from the active side 10 of the prism plate to the latching shoulders 105, 106, 107, and 108. These shoulders have a rectangular cross-section, proceed parallel to the boundary surfaces 1011, 1021 and to the base side 15, and are set back relative to this base side 15. Together, they surround a latching opening 1000.
As shown in FIGS. 3 and 4, a retainer 2 which is quadratic in plan view is inserted into the recess 100 formed by the four sub-plates. The upper part 20 of this retainer 2 fits precisely into this recess 100 and has a planar supporting surface 22 which is flush with the active side 10 or lies somewhat above it (broken lines in FIG. 3). The retainer 2 has a retaining member formed of two resilient holding arms 21 which extend through the latching opening 1000 and overlap the latching shoulders 105, 106 or 107, 108 with latch hooks 210. The latch hooks 210 do not project into the plane of the base side 15. The latching detents 200 of the retainer 2 are thus pressed against the latching shoulders 105 through 108 of the sub-plates 1.1. Thus, the sub-plates joined in accordance with FIGS. 2 and 4 can no longer release since a dislocation of the sub-plates at right angles to their base side 15 would be required for this purpose. However, such a motion is prevented by the retainer 2. As a consequence of the distribution of the projections and projection receptacles at a sub-plate of FIG. 1, two relatively narrow holding arms 21 of FIG. 4 lying opposite one another suffice for this purpose. These holding arms 21 are parallel to one another and to an edge side, preferably to the embankments of the active side 10.
At the inside between its holding arms 21, the retainer 2 has a socket 23--preferably having a cylindrical bore--into which a spacer pin 24 and a spring 25 pressing the spacer pin out of the socket are insertable, as shown in FIG. 7.
The spacing of a prism plate to neighboring parts can be defined at the same time with the assistance of the retainer 2. For this purpose, the retainer can comprise at its upper surface a spacer member 220--shown with broken lines in FIG. 3--which projects beyond the active side and/or can comprise a spacer member 230 shown with broken lines at its underside. The spacer member 230 is formed by the walls of the socket 23 which project beyond the base side 15.
FIG. 5 shows a composite pane comprising two glass panes 31, 32 joined to one another by edge members 30 which thus surround a sealed interior 300. Two prism plates 1, 1' formed of a plurality of joined sub-plates are situated in floating fashion in this interior, namely such that their differently fashioned active sides are directed toward one another. The sub-plates of every prism plate are joined with a positive lock and are latched by retainers, as was set forth with reference to FIGS. 1 through 4. Employed in conjunction with the prism plate 1 is a retainer 2.1 having a spacer member 220 at its upper side. This spacer member 220 comprises a supporting surface 22 which projects beyond the active side of this prism plate and is seated against the supporting surface of a retainer 2.2 of the other prism plate 1'. The supporting surface 22 of the retainer 2.2 of the lower prism plate 1' terminates flush with the active side. In this fashion, the spacing between the prism plates 1, 1' is defined by the retainers 2.1, 2.2.
The retainer 2.2 has a spacer member 230 by means of which the spacing of the base side 15 of the prism plate 1' from the glass pane 32 is defined.
The prism plates 1 and 1' are guided in their edge region by spacers 4. Such a spacer has a shaft 40 comprising a spacer head 41 and is plugged into an edge bore 16' in the prism plate 1' which mates with the shaft. A three-armed spacer disk 43 is slipped onto the shaft 40. This spacer disk 43 lies against the edges of the active side of the lower prism pane 1', and the active side of the upper prism pane 1 is supported thereagainst at the other side. The spacing of the prism plates in the edge region is assured in this way.
The edge bore 16 for the shaft 40 in the upper prism plate 1 is selected larger than the diamter of the shaft 40, so that the two prism plates (which are thermally conditioned) can move relative to one another.
The two prism plates are seated in a practically play-free manner between the glass panes 31, 32 in the edge region of the composite pane. A spacer cap 42 of appropriate height is placed on the end of the shaft 40 (FIG. 6). The spacing between the glass panes 31, 32 depends on temperature and air pressure. This dependency increases toward the center of the composite pane. Therefore, a spring 25 and a spacer pin 24 are inserted into the socket 23 of the retainer 2.1 in the upper prism plate 1. The two prism plates are thus pressed against the lower glass pane 32 which always faces the interior. An equidistant arrangement of the prism plates 1, 1' relative to one another and relative to the glass pane 32 is assured in this way. Accordingly, it is assumed that the height of the spacer head 41 of the edge connector 4 is identical to the height of the spacer member 230 of the retainer 2.2, and the thickness of the spacer diks 43 is idetical to the height of the spacer member 220 of the retainer 2.1.
The prism plates 1, 1.1 have a significantly greater coefficient of thermal expansion than the glass panes. They therefore have an adequate spacing from the edge members 30 and can therefore freely move in the interior. They are seated there in floating fashion.
In accordance with FIG. 7, an interlock member 50 comprising a flange 52 and a journal 51 is plugged from below onto the retainer 2.2. With the journal 51, the holding arms 21 with the latch hooks 210 are secured in the illustrated position. The flange 52 thus also acts as a spacer member (for example instead of 230).
In accordance with a further development of the invention, each prism plate is arranged between two guide legs which are connected to the inside of the insulating glass web such that the guide legs proceed parallel to the glass panes and form a second embodiment of a spacer. Two respective guide legs thus form a channel whose spacing is selected in accordance with the thickness of a prism plate and in which this prism plate can move freely.
The guide legs are preferably of translucent, particularly transparent material, so that they are not very disturbing in the edge region of the composite window.
It lies within the framework of the invention to combine the two guide legs allocated to a prism plate with an assembly leg proceeding at right angles relative to the two guide legs to form a profile member which is connected to the insulating glass web with the assistance of the assembly leg.
Insofar as a plurality of prism plates are to be arranged above one another between the glass panes, it is preferable to form the spacers of a plurality of profile members comprising guide legs and assembly legs. It is then easier to observe very small manufacturing tolerances for the spacings between the guide legs.
An exemplary embodiment of this type is shown in FIG. 8 in which the edge region of a composite window is shown in cross-section. The two glass panes 31 and 32 are thus joined by a known insulating glass web 33 whose interior is filled with a molecular sieve. The outside of the insulating glass web 33 is filled between the projecting glass panes 31 and 32 by an adhesive. The spacer 41 is secured to the inside of the insulating glass web 33, this spacer being formed here of three profile members. Each profile member is composed of a guide leg 41.1, 42.1, 43.1 and of an assembly leg 411.1, 421.1, 431.1. These profile members with an angle profile are connected to the inside of the insulating glass web 33 by rivets or screws such that the assembly legs abut one another in a gap-free manner. The length of these assembly legs thus defines the spacing between neighboring guide legs and thus the width of the channel into which the prism plates 1, 1' are plugged.
Although various minor changes and modifications might be proposed by those skilled in the art, it will be understood that we wish to include within the claims of the patent warranted hereon all such changes and modifications as reasonably come within our contribution to the art.
|
Since only relatively small-area prism sub-plates can be manufactured in warp-free fashion, large area prism plates are formed of a plurality of sub-plates. A connection of the sub-plates must be stable and the expense for joining the sub-plates should be as low as possible. To create the large-area prism plate, adjoining sub-plates are connected to one another in two dimensions by at least one positive lock plug-type connection comprising locking projections and locking projection receptacleswhich form plug-type connections secured by latching devices which do not allow a dislocation of the joined sub-plates in a third dimension.
| 4
|
BACKGROUND OF THE INVENTION
This invention relates to a process for the heat treatment of fine-grained material, particularly cement raw mix, which is preheated with the hot waste gases of a revolving tubular kiln in a multistage cyclone preheater, further heated, particularly calcined, by additional solid fuel, and roasted to completion in the revolving tubular kiln.
In order to relieve the revolving tubular kiln of thermal work and hence reduce its dimensions, it is known that additional fuel may be introduced into the lowermost stage of the preheater so that the material already preheated by the waste kiln gases is further heated (in the particular case of cement raw mix largely calcined) before it subsequently enters the revolving tubular kiln (see German Auslegeschrift No. 2,324,565).
Only a relatively short time is available for transferring the thermal energy present in this additional fuel to the material. Accordingly, it is important in the known process to mix the fuel and the material as quickly and as uniformly as possible in the lowermost stage of the preheater and then to obtain virtually complete combustion of the fuel on or in the immediate vicinity of the material particles.
Where liquid or gaseous fuel is used, no significant problems are involved in meeting the abovementioned requirements. However, this is not the case where solid fuel is used. In order to obtain sufficiently rapid and uniform combustion of the fuel in the lowermost stage of the preheater, the solid fuel has to be dried and very finely ground beforehand which involves considerable costs.
Further difficulties arise where low-quality fuel having a high content of incombustible constituents is used. When fuel of this type is introduced into the lowermost stage of the preheater, a considerable amount of incombustible, cold substances enters the lowermost stage of the preheater as part of the fuel/material mixture and then immediately afterwards the revolving tubular kiln, which seriously impairs the necessary intense calcination of the material before entry into the revolving tubular kiln.
SUMMARY OF THE INVENTION
An object of the present invention is to obviate the difficulties referred to above by providing a process of the kind referred to in such a way that a high degree of calcination of the material is obtained before its entry into the revolving tubular kiln, with particularly low preparation costs for the solid fuel used and with the possibility of using even low-quality fuel. The invention also seeks to create the possibility of optimally adapting the process to different types of fuel.
According to the invention, these objectives are achieved by introducing the additional fuel to the preheater at a zone selected with reference to waste gas temperature and the grain size, reactivity, moisture, and the incombustible constituent content of the fuel in such a way that most of the fuel is almost completely burnt in the lowermost stage of the preheater, i.e., the last stage of the preheater in the direction of movement of the material.
That stage of the preheater into which the additional fuel is introduced is best selected in such a way that at least 90% of the fuel is converted into CO 2 in the lowermost stage of the preheater.
The process according to the invention is carried out particularly simply by introducing lump-form solid fuel into the uppermost stage of the preheater, i.e., the first stage in the direction of movement of the material, in merely prebroken and pit-wet form. In this way, the coarse fuel particles are dried and preheated on passing through the individual stages of the preheater so that, finally, they are able to burn virtually completely in the lowermost stage of the preheater. A particularly advantageous side effect is that, as the coarse fuel particles drop through the individual cyclones and pipes of the preheater, they perform a highly desirable cleaning function by dislodging troublesome deposits.
Where a fuel mixture of different particle sizes is used, it is generally best initially to sieve the fuel and to introduce the fine fraction into the lowermost stage and the coarse fraction into a higher stage of the preheater. If for example the fuel is sieved through a 2 mm mesh sieve, the fine fraction is introduced into the lowermost stage and the coarse fraction into the uppermost stage of the preheater. Introducing the fine fraction of the fuel into the lowermost stage of the preheater ensures that this fraction, too, is only burnt in that region (i.e., in the lowermost part of the preheater) where the thermal energy of the fuel is optimally utilized for intense calcination of the material. In addition, the waste gas losses of the preheater are minimized in this way.
Where a fuel having a high content of incombustible constituents is used, this fuel is not introduced into the lowermost stage of the preheater, but instead into a higher stage. In this way, the incombustible constituents are sufficiently preheated by the waste kiln gases before they enter the revolving tubular kiln with the material.
The choice of that stage of the preheater into which the additional fuel is introduced is governed not only by the particle size, moisture and incombustible constituent content of the fuel, but also by the reactivity of the fuel and in particular by the content of volatile combustible constituents in the fuel. The lower this content of volatile combustible constituents, the higher the level in the preheater at which the fuel is generally introduced.
The particle size of the solid fuel may be up to about 50 mm. At least that fraction of the fuel which has a grain size of more than 3 mm is introduced into the uppermost stage of the preheater.
DESCRIPTION OF THE DRAWINGS
One example of an installation for carrying out the process according to the invention is diagrammatically illustrated in the accompanying drawings, wherein;
FIG. 1 is an elevational, diagrammatic view of a multistage preheater and furnace; and
FIG. 2 is a temperature profile of the contents of the several stages of the preheater.
DETAILED DESCRIPTION OF THE INVENTION
The illustrated installation for the heat treatment of fine grained-material such as cement raw meal comprises a revolving tubular kiln 1 and a multistage cyclone preheater 2 consisting of a lowermost (first) stage with the cyclones 3, 3a, a second stage with the cylcone 4, a third stage with the cyclones 5, 5a, a fourth stage with the cyclones 6a, 6b and a fifth stage with the cyclones 6c, 6d.
The revolving tubular kiln 1 communicates with the cyclones 3, 3a of the lowermost stage through a gas pipe 7 carrying a stream of waste kiln gases. For the rest, the individual cyclones of the preheater 2 are interconnected by gas and material pipes, as shown in the drawing.
The flow path of the gases is indicated by solid-line arrows 8 and a path which the material follows by chain-line arrows 9.
The material (cement raw meal) is introduced into the gas pipes 10, 10a leading to the cyclones 6c, 6d of the uppermost stage and then passes successively in known manner through the five stages of the preheater 2, being preheated by the waste gases of the revolving tubular kiln 1.
In order to calcine the material as far as possible (removal of the CO 2 from the calcium cabonate) before it enters the revolving tubular kiln 1, additional solid fuel is introduced into the gas stream from the revolving tubular kiln 1. In the illustrated embodiment, the lump-form pit-wet fuel (arrow 11) is initially coarsely prebroken in a breaker 12 and then separated on a sieve 13 into a coarse fraction and a fine fraction. The coarse fraction (arrows 14) passes together with the raw meal as a mix into the gas pipes 10, 10a leading to the cyclones 6c, 6d of the uppermost stage of the preheater. The fine fraction (arrows 15) is introduced into the gas pipe 7 leading from the revolving tubular kiln 1 to the cyclones 3, 3a of the lowermost stage of the preheater.
The coarse fuel particles introduced into the gas stream at the uppermost stage of the preheater pass successively with the material through the individual stages of the preheater, being dried and preheated to such an extent that, finally, they are able to burn virtually completely in the lowermost stage of the preheater together with the fine fraction introduced into the gas stream flowing into that stage.
The invention is further illustrated by the following example:
A raw mix of the following analysis is used:
Raw mix incl. 10% coal
Ignition loss: 34.38%
SiO 2 : 13.77
Al 2 O 3 : 4.08
TiO 2 : 0.13
Fe 2 O 3 : 1.98
CaO: 41.31
MgO: 2.81
SO 3 : 0.57
P 2 O 5 : 0.08
Na 2 : 0.18
K 2 O: 0.78
Cl: 0.007
Silicate modulus: 2.22
Alumina modulus: 2.13
Lime standard: 92.7
The analysis of the coal used is as follows:
______________________________________Moisture 0.4%Volatile constituents 5.3%Ash 68.6%Solid fuel 25.7% 100.0%Elemental analysisAsh 68.6%C 25.6%H 0.6%S 1.9%O + N 3.3% 100.0%Calorific value (Hu)Air-dry 9285 kJ/kg______________________________________
This coal leaves the fine crusher with a particle size of up to 25 mm, around 20% of the particles being smaller than 3 mm.
The chemistry of the raw mix requires 0.155 kg of coal per kg of clinker, of which 0.125 kg of coal/kg of clinker is introduced together with the raw mix and 0.030 kg of coal per kg of clinker into the gas pipe leading from the revolving tubular kiln to the lowermost cyclone stage.
If this raw material and this fuel are introduced into the installation shown in FIG. 1 and if the temperature of the gas (θgas), the temperature of the raw material (θR) and the temperature of the coal (θK) are measured in the five cyclone stages, the temperature profile of the preheater illustrated in FIG. 2 is obtained.
As known from the literature (see for example VDI-Bericht No. 211 (1974), pages 131 et seq.), combustion of the coal is preceded by the elimination of volatile combustible constituents. Where gas-rich coals are used, this elimination process takes place at lower temperatures than where low-gas coal is used.
Accordingly, the fuel may be preheated up to the onset of degassing. Thus, the separation grain size for the divided supply of fuel in the process according to the invention is critically determined by the quality of the fuel. In the case of gas-rich coal, the minimum particle size for the common introduction of the fine fraction with the raw meal is higher than in the case of low-gas coal. In the above example, the separation grain size is 3 mm. For this grain size, therefore, the maximum mean heating temperature in the case of the low-gas coal used in the above example is still considerably below the temperature at which pyrolysis begins.
One significant advantage of preheating part of the fuel lies in the increase in the reactivity of the coal which thus releases the heart required for the calcination process in a shorter reaction time. In the case of the above example, the preheating of the fuel brings a saving in the consumption of heat of up to 80 kJ/kg of clinker. Since the heat used to preheat the fuel comes mostly from the low-temperature end of the process which, besides, cannot be fully utilized in the preheater, a considerable saving of heat is obtained in relation to the conventional procedure where the entire precalcination fuel is introduced in the lowermost stage of the preheater. This is because, in this known process, the heat used to preheat the fuel comes from the high-temperature end of the process. Accordingly, it is missing from the calcination process and has to be restored with an approximately 35% higher calorific value to cover the additional waste gas losses.
Accordingly, the main advantage of the process according to the invention lies in a better utilization of fuel. At the same time, it is possible to obtain the same degree of calcination as in the known process (the degree of calcination is a function of the amount of fuel and the reaction behaviour of the raw material). In the above example with approximate 45% of precalcination fuel, the deacidification level amounts to more than 90%.
|
A process for the heat-treatment of fine-grained material using a multistage cyclone preheater and a revolving tubular kiln, additional fuel being introduced into a stage of the preheater which is selected according to the grain size, reactivity, moisture content, and incombustible constituent content of the fuel so that most of the fuel is almost completely burnt in the lowermost stage of the preheater. In this way, it is possible to obtain a high degree of calcination of the material before it enters the revolving tubular kiln with low preparation costs.
| 2
|
BACKGROUND OF THE INVENTION
The present invention relates generally to a closed loop energy conversion system for providing thermal energy from the combustion of a hydrocarbon without releasing air polluting combustion emissions into the atmosphere. The invention particularly relates to a closed loop apparatus and method for generating energy from the combustion of an alkane.
Gas, oil, coal or other fossil fuels are typically combusted in heat (energy) generating apparatuses such as boilers, furnaces and internal combustion engines, producing reaction by-products which pollute the atmosphere. The pollutants include carbon dioxide, nitrogen oxides, and sulfur oxides. The deleterious effects of combustion emissions on mammalian health and the Earth's atmosphere, such as the greenhouse effect and acid rain, are well documented. There is a need in industry to substantially reduce or eliminate such emissions.
The use of fossil fuels producing minimal emissions is highly desirable. Natural gas, a "clean" burning fuel, is in adequate supply at present, but the use of less desirable fossil fuels, such as coal and oil, could be necessitated as the natural gas supply dwindles. Mining, drilling and refining operations required to produce fuel from coal or oil and subsequent transportation of the fuel to the site of use are expensive.
Attempts have been made to reduce the amount of environmental pollution produced by combustion of fossil fuels. U.S. Pat. No. 3,820,965 describes a process in which purified carbon dioxide, water and nitrogen are recovered from stack gas emissions produced by combustion of gas, oil or coal in air. The purified carbon dioxide is reacted with hydrogen gas to form potable water for commercial use and methane. The methane can be recycled and used as fuel for combustion, reducing the amount of pollutants released into the atmosphere. Hydrogen gas is produced by converting nonpotable water from seas, rivers, lakes or polluted water sources into its constituents, hydrogen and oxygen, carbon monoxide or metal oxides. Recovered nitrogen, metal oxides and oxygen are diverted for economical use.
The above-described method is disadvantageous because it requires continuous addition of water and stack gases to the system in order to produce methane. The water generated in the methanation reaction is not recycled and dissociated to provide hydrogen gas for producing methane. Rather, the system must be located near a substantial water source and must include water purifying processes in order to provide water for the dissociation. Oxygen generated in dissociating water is not recovered for use in combusting methane once synthesized. Instead, the methane is combusted in air, which produces nitrogen oxides and other pollutants which are released into the atmosphere.
SUMMARY OF THE INVENTION
Among the objects of the invention, therefore, may be noted the provision of a process for providing energy, such as heat, to an external source from the combustion of a fossil fuel without discharging waste by-products from the combustion into the atmosphere; the provision of such a process for converting a non-fossil fuel energy source such as radiation or electricity into a renewable fossil fuel; the provision of such a closed loop process which generally does not require addition of substantial amounts of reactants or removal of substantial amounts of reaction products; the provision of such a process which produces a fossil fuel for use as an energy source at the location where the fuel is to be used without generating pollutants at the location; and the provision of a closed loop energy conversion system comprised of conventional apparatuses by which such a process is achieved.
The present invention is directed to a closed loop energy conversion apparatus including a dissociation unit for dissociating water into hydrogen gas and oxygen gas and separating hydrogen gas from oxygen gas. An energy source provides energy to the dissociation unit. Oxygen gas and hydrocarbon gas react in a hydrocarbon combustion unit to form a combustion product comprising carbon dioxide gas and water vapor. A first heat exchanger cools the combustion product and condenses water vapor from the combustion product. A carbon dioxide separator separates carbon dioxide gas from water condensed in the first heat exchanger. Carbon dioxide gas reacts with hydrogen gas in a hydrocarbon synthesis reactor to form a mixture comprising hydrocarbon gas and water vapor. A second heat exchanger cools the mixture and condenses water vapor from the mixture. A hydrocarbon separator separates hydrocarbon gas from water condensed in the second heat exchanger. A conduit system directs oxygen gas from the dissociation unit to the hydrocarbon combustion unit, carbon dioxide gas from the hydrocarbon combustion unit to the hydrocarbon synthesis reactor, water from the hydrocarbon combustion unit and the hydrocarbon synthesis reactor to the dissociation unit, hydrogen gas from the dissociation unit to the hydrocarbon synthesis reactor, and hydrocarbon gas from the hydrocarbon synthesis reactor to the hydrocarbon combustion unit.
The present invention is also directed to a method for providing energy from hydrocarbon combustion in a closed loop system. Water dissociates into hydrogen gas and oxygen gas. Hydrogen gas separates from oxygen gas. Oxygen gas reacts with hydrocarbon gas to form a combustion product comprising carbon dioxide gas and water vapor. Energy from the combustion product is transferred to an external source. Water vapor from the combustion product condenses. Carbon dioxide gas separates from water. Carbon dioxide gas reacts with hydrogen gas to form a mixture comprising hydrocarbon gas and water vapor. Energy from the mixture is transferred to an external source. Water vapor from the mixture condenses. Hydrocarbon gas separates from water. Hydrocarbon gas is recycled for reaction with oxygen gas, water from the mixture and the combustion product is recycled for dissociation, and carbon dioxide gas is recycled for reaction with hydrogen gas.
Other objects and advantages of the invention will be apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic flowsheet of the process of the invention, illustrating a closed loop system for generating energy;
FIG. 2 is a schematic flowsheet of a laboratory scale closed loop process;
FIG. 3 is a sectional view of a Sabatier reactor as used in the laboratory scale process; and
FIG. 4 is a sectional view of a methane combustion apparatus, heat exchanger and condenser as used in the laboratory scale process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention, it has been discovered that a fossil fuel can be combusted in a conventional energy generating apparatus, such as a boiler or internal combustion engine, to provide energy without discharging waste by-products from the combustion into the atmosphere by forming a closed loop energy conversion system. Energy provided to the system to dissociate water into hydrogen and oxygen is released when hydrogen and carbon dioxide are reacted to form a hydrocarbon gas and water, and when the hydrocarbon gas is combusted in oxygen to form carbon dioxide and water. The closed loop system generally does not require addition of reactants or removal of products from the system because each of the reaction products is recycled and used as a reactant within the system.
Turning now to FIG. 1, there is shown a closed loop energy conversion system 10. Water is directed to a dissociation unit 12 in which water is dissociated into hydrogen gas and oxygen gas. An energy source 14 supplies power for operation of the dissociation unit. The dissociation unit, when utilizing electrolysis, collects hydrogen and oxygen gasses in separate chambers as the gasses evolve.
Hydrogen gas formed in the dissociation unit passes through a pump 16 which directs the gas to a gas separator 18. The gas separator removes oxygen gas present in the hydrogen gas to provide purified hydrogen gas. The purified hydrogen gas is then directed to a gas mixer 20 which mixes hydrogen gas with carbon dioxide gas. The mixed gas is directed to a preheater 22 for preheating the reactants to the reaction temperature. The gas then flows to a hydrocarbon synthesis reactor 24 in which an exothermic reaction between carbon dioxide and hydrogen results in the formation of a gas mixture comprising hydrocarbon gas and water vapor. Preheater 22 may not be required if the reactor 24 is designed utilizing a heat exchanger to preheat the gas to reaction temperature and to transfer energy to an external source for any desired use. The gas mixture is directed from the reactor 24 to a heat exchanger 26 in which residual energy from the gas mixture is transferred to an external source for any desired use.
The cooled gas mixture is then directed to a condenser 28 in which the latent heat of the water vapor is absorbed by a coolant, causing water vapor to condense. The water and hydrocarbon gas mixture is then directed to a hydrocarbon separator 30. Water collects in the lower portion of the separator 30 and is recycled to the dissociation unit 12 where it is dissociated. The hydrocarbon gas accumulated in the upper portion of the separator 30 flows to a pump 32 which directs the hydrocarbon gas to a gas mixer 34.
As hydrogen gas is purified and supplied to the hydrocarbon synthesis reactor, oxygen gas formed in the dissociation unit 12 passes through a pump 36 which directs it to a gas separator 38. The gas separator removes hydrogen gas present in the oxygen gas to provide purified oxygen gas. Hydrogen gas removed from the purified oxygen gas in separator 38 is mixed with the purified hydrogen gas exiting the separator 18. Likewise, oxygen gas removed from the purified hydrogen gas in separator 18 is mixed with the purified oxygen gas exiting the separator 38. The purified oxygen gas is then directed to the gas mixer 34 which mixes oxygen gas with the hydrocarbon gas. The mixed gas is directed to a hydrocarbon combustion unit 40 in which an exothermic reaction between oxygen gas and the hydrocarbon gas results in the formation of a combustion product comprising carbon dioxide gas and water vapor. The combustion product is directed to a heat exchanger 42 in which energy from the combustion product gas is transferred to an external source for any desired use. The hydrocarbon combustion unit 40 may also incorporate a heat exchanger (i.e., a boiler).
The cooled combustion product is then directed to a condenser 44 in which the latent heat of the water vapor is absorbed by a coolant, causing water vapor to liquefy. The water and carbon dioxide gas mixture is then directed to a carbon dioxide separator 46. Water collects in the lower portion of the separator 46 and is recycled to the dissociation unit 12 where it is dissociated. Carbon dioxide gas accumulated in the upper portion of the separator 46 flows to a pump 48 which directs carbon dioxide gas to the gas mixer 20 for use in the hydrocarbon synthesis reactor 24, thus completing the closed loop system.
The hydrogen gas, oxygen gas, carbon dioxide gas, water, water vapor and hydrocarbon gas reaction products produced by the dissociation, combustion and hydrocarbon synthesis reactions are pumped throughout the system at a rate which provides the proper stoichiometric ratios of reactants for the reactions. Selection of the reactant flow rates and catalysts for use in the reactor is well known in the art and is dependant upon the hydrocarbon to be produced. If methane is produced, for example, the following reactions will occur within the system:
4 H.sub.2 O→4 H.sub.2 +2 O.sub.2 ΔH=231.2 kcal/g-mole
CH.sub.4 +2 O.sub.2 →CO.sub.2 +2H.sub.2 O ΔH=-192.0 kcal/g-mole
4 H.sub.2 +CO.sub.2 →CH.sub.4 +2 H.sub.2 O ΔH=-39.2 kcal/g-mole
As the closed loop energy conversion system is continuously operated, nominal amounts of reactants and/or products may be added to or removed from the system to compensate for reactions which do not proceed to absolute completion. Make-up streams of hydrogen gas, oxygen gas, carbon dioxide gas, hydrocarbon gas and water are fed to the system via lines 50, 52, 54, 56, and 58, respectively, to supply such nominal amounts of reactants to the system as needed. The carbon dioxide gas make-up stream initially provides carbon dioxide gas to the gas mixer 20 at start-up of the closed loop system until adequate carbon dioxide gas is produced by combustion of the hydrocarbon gas.
The dissociation unit 12 is any commercially available apparatus which dissociates water into hydrogen gas and oxygen gas. The unit can operate by well known methods including electrolysis, photoelectrolysis, photolysis, electrochemical photovoltaics, radiolysis, plasmolysis, magnetolysis, thermal catalysis, and bio-catalysis. Preferably, the dissociation unit operates by electrolysis to form hydrogen gas at a cathode and oxygen gas at an anode. Such units have a partition between the cathode chamber and anode chamber to separate hydrogen gas from oxygen gas.
The energy source 14 is any non-fossil energy source such as electricity or radiation. The system of the present invention converts such a non-fossil energy source to a fossil fuel without generating air polluting emissions when the fossil fuel is combusted to provide energy to an external source. The external source can be any object outside the closed loop energy conversion system which is to be heated or which utilizes heat energy, such as a materials stream in a processing plant or an internal combustion engine.
Hydrogen gas formed in the dissociation unit 12 and carbon dioxide gas formed in the hydrocarbon combustion unit 40 are reacted in the hydrocarbon synthesis reactor 24 to form a hydrocarbon gas such as methane, ethane, propane, butane, pentane or other alkane and water vapor. In a preferred embodiment, a Sabatier reaction occurs in the hydrocarbon synthesis reactor. A Sabatier reaction occurs when hydrogen and carbon dioxide gasses react to form methane and water vapor at a temperature between about 275° C. and about 400° C., preferably between about 300° C. and about 400° C., in the presence of a suitable catalyst, such as nickel. Selection and operation of a hydrocarbon synthesis reactor is well known in the art, and is described in Catalyst Handbook (Martin Twigg ed., Wolfe Publishing Ltd., London, England 1989) and Paul Sabatier, Catalysts in Organic Chemistry (E. E. Reid trans., The Library Press, London, England 1923).
The hydrocarbon combustion unit 40 is an indirect-fired unit in which the products of combustion and the flame used to ignite the hydrocarbon are not in direct contact with the material being heated. Such units include boilers, kettles, vaporizers, stills, internal combustion engines, and furnaces. Boilers and furnaces are typically used in combustion of hydrocarbons, and are preferred for purposes of the present invention.
The following example is presented to describe an embodiment of the present invention and is not meant to limit the present invention unless otherwise stated in the claims appended hereto.
EXAMPLE
A closed loop conversion system, as shown in FIG. 2 was assembled on a laboratory scale to illustrate operation of the invention. Compressed cylinders of pure hydrogen and pure oxygen were substituted for hydrogen and oxygen gas formed by dissociation of water.
The process was initiated by feeding pure compressed carbon dioxide gas 60 and pure compressed hydrogen gas 62 through respective gas flow meters at rates of 330 cm 3 /min and 1320 cm 3 /min, respectively, into a 3/8 inch FDA grade clear vinyl tubing. The gases were mixed as they flowed through a portion of the tubing 64 containing about two feet of 1/8 inch Denstone 57 beads.
The mixed gases were then fed to a Sabatier reactor 66 as shown in FIG. 3. The reactor was constructed of 304 stainless steel and included a reaction chamber 68 of 5/8 inch O.D. tubing with 0.035 inch wall thickness. A tube 70 axially centered within the reaction chamber of the Sabatier reactor was composed of 1/8 inch diameter tubing and was used in conjunction with a sliding thermocouple (not shown) for monitoring reaction temperatures. High temperature Dow Corning 210H fluid was fed through an inlet 72 of an outer chamber 74 of 11/2 inch O.D. and 0.065 inch wall thickness, and exited through outlet 76. The fluid was recirculated and maintained at a temperature ranging from about 325° F. to about 345° F. by a Lauda type high temperature heating circulator.
The reaction chamber 68 was initially filled with 1/8 inch×1/8 inch nickel catalyst tablets supported by a fine mesh stainless steel screen 78 at the base of the reaction chamber. However, when the mixed hydrogen/carbon dioxide gas was fed through the reactor inlet 80, a hot spot was formed during the methanation reaction and the catalyst temperature exceeded 750° F. The reactor bed was then replaced with a layered catalyst bed 82 composed of (listed from top to bottom) 11/2 inches of 1/8 inch Denstone beads, 6 inches of a 6:1 by volume mixture of Denstone beads (54 mls) and nickel catalyst (9 ml), 6 inches of a 4:1 by volume mixture of Denstone beads (52 ml) and nickel catalyst (13 ml), 9 inches of a 2:1 by volume mixture of Denstone beads (60 ml) and nickel catalyst (30 ml), and 2 inches of Denstone beads. Essentially all of the methanation reaction took place in the initial 71/2 inches of the catalyst bed. A conversion rate of at least 95% was obtained at a catalyst temperature of 600° F.±25° F. using a recirculating fluid temperature of 335° F.±10° F. The optimum temperature depends upon the space velocity, linear gas velocity, residence time, type of nickel catalyst, and such other parameters.
As shown in FIG. 2, the gas containing methane and water vapor produced in the Sabatier reactor was then fed to a heat exchanger 84 to cool the gas and transfer heat energy to an external source for any desired use. The cooled gas was then fed to a water-cooled condenser 86 to condense remaining water vapor and separate it from the methane gas. The water was collected in reservoir 88. The methane flowed through 3/8 inch vinyl tubing 90 and was monitored via a gas sampling septa. Samples were taken periodically and analyzed for methane, carbon dioxide and oxygen content using a Hewlett-Packard Model 5980A gas chromatograph. The hydrogen feed rate was slightly adjusted to optimize the Sabatier reaction based upon the analysis results. A check valve positioned downstream from the septa was used to prevent possible gas back flow. A flame arrester downstream of the check valve was used to prevent possible flash back.
Pure compressed oxygen gas 92 was fed through a gas flow meter at a rate of 660 cm 3 /min into tubing 90. The gases were mixed in a portion of the tubing 94 containing about 18 inches of 1/8 inch Denstone beads. The gas mixture was pumped through a peristaltic pump 96 at a rate of 990 cm 3 /min. Pressure gauges installed immediately before and after the pump were used to maintain the pressure through the pump by making fine adjustments in the pump flow rate after the system was operating as a closed system. Pressure within the system was maintained at 1-5 lb/in 2 . The gas was then fed to a methane combustion unit 98. A check valve and a flame arrester were installed before the inlet of the methane combustion unit to prevent possible gas back flow or flash back.
FIG. 4 illustrates the methane combustion unit which was constructed of a stainless steel tube 100 (0.040 inch I.D.) inserted through a rubber stopper 102 such that the tip extended about 11/4 inch beyond the stopper. The oxygen/methane gas was fed through the tube 100 and ignited before the stopper 102 was inserted into the opening of the combustion chamber 104 made from 25 mm O.D. Pyrex tubing 106. The tubing 106 is surrounded by a one gallon Nalgene PC bottle 108. Cold water enters the bottle through openings 110 within the top of the bottle. The oxygen/methane gas was combusted to form carbon dioxide and water vapor. Denstone beads 112 (1/8 inch) were placed in the lower six inches of the combustion chamber 104 to facilitate cooling of carbon dioxide and water vapor combustion gases by transferring heat to water within the bottle 108. The gas then flowed through a condenser 114 filled with Denstone beads for transferring heat to the surrounding water coolant which flows through inlet 116 and exits through outlet 118. Water vapor within the gas was condensed and collected in a reservoir 120. Carbon dioxide flowed through 3/8 inch vinyl tubing 122 which was fitted with a gas sampling septa in order to analyze the carbon dioxide and oxygen content of the gas and adjust the oxygen feed rate accordingly to optimize the methane combustion. Carbon dioxide was then pumped to the tubing 64 where it was mixed with hydrogen gas, completing the closed loop system.
In order for the system to operate as a closed loop, carbon dioxide from the methane combustion was vented off before mixing it with hydrogen to purge the system. The compressed carbon dioxide cylinder used to initially operate the Sabatier reactor was no longer required. Three solenoid valves were activated simultaneously to close the carbon dioxide vent line, open the carbon dioxide feed line 122, and close the compressed cylinder carbon dioxide 60. Using the rudimentary laboratory scale equipment, the system was operated for ten complete closed loop cycles before the flame in the methane combustion unit was extinguished.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that it is not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
|
A closed loop energy conversion apparatus including a dissociation unit for dissociating water into hydrogen gas and oxygen gas and separating hydrogen gas from oxygen gas. An energy source provides energy to the dissociation unit. Oxygen gas and hydrocarbon gas react in a hydrocarbon combustion unit to form a combustion product comprising carbon dioxide gas and water vapor. A first heat exchanger cools the combustion product and condenses water vapor from the combustion product. A carbon dioxide separator separates carbon dioxide gas from water condensed in the first heat exchanger. Carbon dioxide gas reacts with hydrogen gas in a hydrocarbon synthesis reactor to form a mixture comprising hydrocarbon gas and water vapor. A second heat exchanger cools the mixture and condenses water vapor from the mixture. A hydrocarbon separator separates hydrocarbon gas from water condensed in the second heat exchanger. A conduit system directs oxygen gas from the dissociation unit to the hydrocarbon combustion unit, carbon dioxide gas from the hydrocarbon combustion unit to the hydrocarbon synthesis reactor, water from the hydrocarbon combustion unit and the hydrocarbon synthesis reactor to the dissociation unit, hydrogen gas from the dissociation unit to the hydrocarbon synthesis reactor, and hydrocarbon gas from the hydrocarbon synthesis reactor to the hydrocarbon combustion unit.
| 2
|
BACKGROUND OF THE INVENTION
The invention relates to a cycle-pedal arrangement comprising a cycle pedal and an associated shoe.
The shoes of a cyclist and the pedals of a bicycle are frequently not ideally matched to one another so that an ideal force transmission from the shoe to the pedal and thus from the cyclist to the pedal crank is not always ensured. There are admittedly safety pedals for cyclists with associated shoes in which the shoe and pedal can be latched together, however a latch between the shoe and the pedal is not always desirable. Thus, even with such bicycle pedal arrangements for racing bicycles, the bicycle pedal can be provided at its pedal face remote from the receiving device with a normal pedal surface, in order that the pedal can also be used when latching of the safety latch between the shoe and the pedal is not desired. With this use of the pedal the shoe can however be placed in a plurality of possible positions on the pedal, so that an ergonomically favourable position is not always found.
It is thus the object of the invention to design a cycle pedal arrangement of the initially named kind such that even with frequent mounting and dismounting an ideal force transmission is ensured between the shoe and the pedal, and such that even when using safety pedals, and preferably when using the pedal face of the pedal not provided with a receiving device, a reproducable and ergonomically favourable positioning of the shoe is made possible.
This object is satisfied in accordance with the invention in that the shoe has a contour in at least one region of its sole which is matched to an essentially complementary contour formed in at least one region of the bicycle pedal and cooperates with the latter at least in a force transmitting manner.
Through this layout of the pedal and sole a particularly good force transmission is provided from the shoe to the pedal. A particularly advantageous solution is characterized in that the cycle pedal is provided at at least one pedal side with a profile-like contour which can be brought into form matched and force transmitting engagement with the profiled sole.
It is advantageous with this arrangement that the profile-like contours engage into one another and produce an intensive contact between the pedal and the sole.
This is in particular advantageous with cross-country journeys or during journeys with a mountain bike when wet conditions between the sole of the shoe and the pedal greatly reduce the frictional adhesion with customary shoe-pedal combinations.
The bars of the shoe and pedal have a semi-trapezoidal cross-section which permits a particularly good meshed arrangement in which both high force transmission between the shoe and the pedal and also precise fixing of the shoe on the pedal is possible.
The vertical surfaces of the semi-trapezoidal bars of the pedal all face in the forward direction of the pedal which permits a particularly effective force transmission since when pressing the pedal downwardly since the vertical edges or side faces of the sole side bars are pressed against the vertical edges or side faces of the pedal side bars and thus a large area region is available for force transmission. The force transmitted from the shoe to the pedal thereby simultaneously brings about a reliable grip of the shoe on the pedal and counteracts the sliding of the shoe away from the pedal face of the pedal.
Having two bars on the pedal or the sole received in one groove of the sole or pedal respectively enables a fine positioning of the show on the pedal.
One can thus ensure that the maximum deviation of the position of the axis of movement of the joint of the toe close to the foot from the ideal position vertically above the pedal axis amounts to only 3 to 7 mm, in particular to 5 mm.
By having an actuating surface in a region of the sole, one obtains a particularly simple and reliable engagement with a pedal on climbing onto it, in conjunction with a cycle pedal having a pedal fixing device.
A plate can be provided in a recess in the sole for receiving in latching or non-latching engagement the second side of the pivotable pedal. This increases the versatility of the cycle pedal arrangement since an intensive connection can be produced between the cycle pedal and the shoe on sections of the journey in which frequent mounting and dismounting is not necessary.
Through the provision of a cover plate for the recess receiving the plate the area of the sole provided with bars can be increased and thus an effective engagement can be achieved between the sole and the pedal face of a pedal provided with bars. The symmetrical construction of the cover plate allows the use of a single cover plate for the left and right shoes.
Both the shoe and also the pedal can be provided with matched reference markings, the mutual force transmitting engagement of which can be sensed by the cyclist on placing the shoe on the pedal, so that a rapid and reliable alignment of the shoe on the cycle pedal is possible.
If the pedal side abutment is formed at the rear edge of the pedal face then the pedal face abutment is automatically led up to the positioning abutment in the region of the sole during the load free upward and forward movement of the pedal, so that in the subsequent force transmitting forward and downward movement the shoe contacts the pedal in the desired ideal position.
The foot of the cyclist adopts an ergonomically particularly favourable position with the engagement of the abutments on the sole and the pedal which ensures a fixation of the shoe in a longitudinal direction of the shoe such that the axis of movement of a joint of a big toe adjacent the upper portion of the sole lies vertically above the transverse axis of the pedal. In this position a maximum force transmission is ensured between the foot and the pedal. A further advantageous solution of the underlying object is characterised that the cycle safety pedal has at least one abutment at its pedal face remote from the receiving means, with the abutment being engagable with a positioning abutment provided in the region of the sole of the cyclist's shoe.
Through the provision of an abutment and a positioning abutment both the shoe and also the pedal are provided with matched reference markings the mutual force transmitting engagement of which can be sensed by the cyclist when placing the shoe on the pedal, so that a rapid and reliable alignment of the shoe on the cycle pedal is possible.
If the pedal side abutment is formed at the rear edge of the pedal face then the pedal side abutment is automatically led up to the positioning abutment in the region of the sole again during the load free upward forward movement of the pedal, so that in the subsequent force transmitting forward and downward movement the shoe contacts the pedal in the desired ideal position.
It is particularly advantageous if, the sole side positioning abutment is formed directly on the plate, and is in particular formed at the rear edge of the plate.
This ergonomically favourable positioning of the foot on the pedal can, also be provided when using the safety latch.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in more detail in the following with respect to examples and with reference to the drawing in which are shown:
FIG. 1 a first embodiment of the cycle pedal arrangement of the invention, with the shoe placed on the pedal,
FIG. 2 a safety pedal with a pedal face provided with bars and a receiving device for a plate,
FIG. 3 a profile pairing between the sole and the pedal shortly before mutual engagement,
FIG. 4 a profile pairing which is in engagement,
FIG. 5 view from below of the sole of a cyclist's shoe provided with a plate,
FIG. 6 a view from below of the sole of a cyclist's shoe provided with a cover plate,
FIG. 7 a second embodiment of the cycle pedal arrangement of the invention shortly before the placement of the shoe onto the pedal,
FIG. 8 a cyclist's shoe placed on the pedal of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a cycle pedal 1 which is pivotally journalled on a non-illustrated pedal crank about a pedal axle 14.
At its upper pedal face 11 the pedal 1 is provided with bars 15 which extend transversely to the direction of travel A. The pedal face 11 has an abutment 12 at its rear edge 13 with respect to the direction of travel A.
An associated shoe is provided with bars 25 at the sole 20 in the ball region, with the bars extending transversely to the longitudinal direction of the shoe. The bars 25 are formed for meshed engagement with the bars 15 provided on the pedal face 11.
The cooperation of the bars 25 at the shoe side and of the bars 15 at the pedal side will be explained in more detail with respect to FIGS. 2 to 4. FIG. 2 shows a pedal 1 which is provided on the pedal face 11 with a plurality of bars 15 which extend substantially parallel to the pedal axis 14.
The bars 15 and also the bars 25 have in cross-section the shape of a half trapezium so that their one transverse edge extends vertically and the other transverse edge extends obliquely. With this arrangement the vertical edge 16 of the bars 15 of the pedal 1 is forwardly directed in the direction of travel A, whereas the obliquely extending edge 17 of the pedal side bars 15 is disposed at the rear side. At the sole 20 the arrangement is precisely reversed so that the vertical edge 26 of the bars 25 is directed rearwardly with respect to the longitudinal direction of the shoe whereas the obliquely extending edge 27 of the bars 25 is forwardly disposed. In this way there arises, as can be seen from FIG. 4, a mesh between the sole of the shoe 20 and the pedal 1 which enables a particular good force transmission from the shoe to the pedal via the closely contacting vertical edges 16 and 26.
In order to prevent the sole 20 of the shoe undesirably sticking to a pedal 1 by suction the obliquely extending edges 17 and 27 can have different angles of inclination so that they only contact over a small portion of their area.
Should the bars 25 and the bars 15 lie opposite to one another when the shoe side positioning abutment 22 contacts the pedal side abutment 12 then, in the case of an elastic construction of the pedal side abutment 12 and/or of the positioning abutment 22, a small displacement of the sole of the shoe to the rear can taken place until a mutual engagement is possible between the shoe side bar contour and the pedal side bar contour (arrow R and broken line in FIG. 3).
The arrangement of the bars 15 shown in FIGS. 3 and 4 with relatively large spacing is particularly advantageous since in this way a contamination of the pedal face and thus the filling up of the spaces between the bars with dirt is extensively prevented. In order to obtain the finest possible grading of the engagement positions in the longitudinal direction of the shoe, despite the large bar spacing at the pedal face, the spacing between the bars 25 at the shoe side can be made smaller. Thus, for example, in the embodiment of FIGS. 3 and 4, the spacing x between two bars 15 on the pedal 1 corresponds to the spacing between three bars 25 on the sole 20.
The shorter spacing between two bars 25 on the sole 20 (bar peak and bar groove) is designated with y in FIG. 4 and amounts to 3 to 7 mm, in particular to 5 mm. Through this layout it is ensured that the maximum deviation of the position of the axis of movement 32 of the joint 31 close to the foot from the ideal position vertically above the pedal axis 14 amounts to only 3 to 7 mm, in particular to 5 mm.
The differential spacing between the bars described in conjunction with FIGS. 3 and 4 can naturally also be such that the shorter bar spacings are provided on the pedal whereas the larger bar spacings are provided on the shoe sole.
FIG. 5 shows a sole 20 of a cyclist's shoe which has a recess 29 at its front side into which a plate 21 can be inserted in recessed manner. The shoe can in this way be engaged without problem into a receiving device or a latch 10 of a safety pedal 1 provided at the side opposite from the profiled pedal face 11. The shoe can however also be placed with its sole on the profiled pedal face 11. For this purpose the sole 20 of the shoe 2 is provided at both sides alongside the receiving recess 29 with the bars 25 which extend transverse to the longitudinal direction of the shoe. The bars 25 are formed for meshed engagement with the bars 15 provided on the pedal face 11.
Alongside the plate 21 an actuation surface 28 is provided in the sole 20 which is raised relative to the recess 29 and serves for the actuation of a release device provided on the associated pedal face for a brake device which prevents the rotation of the pedal. The sole is provided in the heel region and in the region of the tip and also in the outer side region with a profile which deviates from the bars 25 and which is not formed for engagement with the profile of the pedal 1. In FIG. 6 the same sole is shown, however with a cover plate 24 being inserted in place of the plate 21. The mounting of the cover plate 24 is effected by two screws which are arranged spaced apart behind one another in the longitudinal direction of the shoe and which are screwed into the same threads as are also used for the mounting of the plate 21. The cover plate 24 can however also be attached in such a way that prior removal of the plate 21 is not necessary. It can for example be secured to the plate 21.
In this arrangement the cover plate 24 covers over the recess 29 provided in the ball region of the foot received in the shoe. The cover plate is likewise provided with profiling which in the illustrated embodiment is different from the profiling of the bars 25. However the cover plate can in principle also have the same profile shape as the bars 25 and then the bars of the cover plate can likewise extend at the same angle, essentially at a right angle, to the longitudinal axis of the shoe as the bars 25 and the bars of the cover plate 24 can respectively be aligned with the associated bars at the left and the right side of the recess 29. In this manner a continuous active surface arises in the ball region of the sole 20 formed by parallel bars 25, by which a particularly effective engagement with the bars 15 of the pedal surface 11 of the pedal is ensured. Only the actuating surface 28 for the brake device of the pedal thereby interrupts the run of the bars in a region of the active surface.
At the sole 20 a positioning abutment 22 is provided at the rear end of the region provided with the bars 25 and comes into contact with a pedal side abutment 12. In this position shown in FIG. 1 the axis of movement 32 of the joint 31 of the large toe 30 close to the foot of a foot received in the shoe 2 lies vertically above the axis of rotation 14 of the pedal 1. This position of the foot 3 with respect to the pedal axis 14 permits an ergonomically particularly ideal force transmission between the foot and the pedal since the pressure forces exerted by the foot onto the sole 20 of the shoe when pedalling via the joint 31 and the ball 33 located beneath it are fed directly into the pedal axle 14 and thus into the pedal crank without thereby generating an undesired tilting moment of the pedal 1 about the pedal axis 14. Consequently, with this arrangement, the pedal force generated by the cyclist can be essentially fully exploited for the driving of the bicycle.
FIG. 7 shows a cycle safety pedal 101 that is rotatably journalled about a pedal axis 114 on a non-illustrated pedal crank. The pedal 101 has at its lower side a receiving device or a latch 110 for the plate 121 of a cyclist's shoe 102.
At the upper pedal face remote from the receiving device 110 the pedal 101 is provided with an essentially flat pedal face 111'. The pedal face 111 has at its rear edge 113 with respect to the direction of travel A an abutment 112 which projects upwardly out of the pedal surface 111'.
The plate 121 is attached to the cyclist's shoe 102 at its sole 120 in the front region and is normally formed for engagement with the receiving device 110 of the pedal 101. The plate 121 has at its rear edge 123 a positioning abutment 122 which extends essentially vertical to the lower surface 121' of the plate 121. The positioning abutment 122 can however also be formed directly on the sole 120.
When placing the shoe 102 on the pedal face 111 of the pedal 101 the front region of the plate 121 is first placed onto the pedal surface 111' and then the shoe is moved rearwardly and downwardly in the sense of the arrow P so that the shoe side positioning abutment 122 comes into contact with the pedal side abutment 112. In this position shown in FIG. 8 the axis of movement 132 of the joint 131 of the large toe 130 close to the foot of a foot received in the shoe 102 also lies vertically above the axis of rotation 114 of the pedal 101.
The same ergonomically favourable alignment of the shoe on the pedal can also be obtained when using the receiving device 110 for the plate 121 if, in the region of the receiving device 110, a pedal side abutment 118 is likewise provided for the shoe side positioning abutment 122.
With the positioning of the shoe 102 shown in FIG. 8 on the pedal 101 the ergonomically favourable position of the shoe 102 on the pedal 101 can be improved in that both the pedal face 111 and also the lower surface 121' of the plate 121 or, when the plate 121 is arranged sunk in the sole 120, the sole 120 are provided with a profile-like contour such as has been described in conjunction with the first embodiment.
|
A cycle pedal arrangement comprises a cycle pedal and an associated shoe. In this arrangement the shoe has a contour in at least a region of its sole which is matched to at least one essentially complementary contour formed in a region of the cycle pedal and cooperates with the latter in at least a force transmitting manner.
| 1
|
This is a continuation, of application Ser. No. 08/294,080 filed Aug. 22, 1994 abandoned.
BRIEF DESCRIPTION OF THE INVENTION
This invention relates generally to the packaging of integrated circuits. More particularly, this invention relates to an integrated circuit package with an external storage capacitor mounted thereon to improve signal quality for sensitive integrated circuit elements.
BACKGROUND OF THE INVENTION
The evolution of integrated circuit technology continues to increase transistor speed. At high switching frequencies, capacitive loading and coupling parasitics significantly degrade the speed and quality of signals in an integrated circuit. These effects are especially pronounced for those signals that are generated external to the integrated circuit. In other words, those signals that must travel from a printed circuit board, through an integrated circuit package, and into the integrated circuit. This path includes the following elements: a package pin of a printed circuit board component, a printed circuit board signal trace, an integrated circuit package pin, one or more vias, a signal trace or power plane, a package bond pad, a bond wire, and an integrated circuit bond pad. Each of these elements contributes some parasitic resistance, capacitance, and inductance to the signal path.
The parasitic resistance, capacitance, and inductance of the signal path can seriously compromise the quality of signals processed by sensitive integrated elements. As a result, the operation of the entire integrated circuit can be compromised.
The significance of this problem is especially appreciated in the context of a phase-locked loop. A phase-locked loop produces a recovered data or clock signal corresponding to an input reference signal. In the context of an integrated circuit, a phase-locked loop is commonly used to produce a recovered system clock signal that is used to govern the operation of the entire integrated circuit.
A phase-locked loop generally includes a phase comparator that is used in conjunction with a charge pump circuit to provide a pulsed error signal indicative of the phase difference between the reference signal and the recovered signal. The charge supplied by the error signal is used to develop a control voltage across a capacitor. A voltage controlled oscillator operates to vary the frequency of the recovered signal in accordance with the control voltage of the capacitor. Thus, it can be appreciated that when the capacitor of a phase-locked loop receives a degraded signal attributable to parasitic resistance, capacitance, and inductance of a signal path, the operation of the system clock can be compromised.
It would be highly desirable to provide a semiconductor package with an on-board storage capacitor for improved signal quality for sensitive integrated circuit elements, such as a voltage controlled oscillator of a phase-locked loop. It would also be highly desirable to exploit mature assembly processes in constructing such a package.
SUMMARY OF THE INVENTION
The invention is a package for an integrated circuit. The package houses an integrated circuit with a signal quality sensitive integrated circuit element, such as a voltage controlled oscillator of a phase-locked loop. A package-mounted storage capacitor is positioned on the package body to generate a precision control signal. A signal path is constructed between the package-mounted storage capacitor and the integrated circuit to route the precision control signal to the integrated circuit. The relatively short signal path from the package-mounted storage capacitor to the integrated circuit has reduced parasitic capacitance, inductance, and resistance to maintain the quality of the precision control signal. To improve signal quality, certain portions of the signal path are electrically isolated with a shielding trace.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a top view of one embodiment of the integrated circuit package of the invention.
FIG. 2 is a cross-sectional view of one embodiment of the integrated circuit package of the invention taken along the line 2--2 of FIG. 1.
FIG. 3 is a conceptual representation of one embodiment of the package components and electronic components of the invention.
FIG. 4 is a top view of one embodiment of the integrated circuit package of the invention showing a package-mounted storage capacitor well for receiving a package-mounted storage capacitor.
FIG. 5 is a top view of a metal layer including transverse metal regions for routing package-mounted storage capacitor signals associated with one embodiment of the invention.
FIG. 6 is a top view of a metal layer including signal traces for routing package-mounted storage capacitor signals associated with one embodiment of the invention.
FIG. 7 is a bottom view of the external pins of one embodiment of the integrated circuit package of the invention.
Like reference numerals refer to corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a top or plan view of one embodiment of an integrated circuit package 20 in accordance with the invention. The package 20 includes a package body 22 which supports a package-mounted storage capacitor 24. The package body 22 also includes a plurality of decoupling capacitors 26. Decoupling capacitors 26 are known in the art. However, as will be described in detail below, the purpose and implementation of the package-mounted storage capacitor 24 of the present invention is dramatically different than that of a decoupling capacitor 26.
FIG. 1 also illustrates a heat sink 28. A semiconductor (not shown in FIG. 1) is attached to the opposite side of the heat sink 28.
FIG. 2 is a partial cross-sectional view of the integrated circuit package 20 taken along the line 2--2 of FIG. 1. The invention is disclosed in relation to an eight layer, two bond shelf, 313 pin ceramic pin grid array. However, it will be appreciated by those skilled in the art that the techniques associated with the invention are equally applicable to a vast number of package configurations.
The eight metal layer package illustrated in FIG. 2 includes: a pin interconnect layer 32, an output buffer Vcc plane (Vccp) 34, a signal plane 36, an output buffer Vss plane (Vssp) 38, an input buffer Vcc plane (Vcci) 40, an input buffer Vss plane (Vssi) 42, a core logic Vss plane (Vssc) 44, and a core logic Vcc plane (Vccc) 46.
FIG. 2 also illustrates the heat sink 28, which has been implemented in the form of a 800 mm 2 copper/tungsten heat slug. An integrated circuit 48 is affixed to the heat sink 28. Bond wires (not shown) are used to electrically couple the integrated circuit 48 to bond pads (not shown) on package bond shelves 47, 49. Finally, FIG. 2 illustrates a package-mounted storage capacitor well 30 that is used to receive the package-mounted storage capacitor 24 of the invention.
Turning now to FIG. 3, depicted therein is a conceptual schematic of the physical package elements and electronic components of one embodiment of the invention. This embodiment of the invention is disclosed in relation to a phase-locked loop, but, again, it should be appreciated that the package-mounted storage capacitor of the invention may be used in conjunction with any number of sensitive integrated circuit elements (also called signal quality sensitive integrated circuit elements).
FIG. 3 illustrates the integrated circuit package 20 of the invention with its package-mounted storage capacitor 24. The figure also illustrates an external clock pin (Vck) 50. The external clock pin is shown as a package perimeter pin only for the purpose of illustration. The form of the package pin is insignificant. It is only required to provide a pin interface to a printed circuit board, typically of a general purpose computer.
The external clock pin 50 is electrically connected to an integrated circuit 48 of the package 20. The integrated circuit 48 includes a phase-locked loop 52. The phase-locked loop 52 is of the type known in the art. It includes a phase comparator 54, a charge pump 56, and a voltage controlled oscillator (VCO) 58. The output of the VCO 58 is used to control clock-driven internal circuitry 60. A feedback line 62 serves as a second input to the phase comparator 54.
FIG. 3 illustrates that the VCO 58 is connected to a Vcc clock pin (Vccck) 64 by a Vcc clock pin line 65. Similarly, the VCO 58 is connected to a Vss clock pin (Vssck) 66 by a Vss clock pin line 67. A phase-locked loop test pin Vpllrc 68 is electrically connected to the input of the VCO 58 by a capacitor line 69. The package-mounted storage capacitor 24 of the invention is electrically connected between the Vss clock pin line 67 and the capacitor line 69.
In normal operation the Vpllrc pin 68 is left unconnected to external circuitry (it can be connected for testing or debugging purposes). Thus, the voltage on the package-mounted storage capacitor 24 is the sole input on the capacitor line 69. The voltage on the package-mounted storage capacitor 24 constitutes a precision control signal that is processed by the phase-locked loop 52. This improved voltage signal is used by the phase-locked loop 52 in a traditional manner to control the output of the VCO 58. However, in accordance with the invention, the capacitor line 69, also called the package signal path, is relatively short. That is, a relatively short package signal path exists between the package-mounted capacitor 24 and the sensitive integrated circuit element 52. The precise architecture of this signal path is discussed below.
Thus, the present invention is capable of providing a precise and otherwise uncompromised signal to one or more sensitive integrated circuit elements. This stands in contrast to a signal that would be received from an off-package capacitor. Such a signal would be compromised from the significant parasitic resistance, capacitance, and inductance of the signal path.
The construction and operation of the apparatus of the invention is more fully appreciated with reference to FIG. 4. FIG. 4 is a top view of the core logic Vss plane 44. As can be seen in FIG. 4 (and FIG. 2), this plane 44 includes a storage capacitor well 30. At the base of the storage capacitor well 30 is the input buffer Vss plane 42. Also at the base of the well is a set of Vssck vias 70 and a set of Vpllrc vias 72.
FIG. 5 illustrates the input buffer Vss plane 42. The figure shows that the Vssck vias 70 of FIG. 4 terminate at a first end of a Vssck transverse metal 80. The second end of the Vssck transverse metal 80 includes a Vssck signal layer via 86. The Vpllrc vias 72 of FIG. 4 terminate at a first end of Vpllrc transverse metal 82. The second end of the Vpllrc transverse metal 82 includes a Vpllrc signal layer via 88. The Vpllrc transverse metal 82 and the Vssck transverse metal 80 are each surrounded by insulating motes 84.
FIG. 6 illustrates the Vcci input buffer plane 40. The figure shows the Vssck signal layer via 86 terminating in a Vssck trace 90. FIG. 6 also shows the Vpllrc signal layer via 88 terminating in a Vpllrc trace 92. Each trace 90, 92 terminates in a package bond pad 91, 93, respectively.
FIG. 6 also illustrates a Vccck trace 94. This trace is connected to a first end of a Vccck via 96. The second end of the Vccck via 96 is connected to a pin on the pin interconnect layer 32. The Vccck trace 94 terminates on a package bond pad 95.
The Vssck trace 90, the Vpllrc trace 92, and the Vccck trace 96 are isolated from one another by a shielding trace 100. The shielding trace 100 serves to eliminate cross-talk and the effect of transients on the critical signals carried by these traces.
Thus, the present invention provides a short signal path from the package-mounted storage capacitor 24 to the package integrated circuit 48. This path improves signal quality by reducing the parasitic resistance, capacitance, and inductance associated with an analogous prior art signal path. Moreover, the path of the invention is shielded to further enhance signal quality.
FIG. 7 is a bottom view of the package 20 of the invention. This figure is included to provide complete context for the invention. The figure illustrates the same pins shown in FIG. 3. The exact location of the pins is not critical.
It is advantageous that the present invention is able to exploit mature package assembly techniques developed in relation to decoupling capacitors. That is, decoupling capacitor packaging techniques for positioning a capacitor on a semiconductor package may be exploited in accordance with the present invention. The positioning of a capacitor in accordance with the present invention is analogous to the techniques used for decoupling capacitors. However, the topology of the signal path from the package-mounted storage capacitor 24 to the integrated circuit 48 is distinct from the signal path for a decoupling capacitor.
While there are some similarities between prior art decoupling capacitors and the package-mounted storage capacitor of the invention, it should be appreciated that the purpose and topology of decoupling capacitors is completely distinct from that of the package-mounted storage capacitor 24 of the invention.
Decoupling capacitors were developed to reduce switching noise. When a circuit receives a large current, for example, when large off-chip drivers switch, the surge in current, coupled with parasitic inductances, gives rise to Ldi/dt (inductive) losses. When an off-chip driver switches, the Ld/dt term can become significant. This term can cause a drop in the Vcc voltage and a rise in the Vss ground voltage. This decrease in voltage degrades the circuit's noise margins and also increases signal delay.
Decoupling capacitors are used to rectify this problem. A decoupling capacitor has its two terminals connected to the power and ground planes. The path to the power plane from the decoupling capacitor is much shorter than the path from the off-chip drivers. Thus, the decoupling capacitor provides a low inductance path that can be exploited during switching. That is, the charge on the decoupling capacitor supplements the supply current from the off-chip drivers during switching.
Prior art decoupling capacitors have a distinct purpose and topology. This purpose and topology does not suggest the distinct purpose and topology of the package-mounted storage capacitor of the invention. The purpose of a decoupling capacitor is to deliver power to different power planes. In contrast, the purpose of the present invention is to use a package-mounted storage capacitor to deliver a precision control signal to an integrated circuit component that is sensitive to signal quality. The package-mounted storage capacitor of the invention delivers a continuous precision signal, while decoupling capacitors of the prior art are only active during transient conditions. The signal of the package-mounted storage capacitor is independent of any other signal, while decoupling capacitors provide a supplemental power signal to augment an existing power signal.
The topologies of the two packages are distinct. A decoupling capacitor delivers power to power planes. In contrast, the package-mounted storage capacitor of the invention delivers a signal to a trace. In addition, the package-mounted storage capacitor includes shielded signal paths, a feature that is not applicable to decoupling capacitors. To accommodate the package-mounted storage capacitor of the invention, transverse metal regions (80, 82) are used. This structure is not applicable to decoupling capacitors.
The foregoing descriptions of specific embodiments of the present invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, obviously many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following Claims and their equivalents.
|
A package for an integrated circuit is described. The package houses an integrated circuit with a signal quality sensitive integrated circuit element, such as a voltage controlled oscillator of a phase-locked loop. A package-mounted storage capacitor is positioned on the package body to generate a precision control signal. A signal path is constructed between the package-mounted storage capacitor and the integrated circuit to route the precision control signal to the integrated circuit. The relatively short signal path from the package-mounted storage capacitor to the integrated circuit has reduced parasitic capacitance, inductance, and resistance to maintain the quality of the precision control signal. To improve signal quality, certain portions of the signal path are electrically isolated with a shielding trace.
| 7
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of pending U.S. Nonprovisional patent application Ser. No. 11/534,781, entitled, “Dual-Polarized Feed Antenna Apparatus and Method of Use”, filed Sep. 25, 2006, which claims priority to U.S. Provisional Patent Application No. 60/720,331, entitled, “A Dual Polarized Feed Structure Applicable to a Single Antenna or an Array”, filed Sep. 23, 2005, and pending U.S. Provisional Patent Application No. 60/720,296, entitled, “A High Frequency Feed Structure Applicable to a Single Antenna or an Array”, filed Sep. 23, 2005.
STATEMENT OF GOVERNMENT INTEREST
This invention was made with Government support under Grant No. 2106369 LO awarded by the NASA/FSEC. The Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
Light energy is characterized by a dual nature both from a quantum point of view as photons and from a wave point of view as randomly polarized electromagnetic radiation with a wavelength between 400 nm and 700 nm. If the ultraviolet and infrared portion of the spectrum is included, the range of wavelengths is extended at both extremes. Presently, all practical solar cell energy collection schemes utilize the photon nature of light. For example, the conversion of solar energy to electrical energy using the photovoltaic effect depends upon the interaction of photons with energy equal to or greater than the band-gap of the rectifying material. With continued research, the maximum amount of energy captured using the photovoltaic mechanism is estimated to be around 30%.
Optical rectennas are known in the art for harvesting solar energy and converting it into electric power. Optical rectennas consist of an optical antenna to efficiently absorb the incident solar radiation and a high-frequency metal-insulator-metal (MIM) tunneling diode that rectifies the AC field across the antenna, providing DC power to an external load. The combination of a rectifying diode at the feedpoints of a receiving antenna is often referred to as a rectenna. Utilizing a rectenna to harvest solar energy relies upon the electromagnetic nature of radiation and is not limited by the band-gap of the rectifying material. As such, this method is not fundamentally band-gap limited. At microwave frequencies (˜2.4 GHz) the rectenna approach has been demonstrated to be approximately 90% efficient. Rather than generating electron-hole pairs as in the photovoltaic method, the electric field from an incident electromagnetic radiation source will induce a wave of accelerated electric charge in a conductor. Efficient collection of the incident radiation is then dependent upon resonance length scales and impedance matching of the collecting antenna to the rectifying diode to minimize losses. However, prior art methods of harvesting high-frequency radiation utilizing rectennas have identified several key problems with the approach. These problems include impedance matching, rectification, polarization, limited bandwidth and captured power.
Traditionally, the λ/2 dipole antenna is the most commonly used antenna by the designer as the receiving device for a rectenna due to the straightforward design procedure and the ease of fabrication as a printed circuit antenna. However, the λ/2 dipole has shortcoming as an antenna for an optical detector. A λ/2 dipole antenna only supports a single polarization. It exhibits a relatively low gain, it exhibits very high conductor losses at higher frequencies and its radiation pattern is omni-directional. It has been shown that the rectifier efficiency would be less than 0.1% for the calculated power at the terminal of a rectenna utilizing a λ/2 dipole antenna.
Polarization of solar radiation is known to be random (unpolarized). An unpolarized electromagnetic wave is a collection of waves that have an equal distribution of electric field orientations in all directions. A randomly polarized wave can be decomposed into two main components, E x and E y . The λ/2 dipole antenna as is commonly known in the art only supports a single polarization and is therefore not useful for the collection of solar radiation or other unpolarized electromagnetic energy.
Accordingly, what is needed in the art is an improved rectenna for the collection of electromagnetic energy and more particularly an improved rectenna for the collection of solar energy that overcomes the identified deficiencies in the prior art solutions.
SUMMARY OF INVENTION
The present invention addresses the problem of receiving an unpolarized wave with a single antenna using two orthogonal feeds. The essence of the invention for intercepting randomly polarized electromagnetic waves is the employment of a dual polarized antenna, which is excited through an aperture by using two well-isolated orthogonal feeds.
The present invention provides for the collection of electromagnetic energy through an antenna element and a non-radiating dielectric waveguide (NRD) having two orthogonal feeds, and the subsequent extraction of energy from the NRD.
In accordance with the present invention, an antenna apparatus for the reception of, and or transmission of, electromagnetic energy is provided. An antenna apparatus for the reception of, and or transmission of, electromagnetic energy, the apparatus including a non-radiating dielectric waveguide, the non-radiating dielectric waveguide further comprising a first conductive plate and a second conductive plate arranged substantially parallel to each other at a predetermined distance, and a dielectric strip element having a length direction positioned between the first conductive plate and the second conductive plate. The non-radiating dielectric waveguide further includes a first aperture fabricated on the first conductive plate and aligned with the dielectric strip element, a second aperture fabricated on the second conductive plate, aligned with the dielectric strip element and positioned at a proximate end of the second conductive plate and a third aperture fabricated on the second conductive plate, aligned with the dielectric strip element and positioned at a distal end of the second conductive plate. An antenna element, such as a dielectric rod antenna, is then aperture coupled to the first aperture. A first transmission line element is electromagnetically coupled to the second aperture and a second transmission line element is electromagnetically coupled to the third aperture, the first transmission line element and the second transmission line element are positioned to be substantially orthogonal with each other.
In another embodiment, a plurality of antenna elements are provided and a plurality of apertures are positioned on the first conductive plate of the dielectric waveguide, each of the plurality of antenna elements aperture is coupled to the non-radiating dielectric waveguide through one of the plurality of apertures.
The transmission line elements of the present invention may be an electromagnetic waveguide, or an optical waveguide, depending upon the particular application. Additionally, the transmission line elements may further include tuning stubs along its length to adjust the impedance of the line.
In an additional embodiment, the antenna apparatus further includes a rectifier, such as a metal-insulator-metal (MIM) diode in circuit communication with the transmission lines to rectify the transmitted energy into a direct current power source.
In a particular embodiment, an antenna apparatus for the conversion of solar energy to direct current power is provided, the apparatus includes a non-radiating dielectric waveguide, the non-radiating dielectric waveguide further comprising a first conductive plate and a second conductive plate arranged substantially parallel to each other at a predetermined distance, and a dielectric strip element having a length direction positioned between the first conductive plate and the second conductive plate. The non-radiating dielectric waveguide further includes a first aperture fabricated on the first conductive plate and aligned with the dielectric strip element, a second aperture fabricated on the second conductive plate, aligned with the dielectric strip element and positioned at a proximate end of the second conductive plate and a third aperture fabricated on the second conductive plate, aligned with the dielectric strip element and positioned at a distal end of the second conductive plate. A dielectric rod antenna is aperture coupled to the first aperture to receive the randomly polarized electromagnetic solar energy and transmit the energy through the non-radiating dielectric waveguide. A first transmission line element is electromagnetically coupled to the second aperture and a second transmission line element is electromagnetically coupled to the third aperture, the first transmission line element and the second transmission line element are positioned to be substantially orthogonal with each other. A rectifier is electrically coupled to the transmission line elements for rectifying the transmitted electromagnetic solar energy into direct current power.
A method for the reception of electromagnetic energy in accordance with the present invention, include the steps of receiving electromagnetic energy through at least one antenna element, transmitting the received electromagnetic energy from the at least one antenna element through a non-radiating dielectric waveguide and transmitting the electromagnetic energy from the non-radiating dielectric waveguide through a pair of transmission line elements that are positioned at opposing ends a the non-radiating dielectric waveguide and are substantially orthogonal to each other. The electromagnetic energy that is transmitted through the transmission lines may then either be detected or rectified as determined by the particular application of the invention. In a specific embodiment, the electromagnetic energy collected by the antenna is solar energy and the method further comprises rectifying the electromagnetic energy transmitted through the transmission line elements to provide direct current power.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
FIG. 1 illustrates an antenna apparatus in accordance with the present invention.
FIG. 2 illustrates the polarization response of an exemplary 7 GHz dual polarized solar antenna in accordance with the present invention, wherein the solid line is the first polarization and the dashed line is the second polarization. FIG. 2 a is the measured response and FIG. 2 b is the simulated response.
FIG. 3 illustrates the radiation pattern for the first polarization of the exemplary 7 GHz dual polarized solar antenna in accordance with the present invention. FIG. 3 a is the E field and FIG. 3 b is the H field.
FIG. 4 illustrates the radiation pattern for the second polarization of the exemplary 7 GHz dual polarized solar antenna in accordance with the present invention. FIG. 4 a is the E field and FIG. 4 b is the H field.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The radiation from the sun is randomly polarized, so a single linearly polarized antenna can capture only a fraction of the incident radiation. The present invention proposes the use of cross-polarized linear antenna elements to double the radiation capture and resolve the mismatch between the antenna and solar radiation.
With reference to FIG. 1 , the antenna apparatus 10 in accordance with the present invention is illustrated, including a non-radiating dielectric waveguide comprising a first conductive plate 15 , having a first aperture 30 , and a second conductive plate 20 , having a second aperture 45 and a third aperture 50 . The two plates are arranged substantially parallel to each other at a predetermined distance, and a dielectric strip element 25 having a length direction is positioned between the first conductive plate 15 and the second conductive plate 20 . A first transmission line element 40 is positioned to be electromagnetically coupled to the second aperture 45 and a second transmission line element 55 is positioned to be electromagnetically coupled to the third aperture 50 . The first transmission line 45 and the second transmission 55 are positioned at opposite ends of the dielectric strip element 25 and are substantially orthogonal to each other. A dielectric rod antenna 35 is positioned to be aperture coupled with the first aperture 30 . The dielectric rod antenna belongs to the family of surface wave antennas. The dielectric rod antenna exhibits high gain and low conductor losses at optical frequencies. However, the invention is not limited to a dielectric rod antenna and other antennas employing aperture coupling feed techniques are within the scope of the present invention.
The non-radiating dielectric waveguide in accordance with the present invention exhibits low loss and is easy to fabricate. The non-radiating dielectric waveguide consists of a section of dielectric slab 25 sandwiched between two ground planes 15 , 20 . Since the TE modes at the boundary of the dielectric 25 and air are at a maximum, and at the boundary of the dielectric 25 and conductor 15 , 20 are at a minimum, the conductor losses are minimized. The transmission losses of the non-radiating dielectric waveguide consist of the dielectric loss and the conductor loss. The dielectric loss is independent of frequency and the conductor loss decreases as the frequency increases. The non-radiating dielectric waveguide is fed through two orthogonal apertures 45 , 50 in the bottom ground plane 20 by two orthogonal sections of transmission line 40 , 55 on a substrate 60 . By changing the position of the transmission lines 40 beneath the aperture 45 , or by adding tuning stubs, the broadband matching of the antenna's 35 impedance to a known reference impedance can be facilitated.
In an exemplary embodiment, the polarization response of a 7 GHz dual polarized solar antenna in accordance with the present invention is illustrated with reference to FIG. 2 . In this exemplary embodiment, the dual polarized solar antenna had a power gain of approximately 7 dB. As can be seen, the simulated and measured polarization responses are in good agreement. In FIG. 2 , the solid line is the first polarization and the dashed line is the second polarization. FIG. 2 a is the measured response and FIG. 2 b is the simulated response. The simulated and measured radiation patterns of both polarizations are also shown in FIG. 3 and FIG. 4 . As can be seen, the simulated (dashed) and measured (solid) radiation patterns are in good agreement. In FIG. 3 a , the E field radiation pattern is shown for the first polarization and in FIG. 3 b , the H field radiation pattern in shown. In FIG. 4 a , the E field radiation pattern of the second polarization is shown and in FIG. 4 b , the H field radiation pattern in shown.
The present invention is not limited to the solar spectrum, but is also viable at much lower frequencies.
As such, the present invention provides an improved antenna array having the ability to intercept randomly polarized electromagnetic waves by employing a single antenna and two orthogonal feeds. While the antenna apparatus has been detailed with respect to its use at optical frequencies to obtain DC power from a high frequency signal received through an antenna, the invention does not require power rectification and may also be employed as an improved detector.
It will be seen that the advantages set forth above, and those made apparent from the foregoing description, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. Now that the invention has been described,
|
An antenna apparatus and method for the interception of randomly polarized electromagnetic waves utilizing a dual polarized antenna which is excited through a cross-slot aperture using two well-isolated orthogonal feeds.
| 7
|
[0001] A Process for the preparation. of 2-(2-hydroxyphenyl)-benz[1, 3] oxazin-4-one and its use for preparation of 4-[3, 5-bis (2-hydroxyphenyl)-1H-1, 2, 4-triazol-1-yl] benzoic acid.
FIELD OF THE INVENTION
[0002] The present invention is directed to a novel, industrially viable and cost effective process for manufacturing of 2-(2-hydroxyphenyl)-benz[1, 3]oxazin-4-one which is a key intermediate in the synthesis of Deferasirox.
CROSS REFERENCE TO RELATED APPLICATION
[0003] This specification is the complete specification of and claims priority from the provisional application No 2457/CHE/2010 filed on 25 Aug. 2010
BACKGROUND OF THE INVENTION
[0004] 4-[3, 5-bis (2-hydroxyphenyl)-1H-1, 2, 4-triazol-1-yl] benzoic acid commonly known as Deferasirox is represented by Formula I.
[0000]
[0005] Deferasirox (exjade) is an iron chelating agent. Its main use is to reduce chronic iron overload in patients who are receiving long term blood transfusions for conditions such as beta-thalassemia and other chronic anemia's. It is a white to slightly yellow powder and it is practically insoluble in water and in an acid medium, the solubility increasing the pH.
[0006] Deferasirox was first disclosed in U.S. Pat. No. 6,465,504 by Novartis, and its process is as shown in scheme I. The process comprises reacting the salicylamide with salicyloyl chloride by heating at 170° C. provides 2-(2-hydroxyphenyl)-benz [e] [1, 3] oxazin-4-one, which is finally cyclized with 4-hydrazinobenzoic acid in refluxing ethanol.
[0000]
[0007] WO2009094956 of Farmak describes the process for the preparation of Deferasirox as shown in scheme II below. The process comprises the condensation of 2-(2-hydroxyphenyl)-benz [1, 3]-oxazine-4-one with 4-hydrazinobenzoic acid in the presence of organic acid or a mixture of organic acid and an organic solvent.
[0000]
[0008] WO2010023685 of Matrix describes the process for the preparation of Deferasirox as shown in scheme III. The process comprises the Salicylic acid reacted with thionyl chloride in the presence of solvent to give salicyloyl chloride, which is reacted with salicylamide to give 2-(2-hydroxyphenyl)-benz[1,3]-oxazine-4-one, then it is condensed with 4-hydrazino benzoic acid to give deferasirox.
[0000]
[0009] The synthesis of Deferasirox described in earlier process, salicyloyl chloride is very unstable and particularly at higher temperature it will degrade gives impure product and low yields. Hence it is necessary to carried out the reaction at lower temperatures with solvent medium may gives better yield and desire purity. Therefore there is a continuing need for development of cost effective and industrially viable processes for manufacturing of Deferasirox.
SUMMARY OF THE INVENTION
[0010] The invention is a novel process for the synthesis of 2-(2-hydroxyphenyl)-benz[1,3]oxazin-4-one, the process comprising of reacting the salicylic acid with salicylamide in the presence of p-toluenesulfonyl chloride, base and solvent. The 2-(2-hydroxyphenyl)-benz[1,3]oxazin-4-one synthesized by the novel process is used in the preparation of Deferasirox.
[0011] The main object of the invention is to provide a novel process for the synthesis of 2-(2-hydroxyphenyl)-benz[1,3]oxazin-4-one.
[0012] Another object of the invention is to provide a process for producing 4-(3,5-bis(2-hydroxyphenyI)-1H-1,2,4-triazol-1-yl)benzoic acid (Deferasirox) employing the 2-(2-hydroxyphenyl)-benz[1,3]oxazin-4-one synthesized by the present invention.
[0013] Yet another object of the invention is to provide a process to get Deferasirox containing isopropyl alcohol as per ICH guidelines.
DESCRIPTION OF THE INVENTION
[0014] In accordance with the present invention 2-(2-hydroxyphenyl)-benz[1,3]oxazin-4-one is obtained by the reaction of salicylic acid with salicylamide in the presence of p-toulenesulfonyl chloride, base and solvent. The process of the invention is depicted in following scheme-IV.
[0000]
[0015] The process comprises:
a) reacting the salicylic acid of formula II with p-toulenesulfonyl chloride in the presence of organic base selected from the group of triethylamine, diisopropylethylamine, pyridine, diisopropyl amine, DBU and the like; preferably diisopropylethylamine or inorganic base like metal carbonates or metal bicarbonates or metal hydroxides, wherein the alkali metal carbonates is selected from the group sodium carbonate, potassium carbonate, metal bicarbonates like sodium bicarbonate, potassium bicarbonate, alkali hydroxide like sodium hydroxide, potassium hydroxide, lithium hydroxide and the like; preferably potassium carbonate and organic solvent selected from the group consisting of dichloromethane, THF, acetone and the like; preferably dichloromethane to obtain corresponding tosyl compound, which is obtained in situ reacted with salicylamide of compound of the formula III in the presence of solvent selected from the toluene, xylene, anisole, DMF, DMSO, chlorobenzene and the like; preferably toluene to obtain 2-(2-hydroxyphenyl)-benz[1,3]oxazin-4-one of formula IV. b) condensation of compound of the formula IV with formula V in the presence of organic solvent selected from the group consisting of methanol, ethanol, propanol and the like; preferably methanol to obtain Deferasirox.
[0018] The present invention further involves a purification of Deferasirox comprising dissolving Deferasirox in IPA solvent and stir for sufficient period of time which will result in pure Deferasirox but IPA content in the product is very high about 15,000 to 20,000 ppm. In order to limit the IPA content compound taken into methanol and heated to reflux. After 4-5 hour content of IPA was found to be below 3000 ppm.
[0019] The invention is further illustrated with following non-limiting examples:
EXAMPLES
Example 1
Preparation of 2-(2-hydroxyphe41)-benz[1,3]oxazin-4-one
[0020] A mixture of dichloromethane (200 ml), salicylic acid (50.0 gm) and p-toulenesulfonyl chloride (69 gm) were cooled to 10-15° C. Diisopropyl ethyl-amine (139.0 ml) was added drop-wise to the above mixture at 10-20° C. Reaction mass was stirred for 10 min at 10-20° C. and raised the temperature to 25-30° C. The reaction was maintained for 2 hours at 25-30° C. Reaction mass was cooled 0-5° C. Purified water (200 ml) was charged to the above mixture and stirred for 15 minutes. The layers were separated. Salicylamide (39.6 gm) and toluene (200.0ml) were heated to 85-90° C. and the above organic layer was added drop-wise into salicyliamide solution with simultaneous distillation of solvent at 85-90° C. and distilled the solvent upto the reaction mass temperature reaches to 110-120° C. and further reaction was maintained for 3hrs at 110-120° C. Further solvent was distilled under atmospheric pressure upto reaction mass temperature reaches to 140-160° c and further the reaction was maintained for 1-2 hrs at 140-160° C. until the starting material disappears. Reaction mass was cooled to 75-80° C. and distilled off completely toluene under vacuum. Ethanol (50 ml) was added to the above reaction mass at 75-80° C. Reaction was stirred for 15 min and distilled off the ethanol at 75-80° C. Further ethanol (50.0 ml) was added stir for 5-10 min. Ethanol was distilled off completely under vacuum at 75-80° C. Ethanol (150 ml) was charged into above contents at 75-80° C. The contents were maintained for 1 hour at 75-80° C. and slowly cooled to 0-5° C. Reaction mass was maintained for 2 hrs at 0-5° C. The reaction mass was filtered and washed with ethanol (50.0 ml). Dried the compound at 50-55° C. Yield: 39.30%.
Example 2
Preparation of Deferasirox
[0021] A mixture of methanol (450.0 ml), 2-(2-hydroxyphenyl)-benz[1,3]oxazin-4-one (30.0 gm) were stir for 10 min at 25-30° C. To the above contents 4-hydrazino benzoic acid (20.03 gm) was added. The contents were heated to reflux temperature 65-70° C. The contents were maintained for 4 hours at 65-70° C. The reaction mass was cooled Slowly to 0-5° C. and maintained it for 1 hour at 0-5° C. The reaction mass was filtered and washed with methanol (30.0 ml). Compound was taken into methylene chloride and stir for 10 min 25-30° C. The contents were heated to reflux temperature (40-45° C.) and maintained the contents for 1 hr at reflux temperature. Cool the contents to 25-30° C. and stirred for 1 hr at 25-30° C. The reaction mass was filtered and washed with methylene chloride (30.0 ml). Dried the compound at 60-65° C. Yield: 79.0%.
Example 3
Purification of Deferasirox
[0022] Take Isopropyl alcohol (900.0 ml) and Deferasirox crude (30.0 gm) at 25-30° C. Stir the contents for 10 min at 25-30° C. Reaction mass was heated reflux temperature (80-85° C.) and maintained for 30 min at reflux temperature. Activated carbon (3.0 g) was added to the above reaction mass at reflux temperature. Reaction mass was maintained for 30 min at reflux temperature. The reaction mass was filtered through hyflow bed at hot condition and washed with isopropyl alcohol (30.0 ml). Isopropyl alcohol was distilled off until the 150 ml solvent is remained in the flask. Reaction mass was stirred for 30 min at 25-30° C.
[0023] The mass was filtered and washed with isopropyl alcohol (30.0 ml). Methanol (150.0 ml) was added to the above wet compound and stirred for 10 min at 25-30° C. The contents were heated to reflux temperature (65-70° C.) and maintained the contents for 3 hr at reflux temperature. Reaction mass was cooled to 25-30° C. and stirred for 1 hr at 25-30° C. The reaction mass was filtered and washed with methanol (30.0 ml). Dried the compound at 60-65° C. Yield: 91.0%, Purity: >99.9%
|
The invention provides a novel process for the synthesis of 2-(2-hydroxyphenyl)-benz[1,3]oxazin-4-one, the process comprising of reacting the salicylic acid with salicylamide in the presence of p-toluenesulfonyl chloride, base and solvent. The use of 2-(2-hydroxyphenyl)-benz[1,3]oxazin-4-one in the preparation of Deferasirox is also disclosed in the invention.
| 2
|
CLAIM OF PRIORITY
[0001] This application claims priority to an application entitled “Method for Processing Outgoing Call in Voice over Internet Protocol (VIP) Gateway” filed with the Korean Industrial Property Office on May 24, 2000 and assigned Ser. No. 2000-28164, the contents of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates generally to a voice over internet protocol (VIP) gateway system and, in particular, to a method for processing an outgoing internet phone call by using an internet telephony module card (ITM card) of a VIP gateway.
[0004] 2. Related Art
[0005] In general, an ITM card of a VIP gateway has an access code of three digits. The ITM card access code is a code required for transferring an outgoing call to a specific ITM card of a VIP gateway of the other party.
[0006] In such a VIP gateway system, the ITM card has a database table storing only an IP address matched with an access code of the ITM card of the other party. Therefore, a user who desires to make an internet phone call is required to have prior knowledge of all of the access codes of the ITM card, the extension access codes and the office-line access codes of the other parties. Moreover, the user needs to input all of those numbers by using the dial buttons of a phone. This is a significant disadvantage and inconvenience to the users of such a VIP gateway system.
[0007] The following patents generally relate to telephone communication over the internet or switched equipment, but are burdened by the disadvantages of the prior art set forth herein: U.S. Pat. No. 6,151,390 to Volftsun, entitled PROTOCOL CONVERSION USING CHANNEL ASSOCIATED SIGNALING, issued on Nov. 21, 2000, U.S. Pat. No. 6,150,962 to Rossmann, entitled PREDICTIVE DATA ENTRY METHOD FOR A KEYBOARD, issued on Nov. 21, 2000, U.S. Pat. No. 6,144,667 to Doshi, entitled NETWORK-BASED METHOD AND APPARATUS FOR INITIATING AND COMPLETING A TELEPHONE CALL VIA THE INTERNET, issued on Nov. 7, 2000, U.S. Pat. No. 6,097,804 to Gilbert, entitled METHOD AND SYSTEM FOR COMPLETING A VOICE CONNECTION BETWEEN FIRST AND SECOND VOICE TERMINALS IN A SWITCHED TELEPHONE NETWORK, issued on Aug. 1, 2000, U.S. Pat. No. 6,078,582 to Curry, entitled INTERNET LONG DISTANCE TELEPHONE SERVICE, issued on Jun. 20, 2000, U.S. Pat. No. 6,078,579 to Weingarten, entitled TELEPHONE SYSTEMS FOR COMMUNICATION OVER COMPUTER NETWORKS, issued on Jun. 20, 2000, U.S. Pat. No. 6,075,783 to Voit, entitled INTERNET PHONE TO PSTN CELLULAR/PCS SYSTEM, issued on Jun. 13, 2000, U.S. Pat. No. 6,038,227 to Farris, entitled PRESELECTION OF SERVICE PROVIDER AND FUNCTIONALITY, issued on Mar. 14, 2000, U.S. Pat. No. 6,026,087 to Mirashrafi, entitled METHOD AND APPARATUS FOR ESTABLISHING A VOICE CALL TO A PSTN EXTENSION FOR A NETWORKED CLIENT COMPUTER, issued on Feb. 15, 2000, U.S. Pat. No. 6,021,126 to White, entitled TELECOMMUNICATION NUMBER PORTABILITY, issued on Feb. 1, 2000, U.S. Pat. No. 6,016,343 to Hogan, entitled CALL-PROCESSING SYSTEM AND METHOD, issued on Jan. 18, 2000, U.S. Pat. No. 5,956,394 to Andruska et al., entitled COMMON TREATMENT OF CALLS FROM SUBSCRIBERS SERVED BY DIFFERENT TYPES OF TELECOMMUNICATION EQUIPMENT, issued on Sep. 21, 1999, U.S. Pat. No. 5,940,478 to Vaudreuil, entitled METHOD AND SYSTEM FOR EXTENDED ADDRESSING PLANS, issued on Aug. 17, 1999, U.S. Pat. No. 5,911,485 to Rossmann, entitled PREDICTIVE DATA ENTRY METHOD FOR A KEYPAD, issued on Jun. 15, 1999, U.S. Pat. No. 5,524,146 to Morrisey, entitled AUTOMATIC ACCESS TO COMMUNICATION SERVICE PROVIDERS, issued on Jun. 4, 1996, U.S. Pat. No. 5,333,185 to Burke, entitled SYSTEM FOR PROCESSING CALLING PARTY INFORMATION FOR INTERNATIONAL COMMUNICATIONS SERVICES, issued on Jul. 26, 1994, and U.S. Pat. No. 4,159,402 to De Graauw, entitled MEANS FOR IDENTIFYING SUBSCRIBER LINES, issued on Jun. 26, 1979.
SUMMARY OF THE INVENTION
[0008] It is, therefore, an object of the present invention to provide a method for processing an outgoing internet call using an ITM card of a VIP gateway by inputting only a phone number of the other party.
[0009] To achieve the above object, there is provided a method for processing an outgoing call of a VIP gateway, comprising the steps of: setting a port of an ITM card inside the VIP gateway when an outgoing phone number is inputted; recognizing an area code of the inputted phone number as an ITM card access code of the VIP gateway of the other party; adding a trunk access code matched with the ITM access code to the phone number; and transferring the augmented phone number to the ITM card of the VIP gateway of the other party.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, and wherein:
[0011] [0011]FIG. 1 is a table exemplifying a database inside the ITM card of a VIP gateway;
[0012] [0012]FIG. 2 is a diagram illustrating a VIP gateway system according to an embodiment of the present invention;
[0013] [0013]FIG. 3 is a flow chart illustrating a process for handling an outgoing call of a VIP gateway according to an embodiment of the present invention; and
[0014] FIGS. 4 A- 4 C are tables exemplifying a database inside an ITM card of a VIP gateway according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] A preferred embodiment of the present invention will be described below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail.
[0016] [0016]FIG. 1 is a table exemplifying a database inside an ITM card of a VIP gateway.
[0017] Referring to FIG. 1, a user first inputs an ITM card port number of a VIP gateway, to which the user belongs, by using dial buttons of a telephone. As a next step, the user inputs an ITM card access code and an extension access code of the VIP gateway of the other party to be contacted. If the other party is an extension subscriber, the user inputs the corresponding extension number, and if the other party is an office-line subscriber, the user inputs the corresponding office-line number. Then, the ITM card of the VIP gateway of the other party identifies an IP address of the ITM card of the other party, which is connected with the inputted ITM access code through designation, by using a database table as shown in FIG. 1. The ITM card of the VIP gateway then deletes the ITM access code of the other party from the dial numbers inputted by the user, and transfers only the extension access code and the corresponding phone number of the other party to the ITM card of the other party through the internet. The ITM card of the other party subsequently analyzes the extension access code and the phone number to transfer the outgoing call to the extension subscriber or the office-line subscriber through the extension line or a public switched telephone network (PSTN).
[0018] [0018]FIG. 2 is a diagram illustrating a VIP gateway system according to an embodiment of the present invention.
[0019] Referring to FIG. 2, private exchange networks 222 , 214 and public switched telephone networks (PSTN) 226 , 216 are connected to an internet network 200 through the respectively corresponding VIP gateways 202 , 208 . Telephones of extension subscribers 224 , 210 , 212 and office-line subscribers 218 , 220 , 228 , 230 are connected to the private exchange networks 222 , 214 and PSTN 226 , 216 , respectively. The VIP gateways 202 , 204 , 206 , 208 convert signals and data transferred from the respective exchange devices into signals and data compatible with the internet, and link the telephones of the extension subscribers and the office-line subscribers connected to the PSTN 226 , 216 and the private exchange networks 222 , 214 with the internet network 200 .
[0020] [0020]FIG. 3 is a flow chart illustrating a process for handling an outgoing call of an ITM card of a VIP gateway connecting an internet phone by using only a phone number of the other party according to an embodiment of the present invention. FIG. 4 is a table exemplifying a database inside a memory of an ITM card according to an embodiment of the present invention.
[0021] An embodiment of the present invention will now be described in detail with reference to FIGS. 2, 3 and 4 A- 4 C.
[0022] First, a user who desires to make an internet phone call by using an ITM card inputs a phone number only of the called party. In step 300 , the ITM card inside the VIP gateway 202 determines that an outgoing telephone number has been inputted, and then proceeds with step 302 to set a port for connection to the internet in response thereto. In step 304 , the ITM card detects whether or not an area code, which was allocated as an ITM access code among the dial numbers inputted by the user according to an embodiment of the present invention, has been deleted by referring to the database table shown in FIGS. 4 A- 4 C. If the outgoing call by the user is a telephone number within the area of the VIP gateway 208 of the other party who has received the outgoing call, the ITM access code is displayed as “deleted” on the database table. Otherwise, the ITM access code is displayed as “retained” on the database table.
[0023] When the ITM access code is displayed as “deleted,” the ITM card of the user responds to step 306 by deleting the area code corresponding to the ITM access code of the dial numbers inputted by the user in step 308 . For example, assuming that a user in Seoul has inputted dial numbers “051-393-4726,” the VIP gateway of the user in Seoul recognizes that “051” is the access code of the ITM card of the VIP gateway 208 of the other party with respect to the outgoing call according to an embodiment of the present invention. Also, since the database table in FIG. 4A shows that the ITM access code “051” is to be “deleted”, the number “051” corresponding to the ITM access code among the inputted dial numbers is deleted in step 308 .
[0024] In step 310 , the ITM identifies a trunk access code value matching the ITM access code, adds the trunk access code to the dial numbers inputted by the user and from which the ITM access code is excluded, and transfers the numbers to the ITM card of the VIP gateway 208 of the other party. Referring to the dial numbers “051-393-4726” inputted by the user as exemplified above, the trunk access code value corresponding to the ITM access code “051” is set to “9” as shown in FIG. 4A. Therefore, the ultimate dial number transferred to the other party is “9-393-4726.”
[0025] In step 312 , the ITM card identifies an IP table index value corresponding to “051” shown in the database table of FIG. 4A, selects one of the IP addresses shown in the IP address table of FIG. 4B, and transfers the outgoing call to the corresponding ITM card. The ITM card, which has received the outgoing call of other party, detects the trunk access code of the received dial number, determines whether the dial number belongs to an office-subscriber in step 314 , and transfers the outgoing call to the PSTN 216 in step 316 if the dial number is determined to belong to an office-line subscriber. If the dial number is determined to belong to an extension subscriber in step 318 as a result of detecting the trunk access code, the ITM card proceeds with step 320 so to transfer the outgoing call to the corresponding extension subscriber of the private exchange network 214 .
[0026] As described above, the method for processing an outgoing call in a VIP gateway according to the present invention provides the advantage of using an area code as an ITM access code in a direct manner by additionally including diverse information in the database constituting the ITM card of the VIP gateway and varying the length of ITM access code. As a consequence, the user can make an internet phone call with ease and convenience, as in the case of a long-distance call in general.
[0027] While the invention has been shown and described with reference to a certain preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the invention as defined by the appended claims.
|
A method for processing an outgoing call in a VIP gateway system includes the steps of setting a port of an ITM card of a VIP gateway when an outgoing telephone number is inputted, recognizing an area code of the inputted number as an access code of an ITM card of a VIP gateway of the called party, adding a trunk access code matching the ITM access code to the telephone number to obtain an augmented number, and transferring the augmented number to the ITM card of the VIP gateway of the called party.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This non-provisional application claims benefit of the provisional application filed on Jun. 19, 2006 having application No. 60/814,745.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to tile etching and more particularly this invention relates to improving the safety of tile etching solutions containing hydrofluoric acid.
[0004] 2. Description of the Related Art
[0005] Tiles used in flooring surfaces offer numerous advantages. These advantages include ease of cleaning, resistance to abrasion, and fire safety. Generally speaking in the event of fire ceramic and clay tiles employed in flooring do not release toxic smoke, are not flammable, and do not melt and stick to the feet the way that nylon carpets do. In addition, flooring tiles do not capture and hold allergens such as pet dander and pollen and are resistant to mould growth. There are however some drawbacks to tiles employed in flooring applications. Of particular interest is the tendency of flooring tiles to become slippery when wet. Additionally, flooring tiles form a hard surface that may result in severe injuries from slips and falls. Because of this, it is common practice to place throw rugs in areas of high foot traffic. These throw rugs tend to be small and therefore are relatively easy to clean. When employing such throw rugs it is important to prevent the throw rug from sliding against tile surfaces as this sliding may contribute to slips and falls as well.
[0006] There are numerous coatings that may be applied to the exposed surfaces of wet flooring tiles to render them less slippery. Some of these coatings may include the addition of hard, rough, and abrasive materials such as sand. One or more binders may be employed to hold the abrasive material to the flooring surface. These anti-slip coatings may be in complete form ready to use or alternatively a binding agent may be applied to the exposed surfaces of flooring tiles followed by the addition of the abrasive material in granular form. Once the coating is dry, excess abrasive may then be removed and discarded.
[0007] While effective at increasing the anti-slip properties of flooring tiles these coatings may be excessively rough and tend to wear off relatively quickly. This may be especially true when employed in areas of high foot traffic such as in hotel lobbies and restaurant dining areas.
[0008] While special coatings may be applied to tiles to provide anti-slip properties, forming tiles in situ allows individuals to add anti-slip materials to the surface of the freshly cast tiles so that they will become part of exposed tile surfaces on hardening. Additionally, forming tiles in situ enables individuals the ability to use materials like cement that naturally have some anti-slip properties.
[0009] One particularly interesting approach for forming tiles in situ is outlined in U.S. Pat. No. 4,932,182 awarded to John R. Thomasson titled “Floor Tile Forming and Structural Underlayment Device”. A one piece plastic molded sheet having special entrapping designs is used to cast tiles in situ. This approach is especially appealing due to its versatility. The mold entrapping designs prevent the release of the cast tiles thereby eliminating the need to cement individual tiles to the floor. Tile spacing is provided by the mold with raised portions giving the appearance of tile grout. This system allows the person laying down tiles to cast their own tiles out of a wide variety of materials.
[0010] One particularly interesting approach to reduce the slip level of wet tiles is to etch them with a chemical. There are numerous materials that may be employed to etch the surfaces of tiles in order to improve grip. Of particular interest is the use of tile etching solutions to improve the grip between a wet tile surface and the soles of footwear. Such treatment options may be specific to particular tile materials or alternatively may have broad application. For example, hydrochloric acid (sometimes called muriatic acid) is an aqueous solution containing dissolved hydrogen chloride gas. This acid is particularly strong owing to the fact that the hydrogen ions are only loosely associated with the chloride ions in solution. The loose hydrogen ions in solution may be attached to water molecules forming hydronium ion. Hydronuim ions are good at attacking numerous alkaline materials such as marble (calcium carbonate) and certain calcium and/or magnesium containing components in cement. Because of this, hydrochloric acid is often employed in the preparation of cement surfaces. Aqueous solutions containing considerable amounts of hydrochloric acid have a marked tendency toward rapidly dulling marble surfaces to which they may be applied and therefore are not always recommended. In addition, hydrochloric acid is somewhat volatile and may release substantial amounts of hydrogen chloride gas on standing or drying. Hydrogen chloride gas is an irritating vapor that can easily rust steel surfaces. Because of this, the use of hydrochloric acid for the surface etching of tiles may be somewhat limited in nature.
[0011] Hydrochloric acid may be considered to be a strong acid. Other strong acids include phosphoric acid and sulfuric acid. A strong acid is an acid that when placed in water forms a significant portion of hydrogen ions or hydronium ions (hydronium ions are hydrogen ions having a water molecule attached to them).
[0012] Hydrofluoric acid may be employed for etching tile surfaces with considerable success. Hydrofluoric acid is a weak acid (forms little hydrogen or hydronium ion in the presence of water) despite this fact, hydrofluoric acid attacks a significant number of mineral based materials including ceramic, glass, and clay. In addition, because hydrofluoric acid is a weak acid, it will rapidly form in solution if a strong acid such as sulfuric or phosphoric is mixed with an aqueous solution of a fluoride salt.
[0013] Hydrofluoric acid surface treatments of mineral based tiles may produce channels that significantly increase the wet grip toward other surfaces. It should be noted that these channels may be deep enough to provide good wear resistance. The result is a wear resistant surface treatment that significantly improves the wet gripping properties to a variety of contacting substrates such as rubber and leather commonly employed on the bottom of footwear surfaces.
[0014] Because hydrofluoric acid has a strong affinity for calcium and silica, the concentration of hydrofluoric acid in aqueous based tile etching solutions only needs to be on the order of a few percent. It should be noted that adding an excess of a strong acid such as sulfuric or phosphoric to an aqueous solution of a fluoride salt will completely convert any available fluoride ion to hydrofluoric acid and will then rapidly lower the solution pH.
[0015] Mr. John Howard developed a hydrofluoric acid based tile surface treatment solution in the early 1990's. His work was carried out at the British Columbia Research Institute. His anti-slip tile treatment solution contains about three percent hydrofluoric acid in aqueous form. His system consists of the following:
1. A prep cleaner for pre-cleaning flooring tile surfaces prior to hydrofluoric acid etching, 2. Aqueous hydrofluoric acid etching solution containing about 3% hydrofluoric acid 3. A neutralizing solution containing silicates
Mr. John Howard's etching system is very effective owing to the high reactivity of hydrofluoric acid toward both calcium and silica based minerals.
[0019] Unfortunately while effective in etching tile surfaces, hydrofluoric acid presents certain specific handling hazards and may cause significant tissue destruction and bone damage without the persons awareness. There is thus a need for tile etching solutions containing hydrofluoric acid that quickly notify the user that exposure has taken place.
[0020] It is an object of this invention to reduce the slip and fall hazard of wet flooring tile surfaces.
[0021] It is a further object of this invention to provide a non slip-floor tile treatment that has good wear resistance.
[0022] It is a further object of this invention to provide a low cost way of treating existing flooring tile surfaces
[0023] Finally, it is an object of this invention to provide a non-slip flooring tile treatment employing hydrofluoric acid along with additives that reveal when skin contact exposure has taken place.
SUMMARY OF THE INVENTION
[0024] This invention therefore proposes aqueous tile etching solutions containing hydrofluoric acid along with additives that notify the user of exposure. These tile etching solutions can be used to treat a wide variety of tile surfaces such as clay and ceramic. The resulting treated non-slip surfaces exhibit good anti-slip properties when wet and have good wear resistance.
DETAILED DESCRIPTION
[0025] As mentioned earlier, aqueous solutions of hydrofluoric acid will etch ceramic and clay tile surfaces. The concentration of hydrofluoric acid required for a good etch is on the order of 3 percent. At this concentration, a good etch will take place within an hour. After this timeframe the tile surface may then be rinsed clean and subsequently dried off. The resulting tile surface may look slightly duller but other than that the appearance may not have changed significantly.
[0026] Hydrofluoric acid has a tremendous reactivity toward calcium. This may be due at least in part to the exceedingly low solubility of calcium fluoride (fluorospar). Calcium is found all over the human body. It regulates many biological systems and is needed in ionic form for proper functioning. In addition, the bones contain much calcium in the form of phosphates. Hydrofluoric acid has an insidious property of slowly penetrating into the skin and subsequently migrating deeply into tissues even attacking bone. Burns associated with hydrofluoric acid may not become evident for several hours. During this timeframe, hydrofluoric acid may be burning deeper and deeper into underlying tissues and bone. In addition to tissue and bone destruction, calcium depletion may result in numerous health problems. Kidney damage may also occur. Long term exposure to even relatively small amounts of fluoride ion and/or hydrofluoric acid may result in fluorosis.
[0027] The insidious nature of hydrofluoric acid to cause damage over several hours coupled with the fact that an exposed individual may be unaware of the problem necessitates the need to bring immediate exposure awareness to individuals using tile etching solutions containing fluoride ion and/or hydrofluoric acid. There are two primary reasons why individuals working with hydrofluoric acid may not be aware that exposure has taken place.
[0028] 1. Burns may not be visible for some time.
[0029] 2. Burns may not be felt for some time.
[0000] In order to help remedy these issues, additives and/or modifications to the etching solutions may be carried out.
[0030] Visibility of exposure may be significantly improved by the addition of certain dyes to tile etching solutions containing fluoride ion and/or hydrofluoric acid. This is particularly true for dyes that have an affinity for binding to the skin. These dyes may be visible in ambient light or alternatively they may be visible only under black light. Visible dyes may be employed that are unstable in the presence of bleach or other reactive chemical materials so that they may be later decolorized and therefore not stain tile surfaces.
[0031] Gentian violet is a visible dye having a purple color. It has been used as a skin disinfectant. A one percent solution may be applied to the skin as an antiseptic for the external treatment of abrasions, minor cuts, and surface injuries. One particular distributor of gentian violet for skin disinfectant purposes is De La Cruz Products Division of DLC Enterprises, Inc. Paramount, Calif. 90723 USA.
[0032] Gentian Violet will rapidly stain the skin on contact. This stain will eventually fade over several days (especially if the stain is washed repeatedly with soap and water). Gentian Violet like many dyes is rapidly decolorized by ordinary household bleach (a water solution of sodium hypochlorite of about 5% concentration).
[0033] Fluorescent brighteners are materials that absorb ultraviolet light and emit visible light at wavelengths that compensate for yellow colors found in certain fabrics such as cotton. Fluorescent brighteners may form chemical bonds to the fabric so that they do not wash off. Of particular interest are the coumarin based fluorescent brighteners. One brightener in particular, Tinopal SWN by Ciba-Geigy is a coumarin based fluorescent brightener chemically known as 7-diethylamino-4-methylcoumarin.
[0034] A 0.2 gram quantity of 7-diethylamino-4-methylcoumarin was placed into a 250 milliliter Erlynmeyer flask. To this were added 90 grams of distilled water along with 10 grams of concentrated phosphoric acid. The mixture was stirred for several minutes to dissolve the solid. Some solid remained at the bottom of the flask indicating that this particular compound is difficult to dissolve in the above described mixture. A cotton swab was used to apply a small amount of this mixture to the skin. After one minute, the area of application was inspected for fluorescence with a black light. Fluorescence was significant. The area was then rinsed off with water. The result was a slightly lighter but very persistent fluorescent stain. Further rinsing did little to reduce the level of fluorescence. The intensity of the stain was then observed over a timeframe of a few days. During this timeframe the stain faded away.
[0035] The ability of this particular brightener to stain the skin in the presence of acids makes it a good candidate for addition to acid containing fluoride based tile etching solutions. The addition of skin staining fluorescent brighteners such as Tinopal SWN to tile etching solutions containing hydrofluoric acid in combination with follow up procedures using black light illumination represents a significant step forward in the safe handling of these very useful and effective tile etching solutions.
[0036] The next area to be addressed is irritation. Irritation is natures way of telling you that something is wrong and needs to be addressed. If hydrofluoric acid was a strong acid that hydrolyzed in water to form mostly hydrogen ion (hydronium ion in excess water) the hazard level of hydrofluoric acid may be reduced. If you spilled some of the solution on your skin it would tend toward rapid irritation, itching, inflammation, irritation, and discoloration. You would be more keenly aware that exposure occurred and within a short timeframe you would be able to wash the area off with little resultant damage. Unfortunately, hydrofluoric acid is a weak acid that may slowly migrate into the skin and underlying tissues undetected. The insidious nature of hydrofluoric acid is a major contributing factor that makes it so dangerous to handle.
[0037] It should be noted that in many respects hydrofluoric acid on a chemical level behaves similar in nature to ordinary water. Both water and hydrogen fluoride may be formed by reacting hydrogen with a more electronegative element, exhibit hydrogen bonding properties, are inorganic covalently bonded compounds having considerable polarity, and have very high negative heats of formation with respect to their starting elements. The similarities between hydrofluoric acid and water especially with respect to their hydrogen bonding properties may help to explain the ease with which hydrofluoric acid penetrates aqueous laden epithelial tissues.
[0038] Another similarity between hydrofluoric acid and water resides in a particular compound known as ammonium bifluoride. Ammonium bifluoride is the acid salt of ammonium fluoride and hydrofluoric acid. The name ammonium bifluoride may be somewhat misleading. Strictly speaking, that chemical name should represent NH4HF. Since the ammonium ion has a poly atomic valence of +1, and fluoride ion has a valence of −1, there is no room for the extra hydrogen and therefore this chemical formula does not correctly represent ammonium bifluoride. The correct formula for ammonium bifluoride is NH4FHF. This represents ordinary ammonium fluoride NH4F that has been hydrated if you will not with water but rather with waters substitute hydrofluoric acid. It may be that covalently bonded polar hydrofluoric acid is acting as a crystallization stabilizer to ammonium fluoride. Hydrogen bonding along with polar forces may contribute to the incorporation of hydrofluoric acid in the crystals.
[0039] Significant focus and attention has been paid to the use of ammonium bifluoride in etching formulations. This may be due in part to the fact that it is readily available and is a good source of hydrofluoric acid in solid form. Ammonium bifluoride itself is dangerous and needs to be handled with respect. The reason for this is that ammonium bifluoride consists of ammonium ion, fluoride ion, and hydrofluoric acid tied up in a crystalline lattice. The fluoride ion and the resulting hydrofluoric acid need to be respected for their inherent dangers and subsequent hazards associated with their handling.
[0040] Ammonium bifluoride will hydrolyze if placed into water releasing a significant amount of free hydrofluoric acid. If such a solution is then acidified with a strong acid such as sulfuric or phosphoric acid, free fluoride ion will rapidly bond with hydrogen ions forming more hydrofluoric acid in situ. Strong acids such as sulfuric acid can irritate the skin at relatively low concentrations, furthermore such acids may be used to enhance the effects of tile etching solutions containing hydrofluoric acid. Tile etching solutions may be prepared that contain hydrofluoric acid and a strong acid such as sulfuric acid. Increasing the sulfuric acid concentration may enhance skin irritation properties. This irritation enhancement may help to reduce the need for additional irritants that give warning of skin exposure by way of irritation. The excess addition of strong acids to such etching solutions may render them capable of etching a wider variety of tile surface materials than the dilute hydrofluoric acid etching solutions of the prior art. Specific non-reactive irritants may be employed such as formic acid, capsaicin, and other materials capable of producing irritating effects on the skin.
[0041] Outlined below are examples of tile etching solutions employing aqueous hydrofluoric acid. It should be noted that although no hydrofluoric acid was used in their preparation, the interaction of ammonium bifluoride with the strong acid ingredients produces hydrofluoric acid in situ.
[0042] This first example demonstrates the effectiveness of an aqueous hydrofluoric acid based tile etchant on ceramic tiles.
[0043] In a clean plastic container were placed 5.0 grams of ammonium bifluoride crystals along with 85.0 grams of distilled water. The resulting mixture was then stirred until dissolving was complete. To this solution were slowly added 10.0 grams of concentrated phosphoric acid (85%) while stirring.
[0044] The above described solution was applied to the top surface of several ceramic flooring tiles and allowed to sit undisturbed for 30 minutes at room temperature. After this timeframe, the tile was rinsed off and subsequently allowed to air dry. The etched areas of the tiles appeared slightly duller than the non-etched areas. Running the fingers over the dry surface revealed little difference. The tiles were then wet down with water. This time the gripping properties were significantly higher for the treated verses the non treated tiles.
[0045] The previous experiment was repeated using 15.0 grams of phosphoric acid. Similar results were obtained.
[0046] The first experiment was repeated with the addition of a skin labeling fluorescent brightner (0.1 grams of 7-diethylamino-4-methylcoumarin). The results were substantially the same.
[0047] The second experiment was repeated with the addition of a skin labeling fluorescent brightener (0.1 grams of 7-diethylamino-4-methylcoumarin). The results were substantially the same.
[0048] The above described examples provide guidelines for the preparation and subsequent use of hydrofluoric acid based tile etching solutions. The fluorescent brightener employed could be used in varying concentrations to control the relative level of skin fluorescence from a given level of exposure. Had exposure taken place with the solutions containing the fluorescent brightener, visible inspection employing a black light would have revealed the location and extent of any resulting solution contact.
[0049] Black lights are electric lights that emit ultra violet light with minimal visible light. Black lights are typically of the fluorescent configuration and may consist of a mercury vapor discharge that emits substantial amounts of ultra violet light in the near visible spectrum. Many black lights are configured to maximize this light while filtering out both visible light as well as harmful shorter wavelengths that may be below about 350 nanometers. Such black lights may be used to detect fluorescent residues left on the skin after exposure to the fluorescent skin staining dyes contained in the fluoride based etchants of the present invention. Small portable battery powered black lights may be used for this purpose.
[0050] It should be noted that the acidified form of 7-diethylamino-4-methylcoumarin may provide certain beneficial surfactant properties to etching solutions (its molecular structure does resemble some cationic surfactants).
[0051] The phosphoric acid used could be replaced by another strong acid such as sulfuric acid. The source of hydrofluoric acid could come from hydrofluoric acid itself or by the interaction of a water soluble fluoride salt and a strong acid. It should be noted however, that it may be desirable to minimize the amount of toxic hydrofluoric acid in these etching solutions thereby keeping their hazardous properties to a minimum. In that spirit, a working concentration of hydrofluoric acid in these solutions should be kept low at about 3%.
[0052] Added irritants such as formic acid can be added directly to these solutions. Addition of formic acid should be done after any strong acids have been diluted down. Certain strong acids such as concentrated sulfuric acid can dehydrate formic acid into water and carbon monoxide. Carbon monoxide is an odorless, tasteless poisonous gas. Organic based irritants having a low water solubility such as hot pepper oil may require the addition of surfactants to help keep them suspended in the mixture.
|
Aqueous based tile etching solutions are disclosed containing hydrofluoric acid along with additives that can be used to reveal exposure. The exposure revealing additives of the present invention may have irritant properties so that an exposed individual can feel that skin contact has occurred and/or alternatively may dye the skin to reveal a colored or fluorescent stain where contact has taken place. The result is a hydrofluoric acid containing tile etching solution having improved overall safety by revealing when and where exposure has taken place. This becomes very important owing to the fact that skin contact with solutions containing hydrofluoric acid often go unnoticed for some time and may therefore result in substantial chemical injury including bone damage. The hydrofluoric acid employed in the present invention may be formed in situ by the interaction of a strong acid with a water soluble fluoride salt.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. §119(e) of co-pending U.S. Provisional Patent Application No. 62/345,692, filed Jun. 3, 2016, entitled “Flat Notching.” The disclosure of the above-referenced application is incorporated herein by reference.
BACKGROUND
Technological Field
[0002] The present disclosure relates to notching marks made on flanges of a rule.
Background
[0003] Notching marks are made on flanges of a rule to enable bending of the rule into a channel letter. However, additional preparations may be desirable to generate certain shapes or designs of the channel letter.
SUMMARY
[0004] In general, this disclosure describes apparatus and methods related to making notching marks on the flanges of a rule to enable bending of the rule into a channel letter. As used herein, a “rule” may generally refer to a flat metallic strip. Additionally, a “profile” as used herein may generally refer to the rule having a rib as described below. In general, the rule or profile may be interchangeably used. In one embodiment, the flat notching marks are made on flanges of the rule to enable bending of the rule. Embodiments shown below also describe the flat notching marks made on flanges of the rule to enable bending of the rule into sharp angles.
[0005] In one embodiment, a method of making a plurality of notching marks on flanges of a rule to enable bending of the rule is disclosed. The method includes: punching the plurality of notching marks on the flanges of the rule to enable shaping of the rule into a channel letter; and tapering the flanges positioned around sharp notching angles made on the channel letter.
[0006] In another embodiment, an apparatus for making a plurality of notching marks on flanges of a rule to enable bending of the rule is disclosed. The apparatus includes: means for punching the plurality of notching marks on the flanges of the rule to enable shaping of the rule into a channel letter; and means for tapering the flanges positioned around sharp notching angles made on the channel letter.
[0007] In another embodiment, a device configured to make a plurality of notching marks on flanges of a rule to enable bending of the rule is disclosed. The device includes: a punching device configured to punch the plurality of notching marks on the flanges of the rule to enable shaping of the rule into a channel letter; and a tapering device configured to taper the flanges positioned around sharp notching angles made on the channel letter.
[0008] Other features and advantages of the present disclosure should be apparent from the following description which illustrates, by way of example, aspects of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The details of the present disclosure, both as to its structure and operation, may be gleaned in part by study of the accompanying drawings.
[0010] FIG. 1A shows the rule bent into a channel letter shape.
[0011] FIG. 1B shows the completed channel letter (e.g., letter “K”).
[0012] FIG. 2A shows a strip of rule.
[0013] FIG. 2B shows a flange formed on the rule.
[0014] FIG. 2C shows one side surface of a strip of profile.
[0015] FIG. 2D shows the other side surface of the strip of profile.
[0016] FIGS. 3A and 3B show the two ends of a rule connected at a point once the channel letter is formed.
[0017] FIG. 4 shows one example of a sharp notching angle.
[0018] FIG. 5A shows a notching device in accordance with one embodiment.
[0019] FIG. 5B a top perspective view of a sketch of the notching device in accordance with one embodiment.
[0020] FIG. 6A shows the notching marks made on the flange of the rule using the notching punches of the notching device illustrated in FIGS. 5A and 5B , for example.
[0021] FIG. 6B is a side perspective view of the rule with the notching marks and also showing the bending locations.
[0022] FIG. 6C shows the rule partially bent at a bending location.
[0023] FIG. 6D shows the rule completely bent into the sharp angle.
[0024] FIG. 7A shows the rule with the notching marks such that the flange pieces are tapered with tapered portions removed.
[0025] FIG. 7B shows the rule completely bent into the sharp angle.
[0026] FIG. 8 illustrates the difficulties of the rivet side with the bulged head not attaching flat to the surface, which can cause the channel letter to wobble when attached to a surface.
[0027] FIG. 9A shows a first step of a process for using the flat notching punch to remove the flange piece from the first end of the rule.
[0028] FIG. 9B shows the two ends of the rule with flange pieces.
[0029] FIG. 9C shows the two ends coupled together by sliding the two ends toward each other and the overlapping portion over the second end until the flange pieces meet without overlapping.
DETAILED DESCRIPTION
[0030] The detailed description set forth below, in connection with the accompanying drawings, is intended as a description of various embodiments and is not intended to represent the only embodiments in which the disclosure may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the embodiments. In some instances, well-known structures and components are shown in simplified form for brevity of description. As used herein, like reference numerals refer to like features throughout the written description.
[0031] Rules (or profiles) may be used to form channel letters. For example, FIGS. 1A and 1B show a channel letter box 100 made with a profile in accordance with one embodiment of the present disclosure. FIG. 1A shows the rule bent into a channel letter shape. FIG. 1B shows the completed channel letter (e.g., letter “K”). As can be seen in FIG. 1B , for example, the channel letter box 100 includes a top rib 110 for retaining the top plate and a bottom rib 112 for fitting into a bottom plate. In one embodiment, the channel letter can be shaped into any shape, not just a letter of the alphabet or writing (e.g., Chinese letters). For example, the channel letter can be in a shape such as a heart shape.
[0032] In one embodiment, the rules can be made into strips or rolls. FIG. 2A shows a strip of rule 200 . FIG. 2B shows a flange 202 formed on the rule 200 . FIG. 2C shows one side surface 220 of a strip of profile 210 . FIG. 2D shows the other side surface 230 of the strip of profile 210 . The other side surface 230 may include ribs 232 , 234 to support the top and bottom covers of a channel letter. Thus, in one embodiment, a profile can be formed using a rule with at least one strip of rib attached to one surface of the rule.
[0033] In some embodiments, the profile 210 can have a first surface 230 shown in FIG. 2D . The first surface 230 may also be referred to herein as the “inside surface,” indicating that the first surface 230 may generally become the inside of a resulting channel letter once the profile 210 has been cut and folded. The profile 210 (or the rule 200 ) can generally have a profile height 236 on the order of a few centimeters (cm), for example, one or two cm to in excess of 20 cm. The profile height 236 can also describe the height of the first surface 230 . The profile 210 may also be many meters long (in the direction of the profile axis 238 ). In some embodiments, the profile 210 (and the rule 200 ) can be stored in large rolls from which certain portions or lengths can be cut, for example, to produce the portion of the profile 210 shown. Lengths or sections of the profile 210 , can be cut from the roll and then fed into a profile cutting and bending machine (not shown) to make a variety of channel letters or shapes from the profile 210 .
[0034] In some embodiments, the rule 210 can be formed of a suitable metallic material, such as aluminum, steel, stainless steel, or various other alloys that provide a malleable, yet sturdy construction. The rule 210 may further have a protective coating to prevent corrosion or oxidation and to provide a suitable mounting surface for the ribs 232 , 234 . Such a protective coating can be applied at least to the first surface 230 , but can also be applied to an outside surface 220 . The outside surface 220 is opposite the first surface 230 and may generally become the outside of the resulting channel letter once the profile 210 is cut and folded.
[0035] In certain embodiments, such a protective coating may be an enamel coating. In some other embodiments, the profile 210 can be coated with certain types of powder coating, lacquer, or paint applied to the entire rule 200 . In some embodiments, coating the rule 200 in enamel can have certain chemical advantages for adhering or bonding of the ribs 232 , 234 . The coating can further have desirable artistic or design characteristics provided by different colored coatings having various reflective or textured properties. For example, a white first surface 230 may have desirable reflective properties for light emitted from within a completed channel letter. The colors and coatings of the first surface 230 can be different from the colors and coatings of the outside surface.
[0036] As described above, the profile 210 can further have the ribs 232 , 234 . In some embodiments, the ribs 232 , 234 can be attached, bonded, or otherwise adhered to the first surface 230 of the profile 210 . In some embodiments, the ribs 232 , 234 can be formed of a polymer, elastomer, plastic, fiber-reinforced plastic (FRP), or other suitable synthetic materials. In some other embodiments, the rib 232 , 234 can be attached using a machine that applies or adheres the ribs 232 , 234 in place on a blank surface 230 of the profile 210 .
[0037] As noted above, the notching marks are made on the flanges of a rule to enable bending of the rule into a channel letter. However, additional preparations may be desirable to generate certain shapes or designs of the channel letter.
[0038] FIGS. 3A and 3B show notching marks 320 on the flanges 310 of the rule 300 . Notching marks 320 are of different angles, which can range from 0 degree to 180 degrees. A notching angle of 0 degree would be no notching mark, while a notching angle near 180 degrees (e.g., between 140 and 180 degrees) would be a flat notching mark.
[0039] FIG. 4 shows one example of a sharp notching angle 400 . As shown in FIG. 4 , in areas near the sharp notching angle 400 , the flanges interfere with each other, and the flanges must be filed and grounded to bend them into the sharp angle.
[0040] FIG. 5A shows a notching device 500 in accordance with one embodiment. Typically the notching device 500 is one of the units of a bending apparatus.
[0041] FIG. 5B is a top perspective view of the notching device 500 in accordance with one embodiment. The illustrated embodiment of FIG. 5B includes four notching punches 510 , 512 , 514 , 516 of different angles (e.g., 30, 60, 120, and flat or 180 degrees). In one embodiment, the notching punch 510 makes a 30° notching mark. In another embodiment, the notching punch 512 makes a 60° notching mark. In another embodiment, the notching punch 514 makes a 120° notching mark. In yet another embodiment, the notching punch 516 makes a 180° or flat notching mark. In other embodiments, notching marks of different angles can be made.
[0042] FIG. 6A shows the notching marks 600 , 610 , 612 , 614 , 616 , 618 made on the flange of the rule 680 using, for example, the notching punches of the notching device 500 illustrated in FIGS. 5A and 5B .
[0043] In one example, the notching marks 610 , 612 , 614 are made with the 30° notching punch 510 , while the notching marks 616 , 618 are made with the 60° notching punch 512 . Further, the notching mark 600 is made with the flat notching punch 516 to enable the rule 680 to be bent into a sharp angle.
[0044] FIG. 6B is a side perspective view of the rule 680 with the notching marks 600 , 610 , 612 , 614 , 616 , 618 and also showing the bending locations 620 .
[0045] FIG. 6C shows the rule 680 partially bent at bending location 632 . The flange 630 is completely removed by the flat notching punch to make the sharp angle bend (as shown in FIG. 6D ).
[0046] FIG. 6D shows the rule 680 bent into the sharp angle 640 . It can be seen in the illustrated embodiment of FIG. 6D that when the rule 680 is bent at location 632 into the sharp angle 640 , the adjacent flange pieces 652 , 654 may contact or overlap at location 650 . In one embodiment, the sharp notching angle 640 is an angle between 140 and 180 degrees.
[0047] To avoid the contact or interference, the flange pieces (e.g., the adjacent flange pieces 652 , 654 in FIG. 6C or FIG. 6D ) can be tapered.
[0048] FIG. 7A shows the rule 700 with the notching marks 600 , 610 , 612 , 614 , 616 , 618 such that the flange pieces 712 , 722 are tapered with tapered portions 710 , 720 removed. In one embodiment, the notching punches (e.g., punches 510 , 512 , 514 , 516 ) of the notching device (e.g., notching device 500 ) are used to taper the flange pieces. In another embodiment, a cutting device is used to taper the flange pieces.
[0049] FIG. 7B shows the rule 700 bent into the sharp angle 640 . It can be seen in the illustrated embodiment of FIG. 7B that when the rule 700 is bent into the sharp angle 640 , the adjacent flange pieces 712 , 722 do not contact, overlap, or interfere with each other.
[0050] In a further embodiment, the flat notching punch of the notching device is used for other purpose as well. For example, the flat notching punch can be used to punch out the flange of one end of the channel letter formed with the rule.
[0051] As shown in FIGS. 3A and 3B , once the channel letter is formed using the rule 300 , the two ends need to be connected at point 380 (in FIG. 3A ) or 390 (in FIG. 3B ). Thus, to connect the two ends, the ends are overlapped and riveted. However, since the flange side is made to attach the channel letter to a surface, the bulged head of the rivet causes the channel letter to not attach properly (e.g., attach flat) to the surface.
[0052] FIG. 8 illustrates the difficulties of the rivet side with the bulged head not attaching flat to the surface 830 , which can cause the channel letter to wobble when attached to a surface 830 . As shown in FIG. 8 , the two ends 800 , 810 of the rule (i.e., the flange of the rule) are overlapped and riveted with a rivet 820 . However, the rivet 820 causes the channel letter to not attach properly to the surface 830 because the rivet 820 has a rounded and bulged head. Thus, in some embodiments, it is desirable to put the rivet which attaches the two ends on the rule side (e.g., side 200 of FIG. 2B ) rather than on the flange side (e.g., side 202 of FIG. 2B ).
[0053] FIGS. 9A to 9C show the process for using the flat notching punch to remove the flange piece 904 from the first end 900 of the rule (see FIG. 9A ). The remaining flange piece coupled to the first end 900 of the rule is labelled as 902 .
[0054] FIG. 9B shows the two ends 900 , 910 of the rule with flange pieces 902 , 912 . The flange piece 902 is coupled to the first end 900 , while the flange piece 912 is coupled to the second end 910 . The first end 900 also includes an overlapping portion 906 that will receive the rivets.
[0055] As shown in FIG. 9C , the two ends 900 , 910 are coupled together by sliding the two ends 900 , 910 toward each other and the overlapping portion 906 over the second end 910 until the flange pieces 902 , 912 meet without overlapping. Finally, the two ends 900 , 910 are attached together using the rivets 920 . In other embodiments, the two ends 900 , 910 can be attached using adhesives or other attachment means such as by soldering.
[0056] The above descriptions of the disclosed embodiments are provided to enable any person skilled in the art to make or use the disclosure. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles described herein can be applied to other embodiments without departing from the spirit or scope of the disclosure. For example, although the examples shown in the illustrated figures include only one sharp angle made for a channel letter, multiple sharp angles can be made for the channel letter. Thus, it will be understood that the description and drawings presented herein represent embodiments of the disclosure and are therefore representative of the subject matter which is broadly contemplated by the present disclosure. It will be further understood that the scope of the present disclosure fully encompasses other embodiments that may become obvious to those skilled in the art and that the scope of the present disclosure is accordingly limited by nothing other than the appended claims.
[0057] Accordingly, the foregoing embodiments are merely presented as examples and are not to be construed as limiting the present disclosure. The present teachings can be readily applied to other types of apparatus and/or devices. The description of the present disclosure is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art.
|
Making a plurality of notching marks on flanges of a rule to enable bending of the rule, including: punching the plurality of notching marks on the flanges of the rule to enable shaping of the rule into a channel letter; and tapering the flanges positioned around sharp notching angles made on the channel letter.
| 1
|
TECHNICAL FIELD
The invention concerns raised pavement markers primarily used to delineate traffic lanes on roads and highways. More particularly, it concerns an improved marker capable of being struck by a snow plow blade without risk of substantial damage to the marker or the blade.
BACKGROUND
Raised pavement markers offer a greater degree of night delineation, wet or dry, than is offered by painted lines and tapes. They are raised up out of the rain on the street, and they are able to present reflective materials at a more advantageous angle to drivers than flat tapes. However, in areas where snow plows are used, they have not found wide acceptance because they either are removed or damaged by the plows or can damage plow blades.
One solution to the problem of designing a durable pavement marker for snow plow areas is presented in U.S. Pat. No. 4,297,051. That patent shows a deformable highway marker comprising a flexible, cylindrical skirt portion for implanting in a road; a dome-shaped top portion integrally molded with the skirt, for extending above the roadway surface; and a reflecting means associated with the top portion. The dome-shaped top is shown to elastically deform downward when traversed by a snow plow blade, recovering its original shape after the blade has passed.
Although the '051 marker represented an advance in the art, there remained difficulties with its design. It lacked desired durability, and it was difficult to reflectorize.
DISCLOSURE OF INVENTION
Substantial efforts have been made to improve upon the basic concept of U.S. Pat. No. 4,297,051, and they have resulted in a raised marker design which is more durable and a better reflector. The invention can be described as a pavement marker comprising a hollow base having an open bottom and a top closed by a dome, which pavement marker is characterized by:
A. said base having a curved cross sectional shape, selected from circular cylinders, elliptical cylinders, and frustoconical shapes;
B. said dome having an outer surface which approximates a surface of rotation of at least a portion of a sine wave, oriented so that the part of said outer surface nearest the periphery of the base rises gradually (i.e., having a slope substantially lower than the part of said surface midway between the periphery and the dome center) to the center of the dome;
C. said dome having a cross section thickness which is greater at the center than its average thickness and thinner at the periphery of the dome than the average thickness;
D. said dome having at least two ribs projecting from its surface; and
E. being made of an elastomer having a glass transition temperature (T g ) no greater than -50° C.
The base may be in the shape of a right circular cylinder, an elliptically shaped cylinder, or frustoconical.
The configuration of the dome facilitates the translation of horizontal motion (snow plow blade movement) into vertical deflection of the dome itself. The initial slope presented to the plow is much less abrupt than was the case with the marker of U.S. Pat. No. 4,297,051. The thinned section on the periphery of the dome can act like a live hinge, further serving to reduce force required to deflect the dome downward.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a pavement marker within the scope of this invention.
FIG. 2 is an elevation view of the pavement marker of FIG. 1.
FIG. 3 is a plan view of the pavement marker of FIG. 1.
FIG. 4 is a cross sectional view of the pavement marker of FIG. 3 at section line 4--4.
FIG. 5 is a cross sectional view of an installation of the pavement marker of FIG. 1 on a road.
FIG. 6 is an elevation view of a second embodiment of ,the inventive pavement marker.
FIG. 7 is a plan view of the pavement marker of FIG. 6.
FIG. 8 is a cross sectional view of the pavement marker of FIG. 7, along section line 8--8.
DETAILED DESCRIPTION
Snow plows can travel at high speeds (e.g., 50-80 km/hr), imposing rather high strain rates on pavement markers in their path. Therefore, the marker should be designed to resist fracture at such high strain rates and low temperatures (0° to -30° C). Both the marker design and its composition help to accomplish this.
The polymer, and the compound containing said polymer, out of which the inventive pavement marker is made, should be elastomeric and should retain elastomeric properties at the low temperatures likely to be experienced in climates where it snows. Preferably, the T g of the compound is below -55° C.
Various polyurethane formulations have been used. More specifically, aliphatic polyurethanes have been found useful. Aliphatic polyurethanes are polyurethanes derived from at least one aliphatic polyisocyanate preferably without any aromatic isocyanate. Successful formulations have comprised polytetramethylene oxide (PTMO), a short chain (3-6 carbons) diol such as 1,4 butane diol, and a diisocyanate, such as methylene bis (4-cyclohexyl isocyanate) (H 12 MDI). To such formulations have been added hydroxyl terminated oligomer (such as hydroxyl terminated polybutadiene) and a low molecular weight (1-6C) triol to add advantageous properties. A further useful addition has been a lubricating polymer, such as a silicone (e.g., a polydimethylsiloxane).
Improved properties are found in mixed soft segment polyurethanes containing a hydrophobic component, such as hydroxyl terminated polybutadiene and polydimethylsiloxane. A polymer found particularly useful comprises: 2,000 molecular weight (MW) PTMO; 2,400 MW block copolymer of ethylene oxide (A) and polydimethyl siloxane (B) approximately 50% silicone by weight; 2,800 MW hydroxyl terminated polybutadiene (functionality of 2.4-2.6); 1,4 butane diol; trimethylol propane (TMP); and H1 2 MDI in the respective molar ratios between 0.9/0.1/0.0/1.0/0.03/2.1 and 0.6/0.2/0.2/1.0/0.06/2.1. The sources for these materials were:
PTMO - obtained as Terathane 2000 from E.I. DuPont de Nemours & Co.
Polydimethylsiloxane (PDMS) - obtained as Q4 3667 from Dow Corning Corp.
Hydroxyl terminated polybutadiene (HTPB) - R45 HT from Arco Chemical Co.
1,4 Butanediol - DuPont
TMP - Celanese Chemical Co.
H 12 MDI - Desmodur W from Farbenbabriken Bayer AG
The Q4-3667 PDMS contained small but significant amounts of a unifunctional, polyethylene oxide alcohol. This alcohol might have end-blocked the polyurethane, thus limiting its ultimate molecular weight, adversely affecting its strength. An equal molar equivalence of a triol (trimethylol propane ) was added to the formulation to compensate for the unifunctional species. A very useful proportion of the Q4-3667 PDMS was between 7 and 17 weight percent. Another useful silicone was SF-1188 silicone from General Electric Co, a silicone glycol, ABA block copolymer of polyethylene and propylene oxides (A) and polydimethyl siloxane (B) approximately 50% by weight silicone, nominal MW of 3000.
One preferred polyurethane formulation is:
______________________________________ Weight %______________________________________Terathane PTMO 2000 MW 62.60SF-1188 PDMS 12.961,4 Butanediol 3.19Desmodur W H.sub.12 MDI 19.30Tinuvin 292* hindered amine light stabilizer 1.47Tinuvin 328* UV light absorber 0.24Irganox 245* antioxidant stabilizer 0.24______________________________________ *from CibaGeigy Corp.
Sample films of the above referenced polymer have been prepared by reacting them in the one-shot method at 80° C. and curing to a solid elastomer in a pressure chamber at 620 kPa. All pressures stated in this description are gauge pressures. The proportion of PDMS had a significant effect on durability. Silicone soft segments in the polyurethane tend to decrease tear strength. At 0° C., increasing PDMS level decreased the 100% modulus of the polymer. However, these tendencies were outweighed by other benefits. Silicone results in decreased friction, allowing the pavement marker to slide under a plow blade with less force required. The lower T g of the silicone helps maintain flexibility under conditions of high strain rate and low temperatures.
The inventive pavement marker can be made from the above described compositions by reaction casting in a heated silicone mold inside a pressure vessel at 620 kPa. The silicone mold can be made from a master sculpted of modeling clay. The clay master for the outer (female) surface of the marker was inserted inside a steel mold box, and degassed silicone was poured into the cavity between the clay master and the mold box. The silicone was cured for 20 hours at room temperature.
The mold for the marker interior surface required the creation of an intermediate female mold to fix the thickness of the marker cross section. A wooden inner mold master was made, and an intermediate mold master of polyester body filler was cast into the cavity between the wooden inner mold master and the mold for the marker outer surface described above. The polyester body filler required filling of pores and voids with putty. Thus, a less porous polymer, such as for example dental impression casting material, would be preferred.
With the intermediate mold in place inside the mold for the outer marker surface, the male inner mold master was cast out of degassed silicone, using a solid aluminum cylinder as a support for the male mold master. The cylinder had several grooves about 3mm wide and 3mm deep about its circumference for the purpose of giving greater surface area onto which the silicone molding compound could bond.
The method of making the marker generally comprises the following steps:
A. making a polymer premix;
B. heating the premix from step A.
C. heating the pavement marker mold;
D. positioning the reflector within the mold (if the reflector is to be integral or molded-in) and adding to the mold the polymer premix;
E. assembling the mold, inserting the inner mold part;
F. placing the mold in a vessel at elevated temperature and pressure and maintaining pressurized conditions long enough to react the polymer to give the molded marker green strength;
G. releasing the pressure, cooling the mold, and removing the pavement marker from the mold; and
H. post curing the marker, allowing strength to increase.
In step A, required amounts of polyols, antioxidants and light stabilizers are weighed together into cans. The cans are purged with dry nitrogen, sealed, marked with the formulation code and date, then stored. Polyol cans are placed in a vented convection oven and heated to 80° C. Heated cans are placed, each in turn, on a balance located in a fume hood. Diisocyanate at room temperature is metered into a given polyol can using a calibrated pump dispenser. The H 12 MDI diisocyanate is more hazardous to handle at elevated temperatures, due at least in part to increased vapor pressure and the fact that the process used in developing the inventive pavement marker was an open casting process (i.e., one end of the mold being open to the atmosphere).
Catalyst is then added and the total mixture is stirred until homogeneous. The amount of catalyst employed is important. Insufficient catalyst inhibits the reaction temperative recovery (exotherm) from the quenching effect of using room temperature isocyanate. Low catalyst levels also slow the rate at which markers can be cast. Too much catalyst causes difficulties in mold filling and shortens the time available before the mold must be placed in a pressurized environment to prevent bubble formation. Optimum, catalyst level to balance these effects can be determined by experimentation for each formulation.
In certain work during the development of this invention, 250 grams of the urethane compound described above were poured into the heated outer mold. An aluminum form, bearing the inner (male) mold part was pushed down to a stop at which point the silicone lined mold cavity represents the configuration of the pavement marker. The mold halves were secured into position, and the space between them was topped off (filled) with polyurethane compound. Then the entire assembled mold was placed into the pressure vessel.
The time taken for steps C through F is important because, during this time, a fast reacting polyurethane mixture could form bubbles, ruining the casting. Thus, it is desirable to minimize the time to perform those steps. Minimizing this time allows the use of faster curing mixtures and thus shorter curing cycle times.
The pressure curing in step F is for the purpose of preventing bubble formation in the polymer. Bubbles cease to be a problem once the polyurethane has cured to the point at which it has green strength. Catalyst level is determined at least partly by desired pot life of the premix. Pressure vessel residence time for the mold can be reduced by raising cure temperature. This can be done by means of an electrical heater in or on the vessel. Typical cure temperatures range from 60° to 80° C., and typical pressure cure time was one hour.
In step G, the markers are removed from the molds by first connecting the inner mold to a compressed air line, by means of a small tube through the inner mold. When a small pressure (30-100 kPa) is applied, the silicone inner mold form distorts away from its aluminum core. This action partially releases the mold from the inside of the marker casting.
Post curing (step H.) has comprised placing the markers in a forced air oven at about 80° C. for about 12 hours followed by storing at room temperature for a minimum of one week.
Referring to FIGS. 1-5, a first pavement marker 2 is shown, having base 4, base flange 3, and dome 6. The thicker center portion of the dome is shown as part 10. For a dome having a normal average thickness of about 6 mm, the center should be about 10 mm thick. The ratio of center thickness to average thickness is preferably in the range of 1.3 to 2.0. The increased section thickness at the center of the dome helps reduce deformation of the dome in front of a plow blade like a wave front, which would happen with the constant cross-section thickness domes illustrated in the '051 patent This build-up of dome material in front of the plow blade eventually led to tearing of the dome of the '051 marker. The problem of tearing is exacerbated at very low temperatures (e.g., -15° C.) given the short time allowed for dome deformation and recovery (e.g., 5-10 milliseconds) at usual snow plow speeds. The greater thickness at the center of the inventive marker dome causes the larger strains in the dome to be distant from the cutting edge of a snow plow blade. As a blade passes over the center of the inventive marker, the center section rocks back and slips behind the blade as a unit, causing the build-up of dome material to occur behind the advancing blade. This has been called the toggle action of the marker, for convenience.
The thinner peripheral portion of the dome is shown as part 12. For domes having a nominal average thickness of 6 mm, periphery thickness has been typically 3-4 mm. The ratio of periphery thickness to average dome thickness is preferably in the range of 0.4-0.8, more preferably 0.5-0.7. In an embodiment made during the development of the invention, the periphery of the dome was made thinner by designing it with a radius cut (2-4 mm.) on the underside at the corner where the dome and base meet. Ribs 8, which are integrally molded as part of dome 6, protect reflector 14 from being scuffed by snow plow blades.
The shape of the dome gives the marker more time to react to the force of a snow plow blade, because of the gradual ramp at the periphery; whereas, the dome of U.S. Pat. No. 4,297,051 presents a discontinuity to the plow blade at the marker periphery (the point where the dome has the maximum stiffness to downward deflection). As noted above, the dome 6 has an outer surface which approximates a surface of rotation of a sine wave. Preferably, the curve of the dome, shown in cross section in FIG. 4, is defined by three sine wave functions, each one for a different section or zone of the curve. The three sine wave functions can be expressed as follows:
π radians=radius of marker
S=distance above datum plane or x-axis
θ=distance along datum plane or x-axis (starting
from 0=intersection of base 4 and dome 6)
β=marker radius
L=maximum dome height, at center, above x-axis ##EQU1## for zone I along x-axis from θ=0 to θ=(β/8) ##EQU2## for zone II along x-axis from θ=β/8 to θ=(7/8)β ##EQU3## for zone III (7/8)β≦θ≦β ##EQU4##
Reflector 14 can be a cube corner retroreflector made of flexible, transparent polymeric material, preferably a cube corner retroreflector capable of yielding a minimum of 2.5-3.0 candle power per foot candle of incident light (cp/fc). Preferably, a full aperture cube corner material, as described in U.S. Pat. Nos. 4,895,428 and 4,349,598 is used. Such cube corner material comprises a surface layer and a multiplicity of cube corner prismatic reflecting elements each having a rectangular base on the back side of the surface layer, two mutually perpendicular rectangular faces meeting said base at angles (which may be 45°) and two triangular faces at either end of the prism shape at least one of which triangular faces is perpendicular to said rectangular faces and which, together with said rectangular faces, defines a cube corner therebetween. The back side of the surface layer and the cube corner reflector in general is the side opposite the side intended to face incident light (front side).
The reflector should be sealed on its back side (the side facing toward the marker dome) typically by means of a sealing film (e.g., thermoplastic polyurethane) bonded (heat sealed) to the cube corner reflector. The bonding or sealing is done in a way which preserves an air space or a plurality of air spaces or cells between the sealing film and the back of the cube corner reflector. The air interface with the backs of the cube corners maintains the desirable optics of the reflector for efficient reflection, and the concept is well known in the art. The sealing film does not flow into the air space behind the cube corners because the molding temperature of step F is less than the polyurethane melting temperature.
In one embodiment made during the development of this invention, a cube corner reflective lens about 9.7 cm 2 was used in a marker of FIG. 1. Because of its angle to the horizontal, it yielded an actual projected area, straight on, of about 4.8 cm 2 . The thickness of the dome underneath reflector 14 is preferably adjusted to reduce reflector buckling and damage.
In FIG. 5, the pavement is indicated as 20, the hole into which the pavement marker is installed is designated 22, and the filler in between base 4 and pavement 20 is shown as 24. Preferably, the height of the marker base 4 is less than the depth of the first layer of pavement material on the road.
A second embodiment 30 of the inventive pavement marker is shown in FIGS. 6-8. It is similar to the first marker in that it has base 34, base flange 35, dome 36, thick top portion 40 and thin peripheral portion 42. However, it has a plurality of ribs 38 on the dome and a plurality of depressions 39 in between said ribs. Typically, there are from 24 to 35 such ribs on the dome, preferably fewer so that the depressions can be wider in order to accommodate more retroreflective material
This second embodiment is reflectorized by a coating of small retroreflective spherical lenses in said depressions. The layer comprises a multiplicity of such lenses (e.g., glass microspheres) partially embedded in a binder (e.g., polyurethane). Preferably, there is a specular reflector behind the spherical lenses, e.g., a coating of aluminum on the part of the microspheres embedded in the binder. Such a coating can be obtained by coating all the spherical lenses, and removing the aluminum reflective coating from the exposed parts after the binder has been cured, for example by means of an etchant. A method for obtaining a layer of reflectorized microspheres is taught in U.S. Pat. No. 3,885,246, Column 3, lines 1-25.
Also, the surface of the depressions can be given a roughened or stippled surface. This can be done by stippling the surface of the clay master from which the pavement marker mold is cast, for example by applying the ends of a stiff brush to the depression areas while the clay is still in a plastic state.
The binder for the spherical lenses can be an aerosol spray which adheres well to both the polyurethane dome and the lenses themselves. One composition for such a binder is:
______________________________________ Parts by Weight (pbw) Weight %______________________________________Tetrahydrofuran 100.0 44.3Toluene 95.9 42.5Cyclohexanone 20.8 9.2Estane 5712 polyurethane* 5.6 2.5VAGH resin** 3.5 1.5______________________________________ *from B. F. Goodrich Company **terpolymer believed to comprise the following monomers: vinyl chloride (90.-92%), vinyl acetate (3%), and vinyl alcohol (5-7%) from Union Carbid Corp.
To 100 pbw of the above adhesive binder are added 50 pbw of aluminum or silver coated, high refractive index (e.g.,1.9 or 2.26) glass microspheres (40-200 micrometers particle size). A layer of binder is applied (sprayed) onto the to the dome of the marker of FIGS. 6-8 and allowed to partly dry until tacky. This layer should be thick enough, when dry, to anchor the microsphere lenses up to their equators. The mixture of microspheres and binder is applied (poured) over the tacky pavement marker surface, and the excesses is tapped off. Heat is applied to cause the microspheres to sink into the binder and drive off solvent. The exposed microsphere surfaces are etched with an acid/dichromate solution (solvent for the silver or aluminum coating), rinsed and dried to yield properly oriented lenses.
The retroreflective intensity of the inventive pavement markers, having a retroreflective coating of spherical lenses, has been measured at 0.677 candela/foot candle of incident light (0.063 candela/lux) and a retroreflectivity coefficient of about 50 candela/lux/square meter (cd/lx/m 2 ). This compares favorably to the 0.15 cd/fc (0.014 cd/lx) and 0.566 cd/lx/m 2 measured on previously known embodiments of the marker of U.S. Pat. No. 4,297,051. These measurements were made at the following conditions: entrance angle=86°, observation angle =0.2°, rotation angle =0°, and presentation angle =0°.
The inventive markers are installed in holes drilled in pavement, typically by a core drill. Preferably, it is a truck mounted, air flushed drill driven by a power take off from the truck. Drilling time for one marker is about 20 seconds to one minute for a hole 45 mm deep.
The annulus between the base and the pavement is filled with a grout or sealant. One useful sealant is an asphalt extended polyurethane The polyurethane comprises a two part system employing a pre-polymer having an excess of isocyanate and a catalyzed (dibutyl tin dilaureate) hydroxyl terminated polybutadiene. The two parts can be extruded through a static mixer from a two-part cartridge gun. One sealant found useful is LC-7241 Detector Loop Sealant from Minnesota Mining and Manufacturing Company, Canada, Inc., London, Ontario, Canada. A solution of dibutyl tin dilaureate catalyst in toluene can be sprayed on the sealant after it has been poured into the annulus to hasten the formation of a protective surface skin.
The inventive pavement markers have been tested in a machine which simulates the action of a snow plow blade scraping cold pavement. Markers, grouted into concrete blocks, are cooled to temperatures of 0° to -30° C. then secured into the test fixture of the machine. The test involves accelerating a plow blade segment to speed, and directing it to strike the marker dome. A clearance of less than 0.5 mm is maintained between the top of the concrete block and the blade edge.
|
Raised pavement marker useful in geographic areas where snow plows are used and comprising hollow base with an open bottom and dome top, characterized by:
A. base cross section being closed curved shape like cylinder;
B. dome having:
1) outer surface which approximates surface of rotation of a sine wave with highest point in middle of dome;
2) dome cross section is thickest near center and thinnest at p eriphery;
3) at least 2 ribs projecting from surface, to protect reflector which may be cube corner reflectror affixed to dome;
C. material of construction which is an elastomer having T g no greater than -50° C., preferably polyurethane compound containing a lubricating polymer, such as a silicone.
| 4
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a television receiver having the function of displaying a plurality of types of images which differ in the aspect ratio.
2. Description of the Background Art
In digital television broadcasting, not only a television program video having a standard aspect ratio of 3:4 but also a television program video having an aspect ratio of 9:16, for example, a high-definition television program video is broadcast.
JP07-46510, A discloses a television receiver selectively assuming a state where an image reproducing operation is performed on the basis of a high-definition television video signal having an aspect ratio of 9:16 and a state where an image reproducing operation is performed on the basis of an NTSC (National Television System Committee) video signal having an aspect ratio of 3:4.
In such a television receiver, a video signal processing circuit for the high-definition television video signal and a video signal processing circuit for the NTSC video signal are selectively connected to a common image display unit, and an image reproducing video signal based on the high-definition television video signal or an image reproducing video signal based on the NTSC video signal are fed to the image display unit.
When the video signal is fed to the image display unit, a vertical deflection signal and a horizontal deflection signal are fed to a deflecting coil provided in the image display unit. When the image reproducing video signal based on the high-definition television video signal is fed to the image display unit, a vertical deflection signal having a frequency of 60 Hz and a horizontal deflection signal having a frequency of 33.75 kHz are fed to the deflecting coil in correspondence with a field frequency 60 Hz and a line frequency 33.75 kHz which the high-definition television video signal has. On the other hand, when the image reproducing video signal based on the NTSC video signal is fed to the image display unit, a vertical deflection signal having a frequency of 60 Hz and a horizontal deflection signal having a frequency of 15.75 kHz are fed to the deflecting coil in correspondence with a field frequency 60 Hz and a line frequency 15.75 kHz which the NTSC video signal has.
In this case, an image reproducing video signal based on a high-definition television video signal forming a screen having an aspect ratio of 9:16 and an image reproducing video signal based on an NTSC video signal forming a screen having an aspect ratio of 3:4 are selectively fed to the common image display unit. A state where a reproduced image corresponding to the high-definition television video signal is obtained on the image display unit or a state where a reproduced image corresponding to the NTSC video signal is obtained thereon is assumed. In either one of the states, a portion where no image is displayed is formed in the image display unit.
In a television receiver comprising an image display unit 10 having an aspect ratio of 3:4, for example, when a television program video having an aspect ratio of 3:4 is displayed, the television program video is displayed on the whole of a display area of the image display unit 10 . When a television program video having an aspect ratio of 9:16 is displayed, however, the television program video is displayed inside both upper and lower side edges of the display area of the image display unit 10 , as shown in FIG. 1 a . Accordingly, portions where no television program video is displayed respectively appear in the upper and lower side edges of the display area of the image display unit 10 . In the portions where no television program video is displayed, black bands (letter boxes) 11 are respectively on-screen displayed.
On the other hand, in a television receiver comprising an image display unit 20 having an aspect ratio of 9:16, when a television program video having an aspect ratio of 9:16 is displayed, the television program video is displayed on the whole of a display area of the image display unit 20 . When a television program video having an aspect ratio of 3:4 is displayed, however, the television program video is displayed inside both left and right side edges of the display area of the image display unit 20 , as shown in FIG. 1 b . Accordingly, portions where no television program video is displayed respectively appear in the left and right side edges of the display area of the image display unit 20 . In the portions where no television program video is displayed, black bands (side panels) 21 are respectively on-screen displayed.
Under circumstances where a state where the portion where no image is displayed is thus formed on the image display unit is assumed in displaying the reproduced image by the image display unit, when the accumulation time in the state is relatively increased, there occurs a difference in luminescent capability between a portion where no image is displayed (a first area) and a portion where an image is displayed (a second area) in the image display unit because the degree of reduction in the luminescent capability in the second area is higher than that in the first area.
When screen display is performed over the whole surface of the image display unit under circumstances where the difference in luminescent capability thus occurs, luminance in the second area is lower than luminance in the first area so that there occurs a luminance difference between the first area and the second area. In the boundary between the first area and the second area, a stripe-shaped trace, i.e., burn-in is conspicuous due to the luminance difference.
Disclosed as a technique for effectively reducing the degree of the burn-in is a technique for reciprocating the position of an edge in the horizontal direction or the vertical direction of a screen on which a reproduced image is formed in an image display unit in a relatively small movement range in a predetermined long period. That is, as a method of reducing burn-in in an image display unit by a side panel or a letter box used when programs having different aspect ratios are displayed, the side panel or the letter box is moved by slightly moving a deflection circuit.
SUMMARY OF THE INVENTION
In recent years, a liquid crystal panel, a plasma display panel (PDP), an organic EL panel, etc. have been employed as an alternative to a Brawn tube (a cathode-ray tube). In the Brawn tube, a deflection circuit can be slightly moved. Even if a side panel or a letter box is moved in a long period, therefore, a viewer does not have an uncomfortable feeling. When burn-in in a display panel is reduced in the same method as that in the above-mentioned prior art with respect to the liquid crystal panel, the PDP, and the organic EL panel, however, the side panel or the letter box must be moved in pixel units. Therefore, the movement gives an uncomfortable feeling to the viewer. An object of the present invention is to reduce the uncomfortable feeling.
In a television receiver having the function of displaying a plurality of types of television program videos which differ in the aspect ratio, a first television receiver according to the present invention is characterized by comprising means for judging, when channels are switched, whether or not a letter box is displayed on the previous channel and is also displayed on the new channel; and means for moving, when it is judged that the letter box is displayed on the previous channel and is also displayed on the new channel, the position of the letter box displayed on the new channel from the position of the letter box displayed on the previous channel.
In a television receiver having the function of displaying a plurality of types of television program videos which differ in the aspect ratio, a second television receiver according to the present invention is characterized by comprising means for judging, when channels are switched, whether or not a side panel is displayed on the previous channel and is also displayed on the new channel; and means for moving, when it is judged that the side panel is displayed on the previous channel and is also displayed on the new channel, the position of the side panel displayed on the new channel from the position of the side panel displayed on the previous channel.
In a television receiver having the function of displaying a plurality of types of television program videos which differ in the aspect ratio, a third television receiver according to the present invention is characterized by comprising calculation means for calculating, when a letter box is displayed, the average value of luminances in areas respectively composed of upper and lower side edges in the television program video; and means for moving, when the average value of the luminances which is calculated by the calculation means is lower than a predetermined value, the display position of the letter box.
In a television receiver having the function of displaying a plurality of types of television program videos which differ in the aspect ratio, a fourth television receiver according to the present invention is characterized by comprising calculation means for calculating, when a side panel is displayed, the average value of luminances in areas respectively composed of left and right side edges in the television program video; and means for moving, when the average value of the luminances which is calculated by the calculation means is lower than a predetermined value, the display position of the side panel.
In a television receiver having the function of displaying a plurality of types of television program videos which differ in the aspect ratio, a fifth television receiver according to the present invention is characterized by comprising scene change detection means for detecting, when a letter box is displayed, that a scene change occurs; and means for moving, when the scene change detection means detects that the scene change occurs, the display position of the letter box.
In a television receiver having the function of displaying a plurality of types of television program videos which differ in the aspect ratio, a sixth television receiver according to the present invention is characterized by comprising scene change detection means for detecting, when a side panel is displayed, that a scene change occurs; and means for moving, when the scene change detection means detects that the scene change occurs, the display position of the side panel.
In the first television receiver or the second television receiver according to the present invention, when the channels are switched, the display position of the letter box or the side panel is moved. Accordingly, the movement is not easily recognized by a viewer. When the display position of the letter box or the side panel is moved, therefore, no uncomfortable feeling is given to the viewer.
In the third television receiver or the fourth television receiver according to the present invention, when the average value of the luminances in the areas respectively composed of the upper edge and the lower edge (or the left edge and the right edge) in the television program video is lower than the predetermined value, that is, when the luminances in the upper edge and the lower edge in the television program video are close to the luminance of the letter box (or the side panel) in a state where the letter box (or the side panel) is displayed, the display position of the letter box (or the side panel) is moved, so that the movement is not easily recognized by a viewer. When the display position of the letter box or the side panel is moved, therefore, no uncomfortable feeling is given to the viewer.
In the fifth television receiver or the sixth television receiver according to the present invention, when the scene change occurs in a state where the letter box (or the side panel) is displayed, the display position of the letter box (or the side panel) is moved. Accordingly, the movement is not easily recognized by a viewer. When the display position of the letter box or the side panel is moved, therefore, no uncomfortable feeling is given to the viewer.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a and 1 b are schematic views respectively showing a state where a letter box is displayed and a state where a side panel is displayed;
FIG. 2 is a block diagram showing the configuration of a television receiver according to a first embodiment;
FIG. 3 is a flow chart showing the procedure for processing for controlling the display position of a letter box;
FIG. 4 is a flow chart showing the procedure for processing for moving the letter box which is performed in the step S 305 shown in FIG. 3 ;
FIG. 5 is a schematic view for explaining processing for moving a letter box displayed on the upper side of a display area of a liquid crystal panel;
FIG. 6 is a flow chart showing the procedure for processing for controlling the display position of a side panel;
FIG. 7 is a flow chart showing the procedure for processing for moving the side panel which is performed in the step S 605 shown in FIG. 6 ;
FIG. 8 is a schematic view for explaining processing for moving a side panel displayed on the left side of a display area of a liquid crystal panel;
FIG. 9 is a block diagram showing the configuration of a television receiver according to a second embodiment;
FIG. 10 is a flow chart showing the procedure for processing for controlling the display position of a letter box;
FIG. 11 is a flow chart showing the procedure for processing for controlling the display position of a side panel;
FIG. 12 is a block diagram showing the configuration of a television receiver according to a third embodiment;
FIG. 13 is a flow chart showing the procedure for processing for controlling the display position of a letter box; and
FIG. 14 is a flow chart showing the procedure for processing for controlling the display position of a side panel.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, description is now made of an embodiment in a case where the present invention is applied to a television receiver comprising a liquid crystal panel.
[1] Description of First Embodiment
FIG. 2 illustrates the configuration of a television receiver according to a first embodiment.
The television receiver comprises the function of performing an image reproducing operation on the basis of a high-definition television video signal having an aspect ratio of 9:16 and the function of performing an image reproducing operation on the basis of an NTSC video signal having an aspect ratio of 3:4.
Broadcasting radio waves are inputted to a digital TUNER ( 101 ) and a transport stream (hereinafter referred to as TS) is outputted to an AV_DECODER ( 102 ) from the digital TUNER ( 101 ). The AV_DECODER ( 102 ) which has received the TS outputs a digital video signal to an NTSC encoder ( 103 ). The NTSC encoder ( 103 ) which has received the digital video signal outputs a video and reflects the video on a TV set.
[1-1] Description of Case where there is Provided Liquid Crystal Panel Having Aspect Ratio of 3:4
It is assumed that the television receiver comprises a liquid crystal panel having an aspect ratio of 3:4. When a television program video having an aspect ratio of 3:4 is displayed, the television program video is displayed on the whole of a display area of the liquid crystal panel. When a television program video having an aspect ratio of 9:16 is displayed, the television program video is displayed inside both upper and lower side edges of the display area of the liquid crystal panel, and letter boxes 11 are respectively displayed in the upper and lower side edges of the display area of the liquid crystal panel, as shown in FIG. 1 a.
The letter boxes 11 are displayed, as shown in FIG. 1 a , in the liquid crystal panel. When a channel change instruction signal is outputted to a SUB_CPU ( 104 ) from a remote control (not shown), the channel change instruction signal is outputted to a CPU ( 105 ) from the SUB_CPU ( 104 ).
The CPU ( 105 ) reads information related to a channel newly inputted, and judges whether or not letter boxes must be displayed on the new channel, as on the previous channel. When the letter boxes need not be displayed, the instruction signal is fed to the AV_DECODER ( 102 ) as usual, to display a designated program.
When it is judged that letter boxes must be also displayed on the new channel, as on the previous channel, the instruction signal is outputted from the CPU ( 105 ) to the AV_DECODER ( 102 ) such that the position of the letter box, which is displayed by an on screen display (hereinafter referred to as OSD), is slightly moved, as compared with the position where it is displayed on the previous channel. The AV_DECODER ( 102 ) which has received the instruction signal outputs to the NTSC encoder ( 103 ) the digital video signal in a state where the position of the letter box displayed on the previous channel is slightly shifted, and the NTSC encoder ( 103 ) which has received the digital video signal outputs the video and reflects the video on the TV set.
That is, when the channels are switched, the letter boxes are displayed before switching the channels. When the letter boxes are displayed even after switching the channels, the display position of the letter box is moved.
FIG. 3 shows the procedure for processing for controlling the display position of the letter box.
While a user is watching TV (step S 301 ), when the channels are changed by operation buttons in the remote control or the main body of the television receiver (YES in step S 302 ), it is judged whether or not the aspect ratio of a video corresponding to the new channel is 3:4 (whether or not the video is full-screen displayed) (step S 303 ).
When the aspect ratio of the video corresponding to the new channel is 3:4 (the video is full-screen displayed) (YES in step S 303 ), the new channel is selected, to display the video corresponding to the new channel (step S 306 ). The procedure is returned to the step S 301 .
On the other hand, when the aspect ratio of the video corresponding to the new channel is not 3:4, that is, the aspect ratio of the video corresponding to the new channel is 9:16 (NO in step S 303 ), it is judged whether or not the aspect ratio of a video corresponding to the previous channel is 9:16 (step S 304 ).
When the aspect ratio of the video corresponding to the previous channel is not 9:16, that is, the aspect ratio of the video corresponding to the previous channel is 3:4 (NO in step S 304 ), the display position of the letter box remains the position currently held, to display the video corresponding to the new channel (step S 306 ). The procedure is returned to the step S 301 .
When the aspect ratio of the video corresponding to the previous channel is 9:16 in the foregoing step S 304 (YES in step S 304 ), that is, when the letter box is displayed on the previous channel and is also displayed on the new channel, the display position of the letter box is moved by one pixel in accordance with a flow chart of FIG. 4 (step S 305 ), and the video corresponding to the new channel is displayed (step S 306 ). The procedure is returned to the step S 301 .
FIG. 4 shows the procedure for processing for moving the letter box which is performed in the step S 305 shown in FIG. 3 .
FIG. 5 illustrates the letter box displayed on the upper side of the display area of the liquid crystal panel. IVP is a variable representing the display position in the vertical direction of a lower edge of the letter box on the upper side. The position of the lower edge of the letter box on the upper side is moved in pixel units within a range of n pixels above and below the reference position (IVP=0). In this example, n is set to five. A range where the position of the lower edge of the letter box on the upper side is moved is from IVP=−5 to IVP=+5.
In this example, the position of the lower edge of the letter box on the upper side is moved in pixel units upward from the reference position (IVP=0), and is then moved in pixel units downward when it reaches IVP=5. When the position reaches IVP=−5, it is then moved in pixel units upward. IVD is used as a variable representing the current direction of movement. IVD=1 represents an upward direction, and IVD=0 represents a downward direction. When the power supply is turned on, IVP=0 and IVD=1 are set.
Even in the letter box on the lower side, a variable representing the display position in the vertical direction of an upper edge of the letter box on the lower side (a variable corresponding to the above-mentioned IVP) and a variable representing the direction of movement of the position of the upper edge of the letter box on the lower side (a variable corresponding to the above-mentioned IVD) are prepared for the purpose of movement processing.
Although description is made of only processing for moving the letter box on the upper side, processing for moving the letter box on the lower side is also similarly performed.
In the processing for moving the letter box on the upper side, it is judged whether or not the current IVP is less than n (+5 in this example) (step S 401 ). When the IVP is not less than n (NO in step S 401 ), that is, when IVP=+5, the variable IVD representing the direction of movement is set to one. Therefore, the variable IVD representing the direction of movement is set to zero (step S 404 ). Thereafter, the procedure proceeds to the step S 402 . When it is judged in the foregoing step S 401 that the IVP is less than n, that is, when the IVP is a value between −5 and +4, the procedure proceeds to the step S 402 .
It is judged in the step S 402 whether or not the current IVD is one. That is, it is judged whether or not the direction of movement is an upward direction. When IVD=1 (YES in step S 402 ), that is, when the direction of movement is an upward direction; the IVP is updated to (IVP+1) (step S 403 ). Consequently, the display position of the letter box is moved by one pixel upward. The procedure is returned to the step S 306 shown in FIG. 3 .
When it is judged in the foregoing step S 402 that IVD=0 (NO in step S 402 ), that is, when the direction of movement is a downward direction, it is judged whether or not the IVP is more than −n (−5 in this example) (step S 405 ). Unless the IVP is more than −n (−5 in this example) (NO in step S 405 ), that is, when IVP=−5, the variable IVD representing the direction of movement is set to one. Therefore, the variable IVD representing the direction of movement is set to one (step S 406 ), and the IVP is then updated to (IVP+1) (step S 403 ). Consequently, the display position of the letter box is moved by one pixel upward. The procedure is returned to the step S 306 shown in FIG. 3 .
When it is judged in the foregoing step S 405 that the IVP is more than −n (−5 in this example) (YES in step S 405 ), that is, when the IVP is a value between −4 and +5, the IVP is updated to (IVP −1) (step S 407 ). Consequently, the display position of the letter box is moved by one pixel downward. The procedure is returned to the step S 306 shown in FIG. 3 .
[1-2] Description of Case where there is Provided Liquid Crystal Panel Having Aspect Ratio of 9:16
It is assumed that the television receiver comprises a liquid crystal panel having an aspect ratio of 9:16. When a television program video having an aspect ratio of 9:16 is displayed, the television program video is displayed on the whole of a display area of the liquid crystal panel. When a television program video having an aspect ratio of 3:4 is displayed, the television program video is displayed inside both left and right side edges of the display area of the liquid crystal panel, and side panels 21 are respectively displayed in the left and right side edges of the display area of the liquid crystal panel, as shown in FIG. 1 b.
The side panels 21 are displayed, as shown in FIG. 1 b , on the liquid crystal panel. When a channel change instruction signal is outputted to the SUB_CPU ( 104 ) from the remote control (not shown), the channel change instruction signal is outputted to the CPU ( 105 ) from the SUB_CPU ( 104 ).
The CPU ( 105 ) reads information related to the channel newly inputted, and judges whether or not side panels must be displayed on the new channel, as on the previous channel. When the side panels need not be displayed, the instruction signal is fed to the AV_DECODER ( 102 ) as usual, to display a designated program.
When it is judged that side panels must be also displayed on the new channel, as on the previous channel, the instruction signal is outputted from the CPU ( 105 ) to the AV_DECODER ( 102 ) such that the position of the side panel, which is displayed by the OSD, is slightly moved, as compared with the position where it is displayed on the previous channel. The AV_DECODER ( 102 ) which has received the instruction signal outputs to the NTSC encoder ( 103 ) the digital video signal in a state where the position of the side panel displayed on the previous channel is slightly shifted, and the NTSC encoder ( 103 ) which has received the digital video signal outputs the video and reflects the video on the TV set.
That is, when the channels are switched, the side panels are displayed before switching the channels. When the side panels are displayed even after switching the channels, the display position of the side panel is moved.
FIG. 6 shows the procedure for processing for controlling the display position of the side panel.
While a user is watching TV (step S 601 ), when the channels are changed by the operation buttons in the remote control or the main body of the television receiver (YES in step S 602 ), it is judged whether or not the aspect ratio of a video corresponding to the new channel is 9:16 (whether or not the video is full-screen displayed) (step S 603 ).
When the aspect ratio of the video corresponding to the new channel is 9:16 (the video is full-screen displayed) (YES in step S 603 ), the new channel is selected, to display the video corresponding to the new channel (step S 606 ). The procedure is returned to the step S 601 .
On the other hand, when the aspect ratio of the video corresponding to the new channel is not 9:16, that is, the aspect ratio of the video corresponding to the new channel is 3:4 (NO in step S 603 ), it is judged whether or not the aspect ratio of the video corresponding to the previous channel is 3:4 (step S 604 ).
When the aspect ratio of the video corresponding to the previous channel is not 3:4, that is, the aspect ratio of the video corresponding to the previous channel is 9:16 (NO in step S 604 ), the display position of the side panel remains the position currently held, to display the video corresponding to the new channel (step S 606 ). The procedure is returned to the step S 601 .
When the aspect ratio of the video corresponding to the previous channel is 3:4 in the foregoing step S 604 (YES in step S 604 ), that is, when the side panel is displayed on the previous channel and is also displayed on the new channel, the display position of the side panel is moved by one pixel in accordance with a flow chart of FIG. 7 (step S 605 ), and the video corresponding to the new channel is displayed (step S 606 ). The procedure is returned to the step S 601 .
FIG. 7 shows the procedure for processing for moving the side panel which is performed in the step S 605 shown in FIG. 6 .
FIG. 8 illustrates the side panel displayed on the left side of the display area of the liquid crystal panel. IHP is a variable representing the display position in the horizontal direction of a right edge of the side panel on the left side. The position of the right edge of the side panel on the left side is moved in pixel units within a range of n pixels at the right and left of the reference position (IHP=0). In this example, n is set to five. A range where the position of the right edge of the side panel on the left side is moved is from IHP=−5 to IHP=+5.
In this example, the position of the right edge of the side panel on the left side is moved in pixel units rightward from the reference position (IHP=0), and is then moved in pixel units leftward when it reaches IHP=+5. When the position reaches IHP=−5, it is then moved in pixel units rightward. IHD is used as a variable representing the current direction of movement. IHD=1 represents a rightward direction, and IHD=0 represents a leftward direction. When the power supply is turned on, IHP=0 and IHD=1 are set.
Even in the side panel on the right side, a variable representing the display position in the horizontal direction of a left edge of the side panel on the right side (a variable corresponding to the above-mentioned IHP) and a variable representing the direction of movement of the position of the left edge of the side panel on the right side (a variable corresponding to the above-mentioned IHD) are prepared for the purpose of movement processing.
Although description is made of only processing for moving the side panel on the left side, processing for moving the side panel on the right side is also similarly performed.
In the processing for moving the side panel on the left side, it is judged whether or not the current IHP is less than n (+5 in this example) (step S 701 ). When the IHP is not less than n (NO in step S 701 ), that is, when IHP=+5, the variable IHD representing the direction of movement is set to one. Therefore, the variable IHD representing the direction of movement is set to zero (step S 704 ). Thereafter, the procedure proceeds to the step S 702 . When it is judged in the foregoing step S 701 that the IHP is less than n, that is, when the IHP is a value between −5 and +4, the procedure proceeds to the step S 702 .
It is judged in the step S 702 whether or not the current IHD is one. That is, it is judged whether or not the direction of movement is a rightward direction. When IHD=1 (YES in step S 702 ), that is, when the direction of movement is a rightward direction, the IHP is updated to (IHP+1) (step S 703 ). Consequently, the display position of the side panel is moved by one pixel rightward. The procedure is returned to the step S 606 shown in FIG. 6 .
When it is judged in the foregoing step S 702 that IHD =0 (NO in step S 702 ), that is, when the direction of movement is a leftward direction, it is judged whether or not the IHP is more than −n (−5 in this example) (step S 705 ). Unless the IHP is more than −n (−5 in this example) (NO in step S 705 ) that is, when IHP=−5, the variable IHD representing the direction of movement is set to one. Therefore, the variable IHD representing the direction of movement is set to one (step S 706 ), and the IHP is then updated to (IHP+1) (step S 703 ) Consequently, the display position of the side panel is moved by one pixel rightward. The procedure is returned to the step S 606 shown in FIG. 6 .
When it is judged in the foregoing step S 705 that the IHP is more than −n (−5 in this example) (YES in step S 705 ) that is, when the IHP is a value between −4 and +5, the IHP is updated to (IHP−1) (step S 707 ). Consequently, the display position of the side panel is moved by one pixel leftward. The procedure is returned to the step S 606 shown in FIG. 6 .
[2] Description of Second Embodiment
FIG. 9 illustrates the configuration of a television receiver according to a second embodiment. In FIG. 9 , the same units as those shown in FIG. 2 are assigned same reference numerals.
The television receiver according to the second embodiment is provided with a luminance detection circuit ( 501 ).
The television receiver also comprises the function of performing an image reproducing operation on the basis of a high-definition television video signal having an aspect ratio of 9:16 and the function of performing an image reproducing operation on the basis of an NTSC video signal having an aspect ratio of 3:4.
Broadcasting radio waves are inputted to a digital TUNER ( 101 ), and a TS is outputted to an AV_DECODER ( 102 ) from the digital TUNER ( 101 ). The AV_DECODER ( 102 ) which has received the TS outputs a digital video signal to an NTSC encoder ( 103 ). The NTSC encoder ( 103 ) which has received the digital video signal outputs a video.
[2-1] Description of Case where there is Provided Liquid Crystal Panel Having Aspect Ratio of 3:4, and Letter Boxes are Displayed when Video Having Aspect Ratio of 9:16 is Displayed
When a program on which letter boxes are displayed is presented, the AV_DECODER ( 102 ) outputs to the luminance detection circuit ( 501 ) luminance levels at respective addresses in upper and lower side edges of a television program video (addresses in the vicinity of the boundaries between the television program video and the letter boxes). Here, the addresses to be objects are respectively areas, each having a width corresponding to five pixels, composed of the upper and lower side edges of the television program video, for example. Although the width of the object area is set to a width corresponding to five pixels, the width is not limited to the same.
The luminance detection device ( 501 ) calculates the average value of the luminance levels sent from the AV_DECODER ( 102 ), and gives the calculated average value to a CPU ( 105 ). The CPU ( 105 ) judges whether or not the average value of the luminances which is given from the luminance detection device ( 501 ) is lower than a predetermined value (whether or not it is close to the luminance level of the letter box). In a case where it is judged that the average value of the luminances is lower than the predetermined value, even if the letter box is moved, the movement is inconspicuous. Therefore, such an instruction signal as to move the display position of the letter box is outputted to the AV_DECODER ( 102 ). The AV_DECODER ( 102 ) which has received the instruction signal outputs to the NTSC encoder ( 103 ) the digital video signal in a state where the position of the displayed letter box is slightly shifted, and the NTSC encoder ( 103 ) which has received the digital video signal outputs the video and reflects the video on a TV set.
FIG. 10 shows the procedure for processing for controlling the display position of the letter box.
While a user is watching TV (step S 1001 ), it is judged whether or not the display of a program which is being currently viewed is full screen display (the aspect ratio of a video is 3:4) (step S 1002 ).
When the display of the program which is being currently viewed is full screen display, that is, when no letter boxes are displayed, the subsequent frame is displayed as it is (step S 1006 ). The procedure is returned to the step S 1001 .
On the other hand, when the display of the program which is being currently viewed is not full screen display (NO in step S 1002 ), that is, the aspect ratio of the video is 9:16, and letter boxes are displayed, the average value of luminances in upper and lower side edges of a television program video currently displayed is calculated by the luminance detection circuit ( 501 ), and is sent to the CPU ( 105 ) (step S 1003 ).
The CPU ( 105 ) judges whether or not the average value of the luminances is a value close to the black level (lower than a predetermined value) (step S 1004 ). Here, judgment as to how the value close to the black level is to be defined may be freely settable by the user, or may be determined depending on the sensitivity of a designer and set at the time of shipping from a factory. When the average value of the luminances is not the value close to the black level (NO in step S 1004 ), the subsequent frame is displayed as it is (step S 1006 ). The procedure is returned to the step S 1001 .
When it is judged that the average value of the luminances is the value close to the black level, that is, the respective boundaries between the upper and lower side edges of the television program video and the letter boxes are indistinct, the display position of the letter box is moved by one pixel in accordance with the flow chart of FIG. 4 (step S 1005 ), and the subsequent frame is then displayed (step S 1006 ). The procedure is returned to the step S 1001 .
[2-2] Description of Case where there is Provided Liquid Crystal Panel Having Aspect Ratio of 9:16, and Side Panels are Displayed when Video Having Aspect Ratio of 3:4 is Displayed
When a program on which side panels are displayed is presented, the AV_DECODER ( 102 ) outputs to the luminance detection circuit ( 501 ) luminance levels at addresses in left and right side edges of a television program video (addresses in the vicinity of the boundaries between the television program video and the side panels). Here, the addresses to be objects are respectively areas, each having a width corresponding to five pixels, composed of the left and right side edges of the television program video, for example.
The luminance detection device ( 501 ) calculates the average value of the luminance levels sent from the AV_DECODER ( 102 ), and gives the calculated average value to the CPU ( 105 ). The CPU ( 105 ) judges whether or not the average value of the luminances which is given from the luminance detection device ( 501 ) is lower than a predetermined value (whether or not it is close to the luminance level of the side panel). In a case where it is judged that the average value of the luminances is lower than the predetermined value, even if the side panel is moved, the movement is inconspicuous. Therefore, such an instruction signal as to move the display position of the side panel is outputted to the AV_DECODER ( 102 ). The AV_DECODER ( 102 ) which has received the instruction signal outputs to the NTSC encoder ( 103 ) the digital video signal in a state where the position of the displayed side panel is slightly shifted, and the NTSC encoder ( 103 ) which has received the digital video signal outputs the video and reflects the video on the TV set.
FIG. 11 shows the procedure for processing for controlling the display position of the side panel.
While a user is watching TV (step S 1101 ), it is judged whether or not the display of a program which is being currently viewed is full screen display (the aspect ratio of a video is 9:16) (step S 1102 ).
When the display of the program which is being currently viewed is full screen display, that is, when no side panels are displayed, the subsequent frame is displayed as it is (step S 1106 ). The procedure is returned to the step S 1101 .
On the other hand, when the display of the program which is being currently viewed is not full screen display (NO in step S 1102 ), that is, the aspect ratio of the video is 3:4, and side panels are displayed, the average value of luminances in left and right side edges of a television program video currently displayed is calculated by the luminance detection circuit ( 501 ), and is sent to the CPU ( 105 ) (step S 1103 ).
The CPU ( 105 ) judges whether or not the average value of the luminances is a value close to the black level (lower than a predetermined value) (step S 1104 ). When the average value of the luminances is not the value close to the black level (NO in step S 1104 ), the subsequent frame is displayed as it is (step S 1106 ). The procedure is returned to the step S 1101 .
When it is judged that the average value of the luminances is the value close to the black level, that is, the respective boundaries between the left and right side edges of the television program video and the side panels are indistinct, the display position of the side panel is moved by one pixel in accordance with the flow chart of FIG. 7 (step S 1105 ), and the subsequent frame is then displayed (step S 1106 ). The procedure is returned to the step S 1101 .
[3] Description of Third Embodiment
FIG. 12 illustrates the configuration of a television receiver according to a third embodiment. In FIG. 12 , the same units as those shown in FIG. 2 are assigned same reference numerals.
The television receiver according to the third embodiment is provided with a difference detection circuit ( 701 ) for detecting that a scene change occurs.
Broadcasting radio waves are inputted to a digital TUNER ( 101 ), and a TS is outputted to an AV_DECODER ( 102 ) from the digital TUNER ( 101 ). The AV_DECODER ( 102 ) which has received the TS outputs a digital video signal to an NTSC encoder ( 103 ). The NTSC encoder ( 103 ) which has received the digital video signal outputs a video.
[3-1] Description of Case where there is Provided Liquid Crystal Panel Having Aspect Ratio of 3:4, and Letter Boxes are Displayed when Video Having Aspect Ratio of 9:16 is Displayed
When a program on which letter boxes are displayed is presented, the digital video signal outputted from the AV_DECODER ( 102 ) is fed to the difference detection circuit ( 701 ), and is outputted to the NTSC encoder ( 103 ) through the difference detection circuit ( 701 ).
The difference detection circuit ( 701 ) calculates the difference between the accumulated value (or the average value) of luminances in pixel units of a video in the preceding frame and the accumulated value (or the average value) of luminances in pixel units of a video in the current frame, and sends the difference to the CPU ( 105 ).
The CPU ( 105 ) judges whether or not the difference between the accumulated values (or the average values) of the luminances in pixel units which is sent from the difference detection circuit ( 701 ) is more than a predetermined threshold value. When the difference between the accumulated values (or the average values) of the luminances in pixel units is more than the threshold value, it is judged that a scene change occurs. Therefore, such an instruction signal as to move the display position of the letter box is outputted to the AV_DECODER ( 102 ). The AV_DECODER ( 102 ) which has received the instruction signal outputs to the NTSC encoder ( 103 ) the digital video signal in a state where the position of the displayed letter box is slightly shifted, and the NTSC encoder ( 103 ) which has received the digital video signal outputs the video and reflects the video on a TV set.
FIG. 13 shows the procedure for processing for controlling the display position of the letter box.
While a user is watching TV (step S 1301 ), it is judged whether or not the display of a program which is being currently viewed is full screen display (the aspect ratio of a video is 3:4) (step S 1302 ).
When the display of the program which is being currently viewed is full screen display, that is, when no letter boxes are displayed, the subsequent frame is displayed as it is (step S 1306 ). The procedure is returned to the step S 1001 .
On the other hand, when the display of the program which is being currently viewed is not full screen display (NO in step S 1302 ), that is, the aspect ratio of the video is 9:16, and letter boxes are displayed, the difference between the accumulated value of the luminances in pixel units in the preceding frame and the accumulated value of the luminances in pixel units in the current frame is calculated by the difference detection circuit ( 701 ), and is sent to the CPU ( 105 ) (step S 1303 ).
The CPU ( 105 ) judges whether or not the difference between the accumulated values of the luminances in pixel units which is calculated by the difference detection circuit ( 701 ) is more than a predetermined threshold value (step S 1304 ). Although judgment how the threshold value is determined is set at the time of shipping from a factory depending on the sensitivity of a designer, a value is basically set such that a case where the contents of an image are greatly changed in frame units, for example, a case where a scene change occurs can be detected.
When the difference between the accumulated values of the luminances in pixel units is less than the threshold value (NO in step S 1304 ), the subsequent frame is displayed as it is (step S 1306 ). The procedure is returned to the step S 1301 .
When it is judged that the difference between the accumulated values of the luminances in pixel units is more than the threshold value, the display position of the letter box is moved by one pixel in accordance with the flow chart of FIG. 4 (step S 1305 ), and the subsequent frame is then displayed (step S 1306 ). The procedure is returned to the step S 1301 .
[3-2] Description of Case where there is Provided Liquid Crystal Panel Having Aspect Ratio of 9:16, and Side Panels are Displayed when Video Having Aspect Ratio of 3:4 is Displayed
When a program on which side panels are displayed is presented, the digital video signal outputted from the AV_DECODER ( 102 ) is fed to the difference detection circuit ( 701 ), and is outputted to the NTSC encoder ( 103 ) through the difference detection circuit ( 701 ).
The difference detection circuit ( 701 ) calculates the difference between the accumulated value (or the average value) of luminances in pixel units of a video in the preceding frame and the accumulated value (or the average value) of luminances in pixel units of a video in the current frame, and sends the difference to the CPU ( 105 ).
The CPU ( 105 ) judges whether or not the difference between the accumulated values (or the average values) of the luminances in pixel units which is sent from the difference detection circuit ( 701 ) is more than a predetermined threshold value. When it is judged that the difference between the accumulated values (or the average values) of the luminances in pixel units is more than the threshold value, it is judged that a scene change occurs. Therefore, such an instruction signal as to move the display position of the side panel is outputted to the AV_DECODER ( 102 ). The AV_DECODER ( 102 ) which has received the instruction signal outputs to the NTSC encoder ( 103 ) the digital video signal in a state where the position of the displayed side panel is slightly shifted, and the NTSC encoder ( 103 ) which has received the digital video signal outputs the video and reflects the video on the TV set.
FIG. 14 shows the procedure for processing for controlling the display position of the side panel.
While a user is watching TV (step S 1401 ), it is judged whether or not the display of a program which is being currently viewed is full screen display (the aspect ratio of a video is 9:16) (step S 1402 ).
When the display of the program which is being currently viewed is full screen display, that is, when no side panels are displayed, the subsequent frame is displayed as it is (step S 1406 ). The procedure is returned to the step S 1401 .
On the other hand, when the display of the program which is being currently viewed is not full screen display (NO in step S 1402 ), that is, the aspect ratio of the video is 3:4, and side panels are displayed, the difference between the accumulated value of the luminances in pixel units in the preceding frame and the accumulated value of the luminances in pixel units in the current frame is calculated by the difference detection circuit ( 701 ), and is sent to the CPU ( 105 ) (step S 1403 ).
The CPU ( 105 ) judges whether or not the difference between the accumulated values of the luminances in pixel units which is calculated by the difference detection circuit ( 701 ) is more than a predetermined threshold value (step S 1404 ). Although judgment as to how the threshold value is determined is set at the time of shipping from a factory depending on the sensitivity of a designer, a value is basically set such that a case where the contents of an image are greatly changed in frame units, for example, a case where a scene change occurs can be detected.
When the difference between the accumulated values of the luminances in pixel units is less than the threshold value (NO in step S 1404 ), the subsequent frame is displayed as it is (step S 1406 ). The procedure is returned to the step S 1401 .
When it is judged that the difference between the accumulated values of the luminances in pixel units is more than the threshold value, the display position of the side panel is moved by one pixel in accordance with the flow chart of FIG. 7 (step S 1405 ), and the subsequent frame is then displayed (step S 1406 ). The procedure is returned to the step S 1401 .
Although in the above-mentioned first to third embodiments, an example in which an image based on an NTSC system is displayed is illustrated, the present invention is not limited to the image based on an NTSC system. Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims.
|
A television receiver having the function of displaying a plurality of types of television program videos which differ in the aspect ratio comprises means for judging, when channels are switched, whether or not a letter box is displayed on the previous channel and is also displayed on the new channel, and means for moving, when it is judged that the letter box is displayed on the previous channel and is also displayed on the new channel, the position of the letter box displayed on the new channel from the position of the letter box displayed on the previous channel.
| 7
|
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus and a method for separating particles from hot gases.
The present invention particularly relates to a centrifugal separator assembly, which may be connected to a reactor, such as a combustor or gasifier, for separating solid particles discharged with flue gases from its reactor chamber. The peripheral walls of the centrifugal separator's vortex chamber delimit an interior gas volume with at least one gas vortex therein. A first wall portion of the peripheral walls includes an inlet for introducing the flue gases and solid particles entrained therein into the vortex chamber. The vortex chamber further includes at least one gas outlet, for discharging purified gas therefrom, and at least one particles outlet, for discharging separated solid particles therefrom.
The present invention more particularly relates to centrifugal separator assemblies, which are suitable for separating solid particles from process or product gases in fluidized bex reactors, such as circulating fluidized bed reactors used for combustion or gasification of carbonaceous or other fuels.
Conventional centrifugal separators have cyclones delimited by cylindrical peripheral walls and a conical bottom. It has, however, recently been noticed that centrifugal separators can advantageously be made also of planar wall panels, the vortex chamber formed thereby having a non-circular horizontal cross section. U.S. Pat. No. 5,281,398 discloses this kind of a centrifugal separator, according to which particles entrained in hot gases are separated in a vortex chamber delimited by a plurality of substantially planar plates or panels, the vortex chamber having a polygonal, preferably quadrate, horizontal cross section. Such a separator has numerous especially cost saving advantages over conventional centrifugal separators, it is particularly easy to construct, even if made of water tube panels, and it may easily be integrated with reactor furnaces made of similar wall panels, thereby providing a compact overall design. Gas is introduced into the non-circular vortex chamber, through a gas inlet in the side wall thereof, so as to guide the gas as tangentially as possible into the gas vortex formed within the vortex chamber, in order to maximize the swirling or spinning of the gas in the gas vortex.
The advantages of introducing gas tangentially into the vortex chamber is well-known, also in conventional cylindrical cyclones. This advantage has also been noticed in U.S. Pat. No. 5,070,822 suggesting a centrifugal separator having its vortex chamber centrally located within the upper most part of a cylindrical furnace. The centrifugal separator comprises a plurality of wing-like elements arranged one after the other on the upper periphery of the vortex chamber. A plurality of spaced gas inlets is thus formed between the wing-like elements along the entire periphery of the vortex chamber. The wing-like elements, which may be made of a ceramic material, are directed so as to guide the plurality of gas flows through the inlets tangentially into a vortex formed centrally within the vortex chamber.
In a centrifugal separator with planar walls, as disclosed in earlier mentioned U.S. Pat. No. 5,281,398, the inlet to the separator is a vertical slot located so as to lead the gas flow and the solid particles therein as tangentially as possible towards the vertical gas vortex formed within the vortex chamber. A simple opening in a side wall of the vortex chamber does, however, have a rather poor guiding effect on the gas and solid particles flowing into the vortex chamber. A considerable portion of the gas and solid particles introduced through the opening immediately deviates from the intended tangential direction and meets the gas vortex at an angle substantially greater than zero. This to some extent decreases the swirling velocity of the gas vortex and lowers the separation efficiency of the system. Some of the solid particles may also, if not directed correctly, hit the walls of the vortex chamber at an unfavorable angle, thereby causing heavy erosion.
It has been suggested to insert vertical guide plates around the inlet opening in order to increase the horizontal directionality of the gas and solid particle stream, in order to force the gas and solid particles to flow into the vortex chamber in the intended direction. The guide plates form an inlet duct which has to be rather long, in order for the duct to have a real impact on the direction of movement of the gas and solid particle stream introduced into the vortex chamber.
The long guide plates or guiding walls are located within the vortex chamber for achieving the desired effect. Such inserts within a vortex chamber have, however, to be very well supported, insulated and protected in order to endure in the hot surroundings. Large extra constructions are heavy and have to be well supported and they also have to be connected firmly so as not to vibrate and decrease strength of the overall construction. To insert large elements, as suggested, into the vortex chamber goes against the general trend in the manufacturing of particle separators, which is to avoid the addition of any extra elements, which take space, have to be supported and protected. There is a need to make an as simple, straightforward and self-supporting construction as possible.
Further, it has been noticed in non-circular centrifugal separators, closely integrated with the reactor furnace, i.e., being connected by a common wall thereto, and having elements therein forming two or more gas vortices within the vortex chamber, that the strength of the common wall between the separator and the reactor furnace, especially the strength to withstand pressure differences between the furnace and the separator, is an important factor. The common wall tends to vibrate unless supported. It has, therefore, been suggested to dispose in the vortex chamber a partition or supporting wall, extending from the common wall to the opposite wall between two gas vortices, in order to increase the strength and suppress vibration. Such a supporting wall, however, also constitutes a rather large extra element within the vortex chamber, which preferably should be avoided.
Non-circular vortex chambers and reactor furnaces may also be built non-integrated, i.e., without a common wall, and mechanically connected to each other only through a distinct inlet duct. This prevents the pressure difference between the reactor chamber and the vortex chamber from directly having an impact on a wall in the vortex chamber. An inlet duct, if long enough, may further have a positive impact on directionality, i.e., it may help to lead the gas and solid particles tangentially into the gas vortex within the vortex chamber. The non-integrated construction requires, however, a lot of space and gives rise to a considerable increase in the costs.
There is obviously a need for new solutions, particularly in centrifugal separators with planar walls, to improve the directionality or orientation of the stream of gas and particles entering a centrifugal separator, i.e., to introduce the stream of gas and particles into the vortex chamber of the centrifugal separator without the stream being immediately spread or scattered, or without causing turbulence in the stream. The desire is to keep together the stream. This should, however, be done with inserts having a limited length, i.e., inserts which do not protrude so deep into the vortex chamber that they have a negative impact on the gas vortex therein. Such new solutions should preferably also be cost effective and able to improve the strength of the structure without requiring additional space in the vortex chamber.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an improved centrifugal separator assembly and method of separating particles from hot gases.
It is a primary object of the present invention to provide an improved centrifugal separator with gas flow guiding means at the inlet for improving the swirling action of gas, within the vortex chamber.
It is thereby more particularly an object of the present invention to provide an improved centrifugal separator with guiding means of a limited length for providing an improved directionality of the gas and particle stream entering the separator.
It is also an object of the present invention to provide a modified centrifugal separator design with improved strength of the centrifugal separator structure.
It has now been noticed that the horizontal directionality of the stream of gas and solid particles being introduced into a vortex chamber may be increased not only by providing a long inlet duct, but by providing instead of one single inlet duct, two or more narrower and shorter inlet ducts within a certain sector of the vortex. The mere narrowing of one inlet duct increases—at a certain circulation rate—the forces and energy losses due to the increased pressure difference between the furnace and the cyclone. But by providing several narrow inlet ducts, the same open area may be maintained and an increase in pressure difference may be avoided. When utilizing several narrow inlet ducts instead of one single inlet duct, their length may be made correspondingly shorter, while still maintaining the same effect in orientation of the gas stream. Thus, it may be avoided that the inlet ducts have to be made longer than a so-called critical length l critical and penetrate so deep into the vortex chamber that they have an impact on the swirling vortex. The construction may also otherwise be simplified and made less heavy and costly.
Therefore, in order to fulfill the above and other objects, a centrifugal separator assembly connected to a reactor, such as a fluidized bed reactor, comprises according to the preferred embodiment of the present invention besides peripheral walls defining a vortex chamber and at least one gas outlet and at least one solid particles outlet,
at least two inlet ducts arranged side by side in a wall, connecting the vortex chamber with the reactor, within a less than 90° sector of each of the at least one gas vortices formed within the vortex chamber.
The inlet ducts preferably have a length to width ratio l/w>0.8, the length l being the length of the inlet duct in the gas flow direction and the width w being the mean horizontal cross-sectional width of the inlet duct. The length to width ratio may in some exceptional cases be <0.8, particularly if the critical length of the inlet duct is very short. Also, the geometries of the inlet and outlet openings of the inlet ducts have an impact on the length to width ratio. The inlet and outlet openings may be chamfered if desired.
In a centrifugal separator, the two or more inlet ducts typically have identical widths, but may if desired have different widths. The width of single inlet ducts may also vary along their length. The inlet ducts may, e.g., be funnel-shaped, increasing or decreasing in the flow direction. The horizontal axes of the two or more separate inlet ducts may be parallel with each other or form an angle, preferably less than 30°, with each other.
The inlet ducts typically are vertical slots having parallel vertical side walls, the height h of a slot being at least twice, typically five times, the mean horizontal cross-sectional width of the slot.
The two or more inlet ducts may easily be formed according to the invention in an opening, prefabricated in a vortex chamber wall, by dividing the prefabricated opening with one or more vertical partition walls. Alternatively, inlet ducts may be prefabricated by casting in a prefabricated wall portion made of a castable material.
The present invention is particularly well suited to be applied in vortex chambers having cooled peripheral walls made of water or steam tubes forming a tube system, if desired connected to the main water/steam system of the reactor. In cooled walls, the tubes are mechanically connected side by side preferably by fins and in a vertical position. The one or more partition walls dividing the opening, for providing two or more inlet ducts according to the invention, may preferably be made of vertical tubes as well, the vertical tubes forming within the opening a partition wall perpendicular to the main plane of the peripheral wall. The tubes forming the partition wall are preferably connected to the tube system of the peripheral walls.
The one or more partition walls, dividing the opening into two or more inlet ducts, form a delimiting wall in each of two adjacent inlet ducts. The outermost delimiting wall of the inlet ducts, i.e., of the inlet ducts located adjacent to the vertical sides of the opening, may on the other hand be formed of tubes bent out of the main plane of the peripheral wall, when forming the opening.
The length of the inlet ducts, formed of partition walls or other inlet duct delimiting walls, should typically be greater than the thickness of the peripheral wall of the vortex chamber. Thereby, the one or more partition walls and/or the other delimiting walls used to form the inlet ducts protrude from the plane of the peripheral wall, preferably into the vortex chamber, but could protrude in the other direction if desired. The delimiting walls are typically formed of tube panels made of greater than three, preferably, greater than five tubes, mechanically connected side by side by fins.
The vortex chamber is according to a preferred embodiment of the present invention made of mainly planar peripheral walls and has a rectangular or square horizontal cross section, the peripheral walls of the vortex chamber comprising
a common wall portion between the vortex chamber and the reactor chamber, said common wall portion including the first wall portion,
first and second side walls, perpendicular to the common wall portion and
a third side wall opposite to the common wall portion and parallel to the common wall portion, and
the peripheral walls being formed of vertical tubes connected side by side, preferably by fins, and forming a peripheral wall tube system.
In an embodiment in which the vortex chamber has a square cross section, the gas outlet is disposed mainly in the middle of the top portion of the vortex chamber, and the inlet ducts are formed in an opening in the common wall portion adjacent to the first side wall. If desired, the inlet ducts may be located at the end of the common wall adjacent to the first side wall and perpendicular to the common wall. Then, a portion of the first side wall of the vortex chamber may form a side wall in one of the inlet ducts.
The vortex chamber has according to a most preferred embodiment of the present invention a rectangular cross section. Two gas outlets are then disposed one after the other in the longitudinal direction in the top portion of the vortex chamber, for providing two gas vortices within the gas volume in the vortex chamber. Inlet ducts are formed in an opening in the common wall portion between the two adjacent vortices. The inlet ducts are preferably formed in the common wall equidistant from the two vortices, for introducing gas into both of the two adjacent vortices. The delimiting walls of the inlet ducts are formed of
one partition wall, disposed perpendicular to the main plane of the common wall portion, and of
vertical tubes bent out of the plane of the common wall portion forming the outermost side walls in the inlet ducts.
The partition wall is formed of greater than three, preferably greater than five, vertical tubes mechanically connected side by side in a row. The tube construction of the partition wall is preferably covered by a layer of protecting refractory material, the thickness of the layer being chosen according to need. The refractory material may be shaped, e.g., streamlined, to provide advantageous flow properties in the inlet ducts and at their inlets and outlets.
The partition wall structure is especially useful in rectangular vortex chambers when it is constructed so that it also increases the strength of the common wall between a furnace and a centrifugal separator. The partition wall, dividing the opening, is typically mechanically connected to the common wall portion above and below the opening. A prolongation of the partition wall may additionally be mechanically connected to the lower part of a third side wall, opposite to the common side wall, of the vortex chamber, in order to increase the support of the common wall. The prolongation may on the other had alternatively or additionally be connected to supporting structures of the reactor chamber or the vortex chamber.
If desired, the first wall portion connecting the vortex chamber with the reactor chamber, may be made of a mainly homogeneous castable material. Then, the inlet ducts may be formed by casting.
These inlet ducts, which are formed by casting, may also have a length to width ratio l/w>0.8, as inlet ducts made in tube walls. The inlet ducts usually are parallel with each other and perpendicular to the main plane of the wall. The inlet ducts may, however, in some cases be made so as to form an angle less than 90° with the main plane of the wall. Then, also two single inlet ducts may be disposed to form an angle with each other, e.g., an angle of about 5° to 60°.
The present invention, as described above, provides an improved centrifugal separator with gas flow guiding means at the inlet thereof for improving the swirling action of gas within the vortex chamber. The improved swirling action is achieved with relatively short inlet ducts, which act as non-spreading nozzles. The nozzles form controlled pre-oriented gas jets, which introduce the gas in a desired direction and into a desired location within a limited space of the vortex chamber. The present invention thereby particularly provides a centrifugal separator in which the optimization of the directionality of gas and particles entering the separator is accomplished with a construction in which disturbance on the swirling action of the vortex is minimized.
Additionally, the present invention provides means for improving the strength of the centrifugal separator structure. The present invention particularly provides means for increasing the strength of the common side wall between the vortex chamber and the reactor.
BRIEF DESCRIPTION OF THE DRAWINGS
The above description, as well as further objects, features and advantages of the present invention will become more apparent from the following detailed description of the presently preferred, but nonetheless illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic side view, partly sectional and partly elevated, of a circulating fluidized bed reactor with a centrifugal separator according to the present invention;
FIG. 2 is a cross-sectional view of the upper part of the centrifugal separator of FIG. 1 taken along line A—A thereof;
FIG. 3 is a cross-sectional view of the separator of FIG. 2 taken along lines B—B thereof; and
FIGS. 4-6 are views like that of FIG. 3 for alternative embodiments of centrifugal separators according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a circulating fluidized bed reactor comprising a reactor chamber 10 , a centrifugal particle separator (cyclone) 12 and a return duct 14 for returning separated particles back to the chamber 10 . The cross section of the reactor chamber 10 is rectangular, as can be taken from FIG. 3 . The reactor chamber 10 is made of water tube walls, only long walls 16 and 18 of which are shown in FIG. 1 . The water tube walls are formed of vertical water tubes connected by fins in a manner known per se, e.g., as so-called membrane wall panels.
The upper part of wall 18 is bent to form a ceiling 20 of the reactor chamber 10 . The walls in the lowermost section of the reactor chamber 10 are protected with refractory 22 . One inlet 23 only, for solid material such as fuel, is shown, although there may be several different inlets. The bottom of reactor chamber 10 is formed of a distribution plate 24 , which is equipped with nozzles or openings 26 for introducing fluidizing gas from an air plenum chamber 28 into reactor chamber 10 for maintaining a fluidized bed of solid particles therein. Fluidizing gas, e.g., air, is introduced into the reactor chamber 10 at such a high rate that it causes a substantial portion of the bed material to continuously flow together with the gas through the upper section of chamber 10 and through an inlet opening (e.g., slot) 30 disposed in the upper section of chamber 10 into particle separator 12 .
The particle separator 12 is a multivortex centrifugal separator with a vortex chamber 12 with a gas volume having two parallel, vertical gas vortices formed therein, for separating particles from gas introduced from the reactor chamber 10 into the vortex chamber. The vortex chamber 12 defining the separator comprises planar, as can be seen in FIG. 3, primarily rectangular water tube side walls 32 , 34 , 36 and 38 . These side walls 32 , 34 , 36 , 38 are also made of joined, vertical water tubes 37 mechanically connected to each other by fins 39 (as shown in an elevated detail in FIG. 2 ). The vortex chamber 12 has according to FIG. 1 one long wall 32 in common with reactor chamber 10 , i.e., a part of the wall 16 of reactor chamber 10 constitutes wall 32 of the vortex chamber. In some cases, distinct walls for both reactor chamber 10 and vortex chamber 12 may be used.
The upper parts of the side walls 32 , 34 , 36 , 38 in the vortex chamber defining the gas volume are preferably vertical and planar and form an upper section 43 . The lower part of the long wall 36 , opposite to the common side wall 32 , is bent towards the common wall for forming a funnel-shaped lower section 45 of the vortex chamber. By this structure, an asymmetric, long, slightly funnel-shaped gas volume 44 (see FIG. 1) is formed, the bottom part thereof forming a solids outlet 46 .
Solids outlet 46 serves as an inlet into return duct 14 . The long side walls of the return duct are formed by downward extensions of walls 32 and 36 of the particle separator 12 . The end walls of the return duct 14 are correspondingly formed by downward extensions of the side walls 34 and 38 . Only a portion of the ends walls 34 and 38 , having a width of return duct 14 , continues downwardly, thereby forming a return duct. The lower part of return duct 14 is in communication with the lower section of the reaction chamber 10 via an L-bend 48 for returning solids separated in separator 12 into the bottom of the reactor chamber 10 ; other types of solid flow seals may alternatively be used.
In the upper section 43 of the vortex chamber, two successive gas outlet ducts 54 and 56 , for the discharge of purified gas from the gas space of the vortex chamber 12 are disposed in openings 50 and 52 , as shown in FIGS. 2 and 3. The gas outlet ducts 54 , 56 in separator 12 may be made of heat resistant steel, be cooled or be made of ceramic material, in order to resist hot conditions in separator 12 . The purified gases may be discharged in a manner known per se from the separator 12 through duct 60 , passing heat recovery surfaces 62 , and a convection section.
The side walls 32 , 34 , 36 , 38 of the vortex chamber may be protected by a thin layer of heat and abrasion resistant refractory material, not shown in the drawings.
The inlet opening 30 , formed in a first wall portion 32 ′ in the common wall 32 , is divided by a partition wall 70 to form two inlet ducts 30 ′, 30 ″, and is located within a 90° sector β of both gas vortices formed below gas outlets 54 and 56 . The opening 30 is formed at the same distance from both vortices, between the vortices, approximately in the middle of the common wall 32 between chamber 10 and chamber 12 .
At the vertical sides of the inlet opening 30 , water tubes 37 ′ of the water tube wall 32 are bent into the vortex chamber, as best seen in FIG. 3, so that the inlet delimiting vertical side walls 40 , protruding into the vortex chamber, are formed. The side walls 40 are typically perpendicular to the main plane of wall 32 , but could be inclined to form an angle greater than 60° with the main plane of wall 32 . The side walls may be inclined so as to decrease the width of the inlet duct or so as to widen the inlet duct. A vertical partition wall 70 , made of tubes 37 ″, is disposed at the center of the slot-like opening 30 , the partition wall dividing the opening in two similar inlet ducts 30 ′ and 30 ″. The partition wall is slightly longer than the side walls in the horizontal direction. The partition wall 70 and the walls 40 form the vertical delimiting walls for the two inlet ducts 30 ′ and 30 ″ formed in the opening.
The tubes 37 ″ of the partition wall 70 are mechanically connected to wall 32 above and below the inlet ducts 30 ′ and 30 ″ and extend up to a header 74 at ceiling 62 of separator 12 and down to a header 72 below the lower part 45 of separator 12 , as shown in FIGS. 1 and 2. The upper part of tubes 37 ″ may if desired reach through duct 60 and be connected to a header arranged above or on the external side of the duct. At their lower part, the tubes 37 ″ of partition wall 70 are bent out from the wall 32 and through the outer wall 17 of return duct 14 , as shown in FIG. 1, and connected to a separate external header 72 . If desired, the lower part of the tubes 37 ″ may be bent out from the wall 32 already at a higher level than shown in FIG. 1, and may be made to protrude through the lower part of separator wall 36 , thereby providing a stiffening mechanical connection between opposite walls 32 , 36 in the separator. It may, on the other hand, not be necessary to bend the lower part of the tubes 37 ″ at all if the tubes are connected at their lower part to a header located within or in connection with the return duct 14 . Headers 74 and 72 may be supported (not shown in the drawings) so that the tubes 37 ″ increase the strength of wall 32 and increase its ability to bear the pressure difference between furnace 10 and separator 12 .
The inlet ducts delimiting walls 40 and the partition wall 70 define a width “w” of each of the two inlet ducts 30 ′ and 30 ″ formed in the opening 30 . Delimiting sidewalls 40 and partition wall 70 extend inwardly from the common wall 32 between the reactor chamber 10 and the vortex chamber 12 into the vortex chamber a distance “l” which defines the length of the inlet ducts in the flow direction, e.g., a path length of the stream of gas and particles within slot 30 ′ or 30 ″. The ratio of inlet duct length to width l/w gives an indication of the horizontal directionality of the gas and solid particle stream flowing through the inlet duct. The larger the ratio the better the directionality. The ratio l/w is preferably greater than 0.8. At an inlet having two inlet ducts, the ratio may be about one, but may be even greater than one.
The partition walls are in most cases preferably made as thin as possible in order to keep the total width w tot , i.e., the width of the first wall portion with the inlet ducts, as small as possible, in order to allow for the use of as long of inlet ducts as possible without the incoming gas stream interfering with the swirling motion of the gas vortex within the vortex chamber. The critical length of the inlet ducts, i.e., maximum length, of inlet ducts not interfering with the vortex, decreases as the shortest distance between the inlet end of the inlet duct and the vortex decreases. Therefore, inlet ducts should be located in the common wall portion as far away from the vortex as possible. This can be done by squeezing the inlet ducts into an as small a space as possible, i.e., by utilizing as thin of partition walls as possible.
In the embodiment shown in FIGS. 1-3, the directionality can be still improved by increasing the length l of walls 40 and 70 , or by increasing the thickness of the refractory layer on wall 40 and/or wall 70 and thus, decreasing the width w of the inlet ducts. The total open area must, however, be maintained.
If desired, e.g., in order to provide more open area without having to increase the length of the inlet ducts, more than two inlet ducts may be formed. Then, two or more partition walls are used to divide the opening. Typically, the partition walls 70 and the delimiting side walls 40 are of different horizontal lengths, the partition wall being longer in the horizontal direction than the side walls. The walls could, of course, if desired, be of the same length, and the partition wall could even be shorter than the side walls. The partition wall 70 is usually made longer than the side walls in order to still increase its strengthening effect on the common wall 32 .
At the external sides of the delimiting side walls 40 , guiding means are provided, as generally shown by a reference number 33 . The guiding means guide a gas vortex between the common wall 32 and sidewalls 40 so that the flow direction of particles separated from gas in the gas vortex is smoothly changed from generally along the interior of the first wall 32 to substantially perpendicular to the first wall 32 at the gas inlet 30 (i.e., substantially tangential to the gas vortex in the gas volume and along the stream introduced at slot 30 ).
Instead of using the concept depicted in FIGS. 1-3, it may sometimes be preferable to use a double-vortex separator with two inlet openings, as shown in FIG. 4 or a one single vortex separator as shown in FIGS. 5 and 6.
In the embodiment depicted in FIG. 4, there are two inlet openings 30 in the separator. The openings are made in the ends of common wall 32 next to side walls 34 and 38 , the side walls forming delimiting walls for the outermost inlet ducts 30 ″. The partition walls 70 and 70 ′ are disposed very close to walls 34 and 38 and do not essentially increase the strength of wall 32 . Thus, the supporting of the upper and lower ends of the partition walls 70 and 70 ′ is not as critical a factor as may be in the embodiment illustrated in FIGS. 1-3. Each of the two openings 30 , each including two inlet ducts, is located in a 90° sector of one of the vortices, i.e., in a 90° sector of that particular vortex being closer to the inlet.
FIG. 5 shows a further alternative embodiment of the present invention. Three inlet ducts are formed in an inlet opening in a separator having a square horizontal cross section. A single vortex is formed in the vortex chamber. This embodiment illustrates the use of more than one partition wall 70 to provide more than two inlet ducts. Otherwise, this embodiment corresponds to that in FIG. 4 .
FIG. 6 illustrates yet another embodiment of the present invention, wherein a single vortex is formed and the inlet ducts are constructed from slip casting mass. The advantage of using the casting technique is that it makes it possible to easily and with great accuracy form up to three to eight inlet ducts, even ducts of different forms and being disposed at different angles. The inlet ducts are all formed within a 90° sector of the vortex formed in the vortex chamber.
In the embodiment shown in FIG. 6, the first inlet duct 80 closest to the first side wall 34 is parallel with that side wall 34 and perpendicular to the side wall 32 connected to the reactor chamber. The next inlet duct 80 ′ is not parallel with wall 34 but slightly inclined so as to guide the gas and solid particle flow therethrough toward the wall 34 . Next inlet duct 80 ″, further away from the side wall 34 is even more inclined and the last inlet duct 80 ′″, most distant from side wall 34 is most inclined. The different inlet ducts introduce gas and solid particle jets tangentially toward the vortex formed in the vortex chamber, the jets, however, touching the vortex tangentially at different locations of the less than 90° sector. Thus, the different jets enhance the swirling motion of the vortex. The jets are formed so as to interact with vortex 66 as smoothly as possible.
The present invention provides an effective centrifugal separator and method of centrifugally separating particles particularly in polygonal multivortex separators, but can also be used to enhance swirling motion in cylindrical centrifugal separators. The present invention minimizes many of the drawbacks of prior art separators. The present invention particularly sets out to decrease the negative impact introduction of the gas and solid particle stream may have on the separation efficiency of the vortex. The swirling motion of the vortex may be improved with less space consuming inlet ducts than what has been suggested earlier. The present invention simultaneously provides an improvement to the construction of the centrifugal separator, the guiding elements not having to protrude very deep into the vortex chamber and the guiding elements (inlet duct considerations) adding to the strength and rigidity of the vortex chamber.
While the invention has been shown herein and described in what is presently believed to be the most practical, preferred embodiment thereof, it will be apparent to those of ordinary skill in the art that many modifications may be made thereof within the scope of the invention, which scope is to be interpreted broadly so as to encompass all equivalent structure and methods.
|
An apparatus that includes (i) a centrifugal separator assembly and (ii) a fluidized bed reactor having a reactor chamber, the separator assembly being connected to the reactor and provided for separating solid particles from gas discharged from the reactor chamber. The apparatus includes planar peripheral walls defining a vortex chamber, having a rectangular cross section, the vortex chamber having an interior gas volume in which at least two vertical gas vortices can be formed, and the planar peripheral walls including a first wall portion connecting the separator assembly to the reactor chamber, at least two gas outlets, disposed one after the other in the longitudinal direction of the vortex chamber, for discharging cleaned gas from the gas volume, at least one solid particles outlet for discharging separated solid particles from the gas volume, and at least one gas inlet, arranged in the first wall portion, for introducing gas from the reactor chamber into the gas volume. The at least one gas inlet includes at least two inlet ducts which are mainly perpendicular to the first wall portion and arranged side-by-side in the first wall portion within a less than ninety degree sector of one gas vortex within the vortex chamber.
| 1
|
RELATED APPLICATION
[0001] This is a continuation-in-part application of International patent application PCT/DE 00/03730, filed Oct. 20, 2000 and claiming priority of German patent application 199 50 869.0, filed Oct. 22, 1999.
DESCRIPTION
[0002] The invention relates to a method for measuring geometric characteristics of workpieces on coordinate measuring machines or digitalizing machines by means of measuring apparatus, which supply measurement information as to geometric characteristics of the workpiece relative to the measuring apparatus, which is, in short, often characterized as measuring sensors.
INITIAL COMMENT
[0003] In the following, the abbreviation CMA is used for coordinate measuring machines as well as for digital machines.
STATE OF THE ART
[0004] Today, mostly CMAs are used for detecting three-dimensional geometric variables. These CMAs are mostly equipped with switching probes which, when contacting the surface, generate an electric signal. With this signal, the positions of the individual linear or rotational axes of the CMAs are frozen, that is, the axial positions are copied into an output register. This data is then used in the known kinematic of the CMA, including the probe, to generate a measuring point in a stationary coordinate system. When generating a measuring point, partially more extensive error compensations are carried out, such as probe ball radius correction, geometric or thermal machine position error corrections. The basis for the fault correction and, in part, also for the determination of the kinematics, is mostly a calibration process.
[0005] If several points are sequentially measured in the same fixed coordinate system, the relative position of the measuring points in the spatially fixed coordinate system to each other is a measure for the relative position of the contact points on the workpiece surface. In this way, geometric quantities can be determined on the workpiece.
[0006] To an increasing extent, measuring sensors are preferably used in lieu of switching probes for detecting free-form surfaces. Contacting as well as contactless sensors are used. These sensors determine the position of the measuring point on the workpiece relative to the recording thereof, that is, in a sensor fixed coordinate system, hereinafter known as RST coordinate system. A sequence of measuring points is, as a rule, detected during the movement of the CMA and one speaks of a “scanning” operation.
[0007] For computing a measurement point in a stationary coordinate system, the sensor information in the RST coordinate system must be coupled in time synchronism with the information for the position of the sensor in the stationary coordinate system. In methods known at the present time, this takes place in that the result of the measurement of the sensor in the RST coordinate system is detected in time as close as possible to the result of the sensor position determination by the CMA in the stationary coordinate system in a mostly digital signal processing unit and, thereafter, a measuring point in the stationary coordinate system is computed from these two individual informations.
DISADVANTAGE OF THE KNOWN METHOD AND ADVANTAGE OF THE METHOD ACCORDING TO THE INVENTION
[0008] In the known method, so that the information from the sensor and the CMA originates indeed at the same time point, the times for obtaining the measurement value, the measurement value processing and the measurement value transmission, must have the same magnitude for the sensor and the CMA so that the time synchronous coupling of the results corresponds also to the same measurement time point.
[0009] Otherwise, the information of the sensor would be coupled to a position of the sensor which it did not have at the time point of obtaining the information and this would lead to an incorrect computation of the measuring points with the exception of some special cases.
[0010] There are systems known wherein, for unequal but respectively constant signal running times, a correction is preferably carried out via a delay path of the more rapid information utilizing a ring buffer; these systems, however, are subject to disturbances because the assumption of constant signal running times (especially for optical sensors having complex signal processing) cannot be guaranteed and the signal transmission time up to the point of the signal processing unit (at which both informations are detected simultaneously) is generally not constant. This applies primarily when the signal processing unit used is a complex multitasking operating system such as Windows NT.
[0011] Furthermore, all systems have as a precondition that the measurement data rate of sensor and CMA is the same, that is, a result from the sensor is coupled to a result from the CMA.
[0012] The method of the invention overcomes these disadvantages in that the time point of the measurement is determined by an electrical signal (trigger) for the CMA as well as for the sensor.
[0013] All CMAs, which are designed for operation with a switching probe, permit this function in that the trigger signal is treated like a signal of a switching probe. The sensors usable in accordance with the invention likewise have to exhibit a possibility for synchronization. This can be a trigger input for the exact determination of the measurement time point as well as an output signal (SYNC), which indicates the exact measurement time point. In the first case, a measurement data detection system needs to contain a trigger source in accordance with the method of the invention; in the second case, the sensor itself would function as a trigger source.
[0014] A signal processing unit in accordance with the method of the invention ensures that precisely one measurement result from the sensor and one measurement result from the CMA per trigger is further processed.
[0015] In contrast to known methods, different signal running times no longer have an effect because, in the signal processing unit, the simultaneousness of the measurement is determined by the sequence of the results and no longer by the time point of the detection of the results. Stated otherwise, the n-th result after an initialization of the CMA and the n-th result after an initialization of the sensor originate reliably at the same time point because they were triggered by the same trigger.
[0016] Since especially contactless sensors are essentially more dynamic than the CMA, different measurement data rates of sensor and CMA are purposeful and possible with the method according to the invention, preferably when the ratio of the measurement data rates is a whole number. In this case, for the computation of measurement points, the results of the CMA are interpolated in accordance with known methods so that, after the interpolation, the same amount of information is present from the CMA and from the sensor and can be processed further as with the same measurement data rate.
[0017] In order to make the identification more reliable as to which result belongs to the n-th trigger (for example, to detect possibly occurring signal transmission defects), the sensors as well as the CMA should, in a preferred variation of the method of the invention, in addition to its other informations, transmit a TAN-NR (transaction identifier) which is increased with each trigger and is again reset when a maximum number is exceeded. In this way, for a coupling of the CMA data and the sensor data, synchronism can be checked in a simple manner and synchronization reached.
[0018] In a preferred variation, at least the sensor and preferably also the CMA have a FIFO output memory which ensures that even under not real-time capable operating systems (such as Windows NT), a complete and clear transmission of each individual information per trigger is ensured. Especially with the high data rate, which is possible for contactless sensors, it is thereby prevented that the signal processing unit (because of loading with other tasks) cannot process the signal transmission within the time pregiven by the measurement data rate and therefore individual informations are not even processed further.
[0019] The FIFO output memory, especially in combination with the TAN-NR, permits, on the one hand, a very disturbance-free operation compared to present-day solutions and, on the other hand, it permits the information from sensors or CMA to be transmitted in selectable block sizes for several triggers instead individually per trigger which significantly reduces the load of the signal processing unit because of the data transmission.
[0020] The method according to the invention therefore permits a significant increase of the measurement data rate with a simultaneous increase with respect to disturbance reliability and a reduction of the load of the signal processing unit without a significant increase of complexity of present-day conventional CMAs.
SUPPLEMENTARY DESCRIPTION
[0021] In the following, the present invention will be described in greater detail with respect to the embodiments shown in the figures.
[0022] [0022]FIG. 1 shows a block diagram of a first embodiment of the invention; and,
[0023] [0023]FIG. 2 shows a block diagram of a second embodiment of the invention.
[0024] The measuring system 1 in FIG. 1 includes a coordinate measuring apparatus 2 (CMM), a measuring sensor 3 (measuring probe), a signal processing unit 11 (data processing unit) and an external trigger source 4 . The coordinate measuring apparatus includes its own internal control 5 (CMM-control) and the measuring sensor 3 includes its own internal control 8 (MP-control).
[0025] The measuring sensor 3 is accommodated on the coordinate measuring apparatus 2 in a manner known per se and is rotatable via this apparatus in at least three mutually perpendicular spatial directions as well as about additional rotational axes as required.
[0026] The controls 5 of the coordinate measuring apparatus 2 control the movements of the coordinate measuring apparatus 2 and therewith the positioning and, if required, the orientation of the sensor 3 in space and simultaneously control the generation of measurement values of the coordinate measuring apparatus. In a corresponding manner, the control 8 of the sensor 3 controls possible internal movements or measuring force generators within the sensor 3 as well as the measurement value generation of the sensor.
[0027] The controls ( 5 , 8 ) of the coordinate measuring apparatus and of the sensor are autarch, that is, both controls have their own clock generator and work frequencies whereby also the repetition rates of the measured value generation are determined in each case. Since the sensors usually exhibit a higher dynamic than coordinate measuring apparatus, the clock frequencies of the coordinate measuring apparatus and the sensor 3 are different. They distinguish from each other typically by one order of magnitude. Typical clock frequencies for coordinate measuring apparatus are approximately 100 Hz and typical clock frequencies of sensors 3 are approximately 3 KHz.
[0028] The two controls have respective trigger inputs ( 6 , 7 ) via which the measurement value generation can be triggered; that is, when a specific trigger signal, for example a rising signal flank, is applied, the respective actual adjusting values and measurement values are read out and are read out via data outputs ( 9 , 10 ) to the signal processing unit for further processing. With this further processing, the measurement values of the coordinate measuring apparatus 2 and the measured values of the sensor 3 are coupled to each other. The measured value recordation of the coordinate measuring apparatus as well as of the sensor is triggered by the same trigger signal. For this reason, it is ensured that the measurement value generation takes place simultaneously and, accordingly, measured values, which belong to each other in time, are generated with the coordinate measuring apparatus and with the sensor.
[0029] In the embodiment of FIG. 1, the trigger output lies directly on the trigger input 6 of the coordinate measuring apparatus as well as on the trigger input 7 of the sensor 3 . In this case, the repetition rate of the trigger signal, which is generated by the trigger source 4 , may not be greater than the maximum clock frequency of the coordinate measuring apparatus. It is, however, also possible to switch a frequency multiplier or frequency divider into one of the two signal lines in order to utilize the higher dynamic of the sensor 3 .
[0030] In the embodiment of FIG. 2, the measuring sensor 3 has an internal trigger source 4 whose output signal 17 , on the one hand, triggers the measurement value generation of the sensor 3 via the trigger input 7 of the sensor control 8 and, on the other hand, is applied to the trigger input of the coordinate measuring apparatus 2 via a frequency-multiplier/frequency-divider 12 . The pulse repetition rate of the trigger 4 is adapted to the dynamic of the sensor 3 and the frequency-multiplier/frequency-divider 12 is so matched that the pulse repetition rate of the trigger signal is adapted to the lower repetition rate of the coordinate measuring apparatus. The pulse repetition rate of the trigger signal is, as a rule, too high by one order of magnitude. Additionally, the frequency-multiplier/frequency-divider 12 can generate a constant time delay in order to thereby compensate constant running time differences of the trigger signal.
[0031] The sensor 3 as well as the coordinate measuring apparatus each have, in addition to their own controls ( 5 , 8 ), an identifier generator ( 14 , 19 ). Each of these two identifier generators can be relatively simply configured as high-frequency counters, for example, with a counting rate of 10 MHz. The high-frequency counter counts the incoming trigger signals in each case. To each measured value, which is generated by the coordinate measuring apparatus 2 or by the sensor 3 , the corresponding current count of the counter is then added as identifier whereby later a clear assignment of the measurement values of the coordinate measuring apparatus and of the sensor can be guaranteed with the signal evaluation in the signal processing unit 11 . These measured values correspond to each other and are accordingly triggered simultaneously. The counters can operate cyclically, that is, when reaching the maximum number, the counters again start counting anew from 1.
[0032] The coordinate measuring apparatus 2 as well as the sensor 3 have data stores ( 13 , 15 ) wherein the respective measured values can be intermediately stored supplemented by respective identifiers. The capacity of the data stores ( 13 , 15 ) should be adapted to the corresponding identifier generators ( 14 , 19 ) so that the identifier is clear within each intermediately stored set of measured values, that is, the same identifier is not assigned to two measured values triggered at different time points.
[0033] The data stores ( 13 , 15 ) are preferably configured as FIFO stores. In addition, the coordinate measuring apparatus 2 has a unit 16 with which several measured values of the coordinate measuring apparatus are grouped together to blocks in advance of the data transmission in order to relieve the signal processing unit 11 because the data transmission does not have to take place continuously. Here, it is especially practical to provide in the sensor for a corresponding unit for forming data blocks in advance of the data transmission even though this is not shown in FIG. 2.
[0034] In addition to the already mentioned trigger inputs ( 6 , 7 ), the trigger output 17 of the sensor 3 and the measurement data outputs ( 9 , 10 ), the coordinate measuring apparatus 2 and the sensor 3 include two further outputs ( 18 , 20 ) which, to some extent, trigger the signal transmission. Signals are present at these outputs ( 18 , 20 ), respectively, when sensor measured values are present, that is, when data packages are present ready for the data transmission. The application of these signals indicates to the signal processing unit 11 that a data transmission should take place and this unit then triggers the data transmission.
[0035] The coupling of each measured value with an identifier, which is assigned only to this measured value and which is, in turn, determined by the incoming trigger signals, permits erroneous time allocations to be excluded, which, for example, would otherwise be unavoidable in an overtriggering. If, for example, an additional trigger signal is generated, for example, because of a disturbance source (which trigger signal however does not trigger a measured value generation because it followed the previous trigger signal at too small a time distance), then the identifier, which is generated by this additional trigger signal, is not assigned to a measured value and is correspondingly not stored or transmitted. In a later evaluation in the signal processing unit, a conclusion can be drawn from the missing identifiers that the corresponding measured values are not present and, because of this information, the measured values of the sensor and of the coordinate measuring apparatus, which are triggered simultaneously, can be correctly assigned to each other.
[0036] Of course, the frequency divider ratio of the frequency-multiplier/frequency-divider 12 must be considered in the assignment of the respective measured values based on the identifiers. If the frequency divider ratio is, for example, {fraction (1/10)}, that is, the repetition rate of the trigger pulses arriving at the coordinate measuring apparatus amounts to {fraction (1/10)}th of the repetition rate of the trigger pulses arriving at the sensor 3 , then the measured values of the sensors having the identifiers 1 , 11 , 21 , 31 . . . are to be assigned to the measured values of the coordinate measuring apparatus having the identifiers 1 , 2 , 3 , 4 . . . when each trigger pulse has led to a measured value. If, in contrast, no measured value is transmitted with the identifier 11 , then it follows from this that the corresponding trigger pulse has not led to a measured value and, accordingly, the measured values of the sensors having the identifiers 1 , 12 , 22 , 32 . . . are to be assigned to the measured values of the coordinate measuring apparatus having the identifiers 1 , 2 , 3 , 4 . . . .
[0037] Of course, also other identifiers can be generated and added to measured values in lieu of the previously described counts of the counters.
[0038] If, in lieu of an internal trigger of the sensor, an external trigger is used, then also this external trigger can have an additional counter which assigns a count of a counter to respective ones of the originally generated trigger pulses. With a transmission of these respective counter counts to the signal processing unit, the respective identifiers of the measured values and the external counts of the counter can be checked as to plausibility.
[0039] In lieu of using an internal trigger of the sensor, it is, of course, also possible to provide a trigger output on the coordinate measuring apparatus whose signal output then triggers the measured value recordation of the sensor, if required, after a suitable frequency multiplication.
|
The invention relates to a method for detecting measurement data on coordinate measuring and digitalizing machines. Usually, the position of the machine, e.g. the x-, y-, z-coordinate, has to be linked to a value, e.g. distance value, that is generated by calipers or a sensor for obtaining the space coordinates of a surface point during detection of geometries on a coordinate measuring machine or digitalizing machine. It has to be guaranteed that the information of the coordinate measuring machine and the sensor originate from the same measuring time, whereby said information has to be linked, when a measuring sensor is used for detecting the geometry of an object, e.g. a free forming surface, and when said sensor is moved during detection. When the measuring times of the coordinate measuring machine and the sensor are determined by an electric signal (trigger), the equality thereof can be guaranteed and the influence of signal propagation delays can be excluded. The nth sensor information always corresponds to the nth machine information. Allocation is made easier when each value detected at a measuring time obtains an identifier. In one embodiment, surface points of a free forming surface can be detected during movement of the sensor on the coordinate measuring machine and by means of a measuring sensor. The measuring times are determined by an electric signal that is produced by the sensor and is transmitted to the coordinate measuring machine. Said signal triggers distance measuring of the sensor as well as the output of the current machine position.
| 1
|
This is a continuation of application Ser. No. 08/814,809, filed Mar. 10, 1997 now U.S. Pat. No. 5,926,465 which is a continuation of application Ser. No. 08/268,186, filed Jun. 29, 1994, now U.S. Pat. No. 5,610,906.
BACKGROUND OF THE INVENTION
This invention relates to spread-spectrum communications, and more particularly, to a method and system for handing off a base station among a plurality of users in a spread-spectrum network.
DESCRIPTION OF THE RELEVANT ART
Spread-spectrum modulation is a well developed art, in terms of generating chipping sequences, and spread-spectrum processing data signals with the chipping sequences. Using this technology, communication links may be established among a transmitter and a receiver in remote locations. Also, networks may be established, using a conference calling spread-spectrum technique. Conference calling spread-spectrum techniques are disclosed in U.S. Pat. No. 5,179,572 entitled SPREAD SPECTRUM CONFERENCE CALLING SYSTEM AND METHOD, to Schilling, and in U.S. Pat. No. 5,263,045, entitled SPREAD SPECTRUM CONFERENCE CALL SYSTEM AND METHOD, to Schilling.
A problem may exist where a spread-spectrum conference calling system is set up, but the base station may need to change hands. For example, in a military environment, a platoon may use spread-spectrum modulation for conference calling among the members of the platoon. A particular unit in the platoon may be designated as the base station. The cited prior art does not teach how to change a base station from one platoon to another or what would happen among units in the platoon in the event it became necessary to effectuate such a change.
SUMMARY OF THE INVENTION
A general object of the invention is a conference calling spread-spectrum communications system and method, where the base station may be changed upon demand.
Another object of the invention is a spread-spectrum conference calling technique where any unit may serve as a base station.
According to the present invention, as embodied and broadly described herein, a spread-spectrum system having a plurality of spread-spectrum units is provided. Each spread-spectrum unit is capable of operating as a base station and as a remote station. Each spread-spectrum unit includes a base subunit, a remote subunit, and a command subunit.
The method of the present invention includes receiving in the base subunit at a first frequency a plurality of spread-spectrum signals transmitted from the plurality of spread-spectrum units. The plurality of spread-spectrum signals are despread and demodulated in the base subunit to generate a plurality of demodulated signals. The plurality of demodulated signals are combined, and a local signal, such as data signal or a voice signal from the user of the unit, is also combined to generate a combined signal. The base subunit converts the combined signal to a base-data signal. The base subunit spread-spectrum processes the base-data signal, and transmits using radio waves the spread-spectrum-processed-base-data signal at a second frequency as a base-spread-spectrum signal.
At each of the spread-spectrum units, in the respective remote subunit, at the second frequency, the base-spread-spectrum signal is received. The remote subunit includes circuitry for despreading the base-spread-spectrum signal, and demodulating the despread-base-spread-spectrum signal as a base-analog signal. The remote subunit also may take the local voice signal, designated herein as a remote-analog signal, and convert the remote-analog signal to a remote-data signal. The remote subunit spread-spectrum processes the remote-data signal and transmits the remote-data signal at the first frequency as one of the plurality of spread-spectrum signals.
An operator may initiate from the command subunit, a command signal to activate the base subunit. Accordingly, upon initiating the command signal, the command signal is broadcast to the plurality of spread-spectrum units. At each of the spread-spectrum units, in the respective remote subunit, the command signal is received, and in response to receiving the command signal, the remote subunit is activated.
Additional objects and advantages of the invention are set forth in part in the description which follows, and in part are obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention also may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention, and together with the description serve to explain the principles of the invention.
FIG. 1A is a block diagram of a base subunit using a plurality of mixers;
FIG. 1B is a block diagram of a base subunit using a plurality of matched filters;
FIG. 2A is a block diagram of a remote subunit using a mixer;
FIG. 2B is a block diagram of a remote subunit using a matched filter; and
FIG. 3 is a block diagram of a command subunit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference now is made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals indicate like elements throughout the several views.
The present invention provides a unique solution to the problem of a plurality of spread spectrum units in use in a mobile environment in which any one of the spread-spectrum units is vulnerable to neutralization while maintaining communication between all the spread-spectrum units remains crucial. The spread-spectrum changeable base station finds application in a platoon of units, in an army environment, or in a law enforcement application, where a transportable base station might be set up for controlling a plurality of spread spectrum remote units. The problem being addressed for each of these applications is what happens when the base unit becomes disabled or nonfunctional. In the military environment, the base station may be destroyed. In a law enforcement situation, the mobility of the plurality of spread-spectrum units may have a requirement that the base station change from one unit to another.
The spread-spectrum system has a plurality of spread-spectrum units, with each spread-spectrum unit having a base subunit, a remote subunit, and a command subunit. The use of the term “subunits” for designating the base subunit, remote subunit, and command subunit, is for purposes of illustrating the invention. The invention may be built as one totally integrated unit, or as a mixture of more than one unit.
The base subunit is illustratively shown in FIGS. 1A and 1B. The base subunit includes receiving means, despreading means, demodulating means, combining means, converting means, spread-spectrum processing means, and transmitting means. The despreading means is coupled between the receiving means and the demodulating means. The combining means is coupled to the demodulating means and the converting means. The spread-spectrum processing means is coupled to the converting means and the transmitting means.
The receiving means is shown in FIG. 1A as antenna 11 coupled to radio frequency/intermediate frequency (RF/IF) amplifier and filter section 12 . The despreading means is illustrated as a plurality of mixers 13 , 14 , 15 . As shown in FIG. 1B, the despreading means may also be embodied as a plurality of matched filters 22 , 23 , 24 . Each of the plurality of mixers 13 , 14 , 15 has a chipping-sequence g 1 (t), g 2 (t), . . . , g N (t), respectively, for mixing with the received spread-spectrum signal. The plurality of chipping sequences is matched to the chipping sequence of the desired spread-spectrum signal to be despread.
The demodulating means and combining means is shown as the demodulator 16 and combiners 17 A, 17 B. Combiners 17 A, 17 B may be a single combiner performing the combining function, or separate combiners. The converting means is shown as an analog-to-digital converter 18 . The spread-spectrum processing means is illustrated as product device 19 , having a chipping sequence for spreading the data signal from analog-to-digital converter 18 . The transmitting means is illustrated as transmitter 20 and antenna 21 .
The RF/IF amplifier and filter circuits 12 are coupled to the antenna 11 and to the plurality of mixers 13 , 14 , 15 . The plurality of mixers 13 , 14 , 15 is coupled to the demodulator 16 and combiner 17 A, 17 B. The analog-to-digital converter 18 is coupled to the combiner 17 B and to the product device 19 . The transmitter 20 is coupled to the product device 19 and to antenna 21 . Antenna 21 and antenna 11 may be the same antenna with the appropriate isolation circuits, or different antennas.
The RF/IF amplifier and filter circuits 12 receive at a first frequency, f 1 , a plurality of spread-spectrum signals transmitted from the plurality of spread-spectrum units. The plurality of spread-spectrum signals are despread by the plurality of mixers 13 , 14 , 15 . As shown in FIG. 1B, the despreading means may also be embodied as a plurality of matched filters 22 , 23 , 24 . The output of the plurality of mixers 13 , 14 , 15 is a plurality of despread-spread-spectrum signals. The demodulator 16 demodulates the plurality of despread-spread-spectrum signals to generate a plurality of demodulated signals. The combiner 17 A combines the plurality of demodulated signals. The combined plurality of demodulated signals and a local signal from the base station may be combined by second combiner 17 B to generate a combined signal. The term “combined signal”, as used herein, is an analog signal including the voice of the base station and the combined demodulated signals of the combiners 17 A, 17 B.
The combined signal is converted to a base-data signal by analog-to-digital converter 18 . The term “base-data signal,” as used herein, is the digital signal coming from the analog-to-digital converter 18 , and includes the converted analog signals and the data signal at the base station.
The product device 19 spread-spectrum processes the base-data signal from analog-to-digital converter 18 , with a base-chipping sequence. The spread-spectrum-processed-base-data signal is transmitted as a base-spread-spectrum signal by transmitter 20 at the second frequency f 2 . Antenna 11 and antenna 21 may be a single antenna, serving both the receiver and transmitter.
The remote subunit is illustrated in FIGS. 2A and 2B and includes a receiver portion, a transmitter portion, receiving means, despreading means, and demodulating means. The transmitting portion includes converting means, spread-spectrum processing means and transmitting means. The receiving means receives at the second frequency the base-spread-spectrum signal. The despreading means despreads the base-spread-spectrum signal as a despread-base-spread-spectrum signal. The demodulating means demodulates the despread-base-spread-spectrum signal as a base-analog signal.
The converting means converts a remote-analog signal to a remote-data signal. The remote-analog signal typically is the voice of the remote station. The base-analog signal typically is the plurality of voice signals from the base station. The spread-spectrum processing means processes the remote-data signal with a remote-chipping sequence. The transmitting means transmits at the first frequency the spread-spectrum-processed-remote-data signal as one of the plurality of spread-spectrum signals, which are received at the base subunit.
As shown in FIG. 2A, the receiving means includes an antenna 31 and RF/IF amplifier and filter circuitry 32 . The despreading means and demodulating means ate embodied as mixer 33 and demodulator 34 , respectively. As shown in FIG. 2B, the despreading means may also be embodied as a matched filter 39 . The RF/IF amplifier and circuitry 32 is coupled between antenna 31 and the mixer 33 . The demodulator 34 is coupled to the mixer
The base-spread-spectrum signal at antenna 31 is amplified and filtered by RF/IF. The base-spread-spectrum signal is despread by the base-chipping sequence by mixer 33 to generate the despread-base-spread-spectrum signal. The demodulator 34 demodulates the despread-base-spread-spectrum signal as a base-analog signal. The output of the demodulator 34 is the plurality of voice signals from the base station.
The transmitter section of the remote subunit may have the converting means embodied as analog-to-digital converter 35 , the spread-spectrum processing means embodied as product device 36 and the transmitting means embodied as transmitter 37 coupled to antenna 38 . The product device 36 is coupled between the analog-to-digital converter 35 and the transmitter 37 .
The analog-to-digital converter 35 converts the voice of the remote signal, designated here as the remote-analog signal, to a remote-data signal. The remote-data signal is spread-spectrum processed by the product device 36 using remote-chipping sequence. The output of the product device 36 is the spread-spectrum-processed-remote-data signal. The transmitter 37 transmits the spread-spectrum-processed-remote-data signal using antenna 38 , as one of the plurality of spread-spectrum signals. Antenna 31 and antenna 38 may be combined as a single antenna serving both functions.
The command subunit is illustrated in FIG. 3 . The command subunit includes initiating means, broadcasting means, and receiving means. The initiating means initiates a command signal, upon activation by the local user of that spread-spectrum unit. The command signal activates the base subunit in that spread-spectrum unit. The broadcasting means broadcasts the command signal to the plurality of spread-spectrum units. The receiving means receives the command signal when broadcast from a different spread-spectrum unit. The activating means activates the remote subunit upon receiving the command signal.
The initiating means is illustrated in FIG. 3 as a push button switch 43 . The broadcasting means is illustrated as a transmitter portion of the transmitter/receiver 42 . The transmitter transmits at frequency f 3 . The receiving means is illustrated as the receiver portion of transmitter/receiver 42 . The receiver receives at frequency f 3 . The transmitter/receiver 42 is coupled to antenna 41 for radiating and receiving signals. The activating means includes the necessary circuitry for disconnecting the base subunit and activating the remote subunit of a particular spread-spectrum unit. The activating means is illustrated as control circuitry 44 . The present invention may also be used for data in place of voice signals.
In use, a particular spread-spectrum unit might be operating with its remote subunit activated. Thus, the remote subunit of that particular spread-spectrum unit receives at the second frequency the base-spread-spectrum signal, and despreads the base-spread-spectrum signal as a despread-base-spread-spectrum signal. The despread-base-spread-spectrum signal is demodulated. Thus, that particular spread-spectrum unit receives all of the base signals via its remote subunit. While transmitting to the plurality of spread-spectrum units, that particular spread-spectrum unit converts the voice signal, embodied as the remote-analog signal, to the remote-data signal. The remote-data signal is spread-spectrum processed and transmitted at the first frequency as one of the plurality of spread-spectrum signals.
Upon initiation of the command signal by the user of that particular spread-spectrum unit, by pushing push button 43 , that particular spread-spectrum unit switches from operating with the remote subunit to operating with the base subunit. At the same time, the command signal is radiated to the other spread-spectrum units of the plurality of spread-spectrum units. Upon receiving the command signal, each of the spread-spectrum units has its remote subunit activated and thereafter works in a remote subunit mode. The particular spread-spectrum unit has then become the base station.
When operating as the base station, the particular spread-spectrum unit has its base subunit activated. Accordingly, the plurality of spread-spectrum signals transmitted from the plurality of spread-spectrum units at each unit, is received by the RF/IF amplifier and circuitry 12 via antenna 11 . The plurality of spread-spectrum signals are despread by the plurality of mixers 13 , 14 , 15 , and demodulated by the demodulator 16 which outputs a demodulated signal. The plurality of demodulated signals from combiner 17 A are the voices from the plurality of remote stations. The voices from the plurality of remote stations are combined with the voice of the base station by combiner 17 B, and converted by analog-to-digital digital converter 18 to the base-data signal. The base-data signal is spread-spectrum processed by the product device 19 and transmitted by transmitter 20 and via antenna 21 at the second frequency.
It will be apparent to those skilled in the art that various modifications can be made to the spread-spectrum changeable base station of the instant invention without departing from the scope or spirit of the invention, and it is intended that the present invention cover modifications and variations of the spread-spectrum changeable base station provided they come within the scope of the appended claims and their equivalents.
|
A conference calling spread-spectrum communications system and method using a plurality of spread-spectrum units, any one of which may serve as the base station and where the base station may be changed from one spread-spectrum unit to another upon command. Each spread-spectrum unit includes a base subunit, a remote subunit, and a command subunit. An operator may initiate from the command subunit of a particular spread-spectrum unit, a command signal to activate the base subunit of the particular spread-spectrum unit. Upon initiating the command signal, the particular spread-spectrum unit is activated as the base station and the command signal is broadcast to the remaining plurality of spread-spectrum units. At a respective remote subunit of each of the remaining plurality of spread-spectrum units, the command signal is received and, in response to receiving the command signal, the respective remote subunit in each of the remaining plurality of spread-spectrum units is activated to operate the remaining plurality of spread-spectrums units as remote units.
| 7
|
BACKGROUND OF THE INVENTION
The invention relates to a snow lance head for use in a snow lance with a housing having nozzles for the outlet of water and/or air and with at least one first chamber formed in the interior of the housing through which water emerging from at least some of the nozzles flows.
The invention also relates to a nozzle arrangement with at least one nucleator and at least one water nozzle.
So-called “snow lances” used to produce artificial snow are known in the art and consist essentially of a snow lance body and of at least one snow lance head provided on the snow lance body, the head has one or more nozzles ( 12 , 15 , 18 ) for compressed air and water under pressure, wherein at least one nozzle is designed as a so called “nucleator”, which is fed with water and air and which is used to produce nuclei, i.e. to produce small kernels or very small frozen particles, which initiate the formation of snow from the water sprayed from the snow lance head into the air current.
It is an object of the invention is to provide for a snow lance head that effectively prevents the formation of ice on the lance head, in particular preventing the housing of the head from icing up, under unfavorable weather conditions, especially during low temperatures and a strong headwind, which causes considerable accumulation of moisture on the outer surface of the snow lance head due to water from the nozzles.
SUMMARY OF THE INVENTION
An objective is achieved by a snow lance head for use in a snow lance with a housing having nozzles for the outlet of water and/or air and with at least one first chamber formed in the interior of the housing through which water emerging from at least some of the nozzles flows, with the inner surface of the chamber being at least equal to the outer surface of the housing, preferably greater than outer surface of the housing.
Furthermore this objective is achieved by nozzle arrangement with at least one nucleator and with at least one water nozzle with the nucleator and the at least one water nozzle being provided on a common support.
A special feature of the snow lance head according to the invention is the fact that limiting surface of the chamber which chamber is formed in the interior of the housing and through which chamber water flows during normal operation of the snow lance head and of the snow lance is equal to, or preferably greater than the outer surface of the housing, so that even under unfavorable weather conditions, i.e. at very low temperatures, the outer surface of the housing is kept at a temperature above the freezing point by the water flowing through the first chamber and the snow lance head is prevented from icing up already by these means.
In a preferred embodiment, the housing is convexly rounded on its outside at least in the area where the nozzles are located, preferably three-dimensionally, i.e. with or around at least two spatial axes extending perpendicular to each other, which results in faster and more effective dripping of water on the outer surface of the housing, for example after it has emerged from the nozzles. This special housing form also helps to prevent the formation of ice, in particular also the accumulation of ice on the outside of the housing.
The nozzle arrangement according to the invention, and can be used, for example, for a snow lance head, and can also be used with other snow lance heads or snow generators and which combines at least one nucleator and one further water nozzle on a common support, features a compact design, space-saving and simplified installation and a high degree of service friendliness.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described below based on an exemplary embodiment with reference to the drawings, wherein:
FIG. 1 shows a simplified cross section of a head of a snow lance;
FIG. 2 shows a component representation in top view of a multi-purpose nozzle for use in a snow lance, for example in the snow lance of FIG. 1 ;
FIG. 3 shows a cross section corresponding to line A-A of FIG. 2 ;
FIG. 4 shows a cross section corresponding to line C-C of FIG. 1 ;
FIG. 5 shows a frontal view of a snow lance head housing for use in a snow lance, for example in the snow lance according to FIG. 1 ;
FIG. 6 a shows a frontal view of the side of the snow lance head housing comprising the nozzle arrangement;
FIG. 6 b shows a cross section corresponding to line B-B of the snow lance head housing of FIG. 6 a; and
FIG. 6 c shows a cross section corresponding to line B-B of the snow lance head housing of FIG. 6 a.
DETAILED DESCRIPTION OF THE INVENTION
The snow lance head generally designated 1 in the drawings is part of a snow lance for generating snow from water and air and is mounted, for example, on the top of snow lance body or member 3 .
The snow lance head 1 is made up of a spherical housing 2 , which in the depicted embodiment is made of aluminum or an aluminum alloy and which on the end of a schematically depicted snow lance body 3 is fastened with a housing section 2 . 1 to the latter tightly overlapping and features a nozzle arrangement 9 .
Four separated channels 4 , 5 , 6 , 21 are provided in the snow lance body 3 , namely a first and second channel 4 and 5 for feeding water and a third channel 6 for feeding compressed air, preferably cooled compressed air, to the snow lance head 1 and a fourth channel 21 (not depicted in FIG. 1 ) for feeding water at a fixed rate that means water the amount of which is not controlled depending on the weather conditions.
The interior of the housing 1 in the depicted embodiment is sub-divided essentially into three separate chambers, namely the larger chamber 7 and a first and second smaller chamber 8 . 1 , 8 . 2 , which in the depicted embodiment concentrically enclose a nozzle arrangement 9 , provided on the side of the snow lance head 1 , and the middle axis DA of the nozzle arrangement, and which are formed within the spherical outer wall of the housing 2 . The first smaller chamber 8 . 1 is connected to the first channel 4 by means of a connecting channel 10 formed in the housing 2 or by a connecting line, which in the depiction in FIG. 1 is connected at its lower end with the first channel 4 and leads into the upper section of the first smaller chamber 8 . 1 . The second channel 5 leads into the larger chamber 7 , which is closed in a suitable manner at the junction to the snow lance 3 , for example by an end piece 11 that closes the snow lance body 3 at its upper end outside of the first through third channels 4 - 6 .
Distributed around the nozzle arrangement 9 or its axis DA several nozzles 12 are provided, which are connected with the first and second smaller chamber 8 . 1 , 8 . 2 and which are used to discharge water in finely distributed form.
The nozzle arrangement 9 in the depicted embodiment consists of a disk-shaped support 13 , the middle axis of which is the nozzle axis DA. In the middle, the support 13 has an opening 14 with inner threads in which a nucleator 15 is provided, i.e. a nozzle that can be pressurized with an air-water mixture for creating nuclei, i.e. miniature or micro snow or ice particles initiating the generation of snow in the air current emerging from the nucleator 15 . By means of an internal connection 16 in the housing, the nucleator 15 is connected with the third channel 6 for feeding air and the second smaller chamber 8 . 2 is connected via a second internal connection 17 in the housing with the second channel 5 for feeding water. The air fed via the third channel 6 is mixed with the fixed water to from an air-water mixture before emerging from the nucleator 15 .
On the support 13 , distributed around the nucleator 15 , a plurality of water nozzles 18 is provided, by means of which the water or fixed water emerges from the larger chamber 7 in the form of fine spray into the air current of the nucleator 15 .
While the nucleator 15 has one or more nozzle openings, of which the axis of the nozzle opening 15 . 1 is coincident with the axis DA, and the axes of the nozzle openings 15 . 2 form an angle smaller than 90° with the nozzle axis DA, which (angle) opens toward the side facing away from the housing interior, the nozzles 18 are oriented with their axes parallel to the nozzle axis DA.
The nozzles 18 are fastened to the support 13 by screwing. The support 13 is fastened in an opening 19 of the housing 2 by suitable means, e.g. by screwing, so that the inner side of the support 13 is part of the inner surface of the chamber 7 .
FIG. 4 shows a cross section along the line C-C indicated in FIG. 1 of the snow lance 3 , which has four separated channels 4 , 5 , 6 , 21 . The first and second channels 4 , 5 are provided for feeding water into the first and second chambers 8 . 1 , 8 . 2 of the housing 2 and the third channel 6 is provided for feeding air to the nucleator 15 . By means of the fourth channel 21 of the snow lance 3 , fixed water is fed to the larger chamber 7 , flowing through the hollow spaces, for example the hollow chambers 7 . 1 , 7 . 2 , 7 . 3 of the larger chamber 7 depicted in FIG. 4 and energy is transmitted to the spherical housing 2 .
FIG. 5 shows in an alternative embodiment, by way of example, the frontal view of a snow lance head housing 2 without nozzles 12 or a nozzle arrangement 9 . The depicted snow lance head housing 2 has a first and a second opening 19 , each of which holds a nozzle arrangement 9 according to FIGS. 2 and 3 . Furthermore, additional openings 22 are provided in the snow lance head housing 2 above and below the openings 19 for holding additional nozzles 12 , whereby in the depicted embodiment three openings 22 are located above and below the openings 19 in the snow lance head housing 2 along a circular disk-shaped line on the housing surface. In a preferred embodiment, the openings 19 and 22 each have inner threads for screwing in of the circular disk-shaped support 13 of the nozzle arrangement 9 or of the nozzles 12 .
FIG. 6 a shows, by way of example, a depiction of the schematic representation of the snow lance head housing 2 according to FIG. 5 from a slightly different angle of view. FIGS. 6 b and 6 c each show a cross section along the axes B-B and F-F of the snow lance head housing 2 depicted in FIG. 6 a. FIG. 6 b shows, by way of example, one of the openings 22 for holding the nozzles 12 , which are fed with water by means of the first and second smaller chamber 8 . 1 , 8 . 2 . Furthermore, the larger chamber 7 is depicted, which has several ribs 20 for increasing the inner surface of the chamber 7 .
FIG. 6 c shows a further cross section along the axis F-F of the housing 2 according to FIG. 6 a, from which the feeding of water via the second channel 5 to the second smaller chamber 8 . 2 is clearly depicted.
The fixed water fed via the fourth channel 21 to the larger chamber 7 emerges partially at the nucleator 15 and partially at the nozzles 18 . Water is additionally fed via the first and second channel 4 , 5 to the first and second smaller chambers 8 . 1 , 8 . 2 and to the nozzles 12 connected to these chambers, in particular when the weather conditions allow additional generation of snow with the water emerging from the nozzles 12 .
A special feature of the snow lance head 1 is the fact that the inner surface limiting the chamber 7 is provided at least partially with ribs 20 protruding from the respective inner surface, so that the inner surface of the housing 2 through which the water flows in the chamber 7 is significantly larger than the outer surface of the housing and therefore taking into consideration in particular also the highly heat-conductive material used for the housing 2 , it is assured that the outer surface of the housing 2 is maintained within a temperature range above the freezing point even when it is extremely cold.
Furthermore, the compact design and spherical shape of the housing 2 results in fast dripping of water spray from the nozzles 12 and 18 accumulating on the outside surface of the housing, thus effectively preventing the formation of ice on the snow lance head 1 .
The nozzle arrangement 9 features the use of standardized components to the greatest possible extent, a compact design, simplified mounting and a high degree of service friendliness, for example by the fact that all components of said nozzle arrangement 9 are located on a common support 13 in a very compact manner.
Furthermore, the nozzle arrangement 9 provides additional protection against the formation of ice, due to the warmer air of the nucleator 15 .
In a preferred embodiment of the snow lance head 1 , the latter comprises at least two nozzle arrangements 9 , whereby the nozzle axes DA of the at least two nozzle arrangements 9 form an angle between 30° and 50°, in particular 40°.
The invention was described above based on an exemplary embodiment. It goes without saying that numerous modifications and variations are possible without abandoning the underlying inventive idea upon which the invention is based.
REFERENCE NUMBERS
1 snow lance head
2 snow lance head housing
3 snow lance
4 first channel in snow lance 3
5 second channel in snow lance 3
6 third channel in snow lance 3
7 larger chamber in housing 2
7 . 1 , 7 . 2 , 7 . 3 hollow chamber sections of larger chamber 7
8 . 1 , 8 . 2 first and second smaller chambers in housing 2
9 nozzle arrangement
10 connecting channel
11 end piece
12 nozzle
13 disk-shaped support
14 opening
15 nucleator
15 . 1 , 15 . 2 nozzle opening of nucleator
16 connection
17 opening
18 nozzle
19 opening
20 rib
21 fourth channel in snow lance 3
22 opening
DA nozzle axis of nozzle arrangement 9 and of nucleator 15
|
In a snow lance head for use with a snow lance with a housing having nozzles for the outlet of water and/or air and with at least one first chamber formed in the interior of the housing, through which water emerging from at least some of the nozzles flows, the surface area of the inner surface of the chamber is at least equal to, but preferably greater than the outer surface of the housing.
| 5
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This patent application claims priority to Provisional Patent Application Ser. No. 62/333,214, entitled “Memory and Processing Architecture for Hardware Accelerated Machine Learning,” filed May 7, 2016, which is hereby incorporated by reference herein in its entirety.
BACKGROUND
[0002] Machine learning and deep neural networks, including deep belief networks (collectively called neural networks), are rapidly becoming ubiquitous. Applications initially began with object recognition in computer images and with speech recognition now common in voice user interfaces such as Apple Siri™ Microsoft Cortana™, Amazon Alexa™, Google Assistant™ and the like. Neural networks are presently being applied to industrial controllers, medical diagnoses, leading to a burgeoning of neural networks.
[0003] However, neural network operations, at least as applied to machine learning and deep neural networks, typically make use of dense linear algebra operations, such as matrix operations, as well as more neural network specific operations such as convolutions, max pooling, and data noise generation. Such operations lend themselves to parallel operations, such as calculating matrix rows in parallel, which if performed on commonly available central processing units (CPU) which generally are not parallel, leads to suboptimal performance.
[0004] Accordingly, arrays of graphical processing units (GPU), which are optimized for matrix operations and parallel operations have been applied to neural networks, such as via NVidia's CUDA™ architecture. However, while GPUs are optimized for matrix operations, they do not provide optimizations specific to neural networks, such as convolutions, max pooling and noise generation, thereby limiting their performance in neural network operations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The Detailed Description is set forth with reference to the accompanying figures.
[0006] FIG. 1 is a context diagram of a system environment for machine learning hardware acceleration.
[0007] FIG. 2 is a block diagram for machine learning hardware acceleration.
[0008] FIG. 3 is a block diagram for multicast network optimizations for machine learning hardware acceleration.
[0009] FIG. 4 is a flow chart for multicast network optimizations for machine learning hardware acceleration.
[0010] FIG. 5 is a context diagram for accessing strides of contiguous banked computer memory.
[0011] FIG. 6 is a block diagram for a permutaton used in DRAM transfer optimizations for machine learning hardware acceleration.
[0012] FIG. 7 is a block diagram for DRAM transfer optimizations for machine learning hardware acceleration.
[0013] FIG. 8 is a flow chart for DRAM transfer optimizations for machine learning hardware acceleration.
DETAILED DESCRIPTION
Overview of Multicast Network and Memory Transfer Optimizations for Neural Network Hardware Acceleration
[0014] Neural network hardware acceleration occurs within the context of an environment to develop, compile (or programmatically transform), and execute applications that make use of neural networks. Such applications are often called machine learning applications, deep neural network applications, and/or deep belief network applications. While machine learning does not strictly demand the use of a neural network, many common present day frameworks and techniques make use of neural networks. Deep neural networks may be roughly considered to be a series or network of neural networks.
[0015] As stated above, present day hardware, either in the form of a central processing unit (CPU) or a graphical processing unit (GPU) array do not provide hardware optimizations for many operations common to neural networks. Disclosed herein are various techniques for neural network hardware acceleration, specifically in for multicast networks for data dispatched to data receivers such as execution units, and for memory transfer.
[0016] The optimizations disclosed herein are designed to perform those operations in hardware in constant time (Big O(C)) or linear time (Big O(n)) that CPUs and/or GPUs would otherwise use Big O(n log(n)) or higher polynomial time. The optimizations may make use of information at design time and/or compile time, may make use of transformations to enable multidimensional operations common to matrix and tensor operations, and may recognize and exploit instruction pipeline opportunities in hardware.
[0017] FIG. 1 provides a context diagram 100 in which neural network hardware acceleration may occur. Specifically, a user 102 , accesses computing services from cloud 104 . The user may be a developer or may be an end user.
[0018] Cloud 104 is comprised of several servers 106 capable of storing computer readable data and executing computer readable instructions. Those servers 106 may be disaggregated by a hypervisor 108 to serve virtual machines 110 .
[0019] A compiled neural network application 112 may execute either directly on a server 106 or on a virtual machine 110 . The server 106 and/or the virtual machine 110 may be provisioned by one or more neural network frameworks and/or runtimes 114 . A neural network hardware acceleration unit 116 may be connected to a server 106 or may be standalone. As a resource of a server 106 , a neural network hardware acceleration unit may be disaggregated as well by hypervisor 108 thereby making its resources available to a virtual machine 110 .
[0020] The compiled neural network application 112 is a result of source code 118 for the neural network application as compiled by compiler 120 . The neural network application 112 may also have been linked to libraries specific to the neural network frameworks or runtimes 114 .
[0021] Turning back to the neural network hardware accelerator unit 116 , it comprises a system control block 122 that among other operations may transfer instruction. It interfaces with a controlling CPU via a communications bus 124 . The hardware accelerator unit will have an instruction interpreter 126 that interfaces with local memory 128 , one or more multicast networks 130 and a plurality of data receivers 132 . In some embodiments, the data receivers 132 may be execution units. The interface with offsite data may be via a data transfer unit 134 interfacing over a memory bus 136 .
[0022] The neural network hardware accelerator unit 116 is described in further detail with respect to FIG. 2 below. Note that the one or more multicast networks 130 and the data transfer units 134 have several optimizations. The multicast network optimizations are described in further detail with respect to FIGS. 3 and 4 below. The data transfer unit optimizations make use of features of group theory as described with respect to FIG. 5 below. The data transfer unit optimizations themselves are described with respect to FIGS. 6, 7 and 8 below.
Exemplary Architecture of a Neural Network Hardware Acceleration Unit
[0023] A closer examination of a neural network hardware acceleration unit 116 is merited. FIG. 2 provides a block diagram 200 of a neural network hardware acceleration unit expanding on the detail described with respect to FIG. 1 .
[0024] The neural network hardware accelerator unit 202 , it may interface with a server or with some other controlling CPU via a system control block 204 via a parallel bus or serial bus 206 . In some implementations the interface is a PCI bus or PCI-E bus. However, any standardized bus is sufficient. A serial bus may be used, but at a performance cost of the overhead of serialization.
[0025] Computer instructions and/or operation codes may be stored in local memory 208 and interpreted by an instruction interpreter 210 . The computer instructions may arrive via the system control block 204 . Local memory 208 may be static random access memory (SRAM). The SRAM may be subdivided into a location for computer instructions to interpret and execute, and one or more areas of working memory 208 ( a ), 208 ( b ) each of which may be in at least some portion subdivided into multiple banks of memory.
[0026] At least some of the areas of working memory 208 ( a ), 208 ( b ) may be each associated with a multicast network 212 ( a ), 212 ( b ) comprised of switch nodes, which dispatch data stored in the working memory areas 208 ( a ), 208 ( b ) to one or more data receivers 214 .
[0027] As described in further detail with respect to FIGS. 3 and 4 , the switch nodes comprising a multicast network 212 ( a ), 212 ( b ) are organized into a plurality of layers, the first layer being proximate to the memory 208 ( a ), 208 ( b ) and the last layer being proximate to the data receivers 214 . The switch nodes comprising the last layer access the data receivers 214 in some permutation of connections. Note that the connection permutations of the last layers of the different multicast networks 212 ( a ), 212 ( b ) respectively need not be the same.
[0028] Data receivers 214 may be one of several embodiments, depending on the application. For neural network applications 112 , the data receivers 214 may be a plurality of execution units 214 , each capable of executing computer executable instructions.
[0029] Data may be transferred from local memory 208 to off board memory, may be performed by a data transfer unit 216 over a data bus 218 . In the case where off board memory is in the form of dynamic random access memory (DRAM), the data transfer unit 216 is a DRAM transfer unit and the data bus 218 is a DRAM bus.
[0030] Multicast Network Optimizations for Neural Network Hardware Acceleration
[0031] The multicast networks 212 ( a ), 212 ( b ) are designed to reorder and duplicate data from the memory 208 ( a ), 208 ( b ) in order to feed portions and permutation of the data in the memory 208 ( a ), 208 ( b ) deterministically. To achieve this, multicast networks 212 ( a ), 212 ( b ) are configured as Bene{hacek over (s)} networks, which are sets of switch nodes, organized into layers, where each switch node in a layer can duplicate and/or forward data to one or more switch nodes in subsequent layers. When input data have traversed all the layers, the data will have been rearranged into a desired permutation.
[0032] This feature of Bene{hacek over (s)} networks is desirable for neural network operations which make use of multidimensional matrices known as tensors. Tensors may be stored in contiguous memory, meaning that each of the data elements comprising a tensor resides in a memory block with sequential and uninterrupted memory addresses. By being able to select and permute arbitrary data elements, a Bene{hacek over (s)} network multicasting data elements to data receiver execution units 214 enable parallel operations on those multicast data elements.
[0033] For purposes of hardware acceleration, by making Bene{hacek over (s)} network configuration data globally accessible to all switch nodes in a multicast network, and by pipelining execution instructions, configuration and operation may be reduced to constant time (Big O(c)). FIG. 3 is a block diagram 300 of two multicast networks 302 ( a ), 302 ( b ), permuting input data into data receivers 304 .
[0034] Each multicast network 302 ( a ), 302 ( b ), receives input data, usually in the form of data elements of a tensor, from areas of working memory 306 ( a ), 306 ( b ) organized into banks. As will be seen with respect to FIG. 5 , organization of data elements of a tensor into banks lends itself to further optimization.
[0035] Each multicast network 302 ( a ), 302 ( b ) is comprised of switch nodes 308 , organized into layers 310 . The layers are ordered, where the first layer is proximate to the memory 306 ( a ), 306 ( b ) and the last layer is proximate to the data receivers 304 .
[0036] One purpose for implementing two multicast networks 302 ( a ), 302 ( b ), is that in tensor operations, it may be desirable to access different partitions of the tensor. For example, in a two dimensional tensor, a matrix, the first multicast network 302 ( a ) may perform operations on rows, and the other multicast network 302 ( b ) may perform operations on columns. For this reason, the permutation of switch nodes 308 interfacing the data receivers 304 from the one multicast network 302 ( a ) (i.e. the last layer of switch nodes of the first multicast network 302 ( a )) need not be the same permutation of switch nodes 308 interfacing the data receivers 304 from the other multicast network 302 ( b ) (i.e. the last layer of switch nodes for the second multicast network 302 ( b )). In one embodiment, the first multicast network 302 ( a ) permutation is modulo, and the second multicast 302 ( b ) permutation is grouped fanout.
[0037] An individual switch node 308 , may contain a one or more data entries, either received from memory 306 ( a ), 306 ( b ), or from a switch node 308 from a prior level 310 . A switch node may contain a configuration indicator 314 and a controller indicator. The configuration indicator 314 specifies whether to perform a broadcast mode whether input data is to be forwarded according to the configuration data, or a passthru mode wherein input data is to be forwarded regardless of the configuration data. The controller indicator 316 specifies whether to update at least one switch node entry.
[0038] There may be a separate global configuration data store 318 , either in the form of registers, or in the form of memory. The global configuration data is accessible by all switch nodes 308 , and holds the value of the configuration indicators 314 and the controller indicators 316 of the switch nodes 308 respectively. Since the configuration data store 318 is globally accessible, in some embodiments, the switch nodes 308 may potentially not have locally stored values of the configuration indicator 314 and the controller indicator 316 , and may instead just access the global configuration data store 318 .
[0039] FIG. 4 is a flow chart 400 of a potential operation of the multicast networks 302 ( a ), 302 ( b ).
[0040] Block 402 starts configuration of a multicast network 302 ( a ), 302 ( b ) by retrieving configuration data retrieved from a known address from computer memory 306 ( a ), 306 ( b ). The retrieved configuration data is for configuring the switch nodes 308 comprising the multicast network 302 ( a ), 302 ( b ). In block 404 , the retrieved configuration data is then stored in the global configuration data store 318 .
[0041] In block 406 , the data elements in computer memory 306 ( a ), 306 ( b ) to be operated on may be stored in the data entry storage 312 of the switch nodes.
[0042] Since all the switch nodes 308 have access to the global configuration data store 318 , in block 408 , at least the first layer 310 of switch nodes 308 in the multicast network 302 ( a ), 302 ( b ) may have their respective configuration indicators 314 and controller indicators 316 populated with the control data in the global configuration data store 318 .
[0043] Note that at this point, the multicast network 302 ( a ), 302 ( b ) is configured. If blocks 402 and 404 are executed within one clock cycle, and block 408 is executed within one clock cycle, in effect (not counting insertion of no-operation instructions, also called no-ops), the multicast network 302 ( a ), 302 ( b ) is configured in two clock cycles, regardless of the amount of data. In effect the multicast network configuration is achieved in constant time (Big O(c)).
[0044] In block 408 , a Bene{hacek over (s)} multicast operation at the first level of switch nodes commences the reordering and copying of the data elements stored in those switch node. A switch node 308 will determine whether to use configuration information, or to passthru data regardless of configuration based on the configuration indicator 314 . The switch node 308 also considers the controller indicator 316 to determine which pattern to permute the data entries 312 to the next layer of switch nodes (or in the case of the last layer, to the data receivers 304 ).
[0045] The Bene{hacek over (s)} multicast operations are performed sequentially through each layer 310 of switch nodes 308 , in block 410 , until the last layer in block 412 performs the last Bene{hacek over (s)} multicast operation to permute the data elements into the data receivers 304 .
[0046] Note that in the case of passthru, because operation proceeds regardless of the value of the configuration indicators 314 and controller indicators 316 , operation may proceed within one clock cycle, skipping the operations to load and propagate control information.
Group Theory Backgrounder for Memory Transfer Optimizations
[0047] Before discussing memory transfer optimizations, a background in the group theory underpinnings of the disclosures herein is in order. Common operations in neural networks include tensor operations involve one partition of a tensor, is operated on another partition of that tensor or a different tensor. The partitions are comprised of data elements that are regularly spaced within their tensor. The data elements comprising the partitions may be called tiles.
[0048] Since the tiles comprising a partition may operate on their operands independently, this gives rise to an opportunity to perform the operation in parallel, thereby greatly saving processing time. Accordingly, it is useful to have the ability to retrieve and move tiles of a partition of a tensor in as small a number of operations as possible.
[0049] Group theory is the branch of mathematics that describes sets and their respective behavior over an operator. For example, the set of integers is a group with respect to the addition operation, since the addition of any two integers yields an integer. There are other aspects of a set that give rise to a group.
[0050] One group is a finite group of integers modulo D, where D is some positive integer. Such a group is also called a cyclic group D, denoted herein C D . The memory techniques herein make use of a cyclic group C D where D is the number of banks in a working group of memory. FIG. 5 is a diagram 500 of such a working area 502 . The banks 504 are indexed from 0 to D−1, and store a plurality of data elements 506 . The data elements comprising a partition 508 are indicated in brackets.
[0051] The data elements are stored in contiguous memory. Note that contiguous means that the data elements are stored in consecutive, uninterrupted, memory addresses. The memory addresses need not be physical address, but can also relate to a virtual memory space. Since the partitions are spaced in regular intervals, and because we access data elements across the distance of those regular intervals, called “strides” (i.e. that is every Dth element plus some offset 0), we can identify the bank that stores the desired data element according to the formula O+(M*i) % D, where O is the starting offset of a memory storing a tensor, D is the number of banks, and M is the stride of the tensor in memory. This ability lets us access tiles from a tensor in a constant number of operations, potentially within in a single processor instruction.
[0052] To avoid collisions, the number of banks D should be prime and the stride of the data elements M is not a strict multiple of D. Alternatively the number of banks D should be relatively prime to the stride of the data elements M, and the partition to be retrieved should be a vector with less than D data elements.
[0053] For example, say we want to access every fifth element. This would be to say that M=5. Let us also presume that the starting offset address 0 is 2 and that the number of banks D is 7. Consequently we may read up to 7 elements, each of which will be read from a distinct bank of memory since 5 is relatively prime to 7. (Most certainly both 5 and 7 are prime numbers in their own right.) Accordingly:
[0000] (2+5*0)% 7=2% 7=2
[0000] (2+5*1)% 7=7% 7=0
[0000] (2+5*2)% 7=12% 7=5
[0000] (2+5*3)% 7=17% 7=3
[0000] (2+5*4)% 7=22% 7=1
[0000] (2+5*5)% 7=27% 7=6
[0000] (2+5*6)% 7=32% 7=4
[0054] For a given value of O and M, as long as M is relatively prime to D, we can always permute the logically ordered data elements, so that each access i goes to a unique bank. However, in a hardware implementation we must physically perform this permutation for arbitrary O and M. To remove the effect of O, it suffices to perform a rotation. Fast hardware implementation of rotation is an understood problem. To handle the effect of the stride, M, we rely on another property of prime fields. Specifically, multiplication modulo D, for a prime D, of the elements 1 to D−1 form a group as well. This group is in fact isomorphic to the cyclic group D−1. If M is not a strict multiple of D, this means that we can implement the effect of the multiplication by M by first applying a fixed permutation to map from the multiplication group of D to the cyclic group D−1, followed by a rotation in the group D−1, followed by another fixed permutation to back to the multiplication group of D. Hardware to implement fixed permutations can be done by wiring in metal layers, and the rotation as mentioned earlier is well understood.
[0055] Now we need to determine the fixed permutation use, as well as to compute the amount of rotation within the cyclic group D−1, which we shall call ‘r’.
[0056] To define these permutations, we must choose a generator over the multiplication prime field in question. A generator for a group is an element that, by repeated applications, produces all the elements of the group. For example, for the prime field over D=7, 3 is a multiplicative generator:
[0000] 3 1 (mod 7)=3
[0000] 3 2 (mod 7)=2
[0000] 3 3 (mod 7)=6
[0000] 3 4 (mod 7)=4
[0000] 3 5 (mod 7)=5
[0000] 3 6 (mod 7)=1
[0057] The chosen generator is denoted as g. Note that D and g are fixed at the time of design. A discrete log with respect to g, log g (x), can be defined as the value y such that g y (mod D)=x. For example, for g=3, D=7, we compute log g (6)=3.
[0058] Since the rotation to handle the multiplicative part of the permutation happens in the cyclic space, it is required to compute the discrete log to determine the amount to rotate, which is complex to perform in hardware. In practical implementations, one may presume that M, and thus m, and log g (m) are known in advance. This allows a compiler to perform the appropriate computations and provide a fixed constant for the rotation. Specifically, to determine the necessary rotation, we compute:
[0000] n =(log g ( m )+1)%( D− 1)
[0059] Namely, to specify a transform, o and r are provided at the time of permutation. It is to be noted that the permutation network may be configured to one of two different variants. The first variant is called a forward modulo permutation network, which maps each i<D to a correspondingly appropriate bank position b=(O+M*i)% D given the correct o and n. This permutation is used to send address and data to the memory banks (i.e., for memory write operations). The second variant is called the reverse modulo permutation network, which simply performs the inverse mapping of the forward modulo permutation network, and is used to appropriately reorder the read data elements due to memory read operations.
[0060] Before forward and reverse modulo permutation networks can be described in greater detail, two simple wiring patterns are to be defined. The two wiring patterns are used to perform the mapping a logical group and a cyclic group. Specifically, a first wiring pattern, map_to_cylic is defined to take D−1 elements and map each entry i of the D−1 elements to entry log g (i), for 1←i<D. A second wiring pattern, map_from_cylic is defined to do the opposite and map entry i to entry g i (mod D). Since 0 is not a member of the multiplicative group, entry 0 of the elements is left unaltered by both the mapping and the rotations. This structure is described in greater detail with respect to FIG. 6 below.
Permutatons
[0061] The hardware implementation of the memory transfer operations described above include the ability to permute data elements. A hardware device to do so is termed a permutaton. FIG. 6 is a block diagram 600 of a permutaton 602 .
[0062] Consider receiving a parameter where o=O% D, where O is the offset start in memory, the memory storing data elements in contiguous memory and the memory organized into D banks in the memory. Further consider receiving a parameter r which represents the number of rotations to perform for a cyclic group less than D, wherein r is based at least on the discrete log of a generator g, log g .
[0063] A permutaton comprises a number of inputs to permute 604 . The inputs will generally correspond to D inputs, usually banks. Those inputs 604 , are then mapped to a permutation via a first cyclic map 606 from inputs indexed 1 through D. In hardware this operation may be implemented via a right barrel shifter, which performs a right rotation of the data elements from 1 through D.
[0064] The permutaton then permutes the data elements via a second cyclic map 608 that rotates of all the data elements from 0 through D−1 to the right. This may be performed via a right barrel shifter, which performs a right rotation of the data elements from 0 through D−1 and thereto forward the permuted data elements to outputs 610 .
[0065] Note that a reverse permutaton, which restores the data elements to their original positions, may be implemented via a left barrel shifter which performs a left rotation of the data elements 0 through D−1, followed by a left barrel shifter which performs a left rotation of the data elements 1 through D. In this way, a reverse permutaton is the hardware inverse of a permutaton.
[0066] Between the permutaton and the reverse permutaton, hardware support for permutation operations for the memory transfer techniques disclosed herein are supported.
Memory Transfer Optimizations for Neural Network Hardware Acceleration
[0067] Permutatons may be applied to create a memory transfer unit optimized for neural network hardware acceleration. FIG. 7 is a block diagram 700 of an exemplary memory transfer unit 702 . FIG. 8 is a flow chart 800 of an exemplary operation of the memory transfer unit 700 .
[0068] A modulo address generator 704 is a forward or standard permutaton. It receives inputs from data banks, permutes the data elements per input parameters o and r as described with respect to FIGS. 5 and 6 above. Specifically, per block 802 in the flow chart 800 , the modulo address generator receives a memory address and a length, and in block 804 of the flow chart 800 , the modulo address generator 704 generates a set of memory addresses corresponding to data elements stored in a computer readable memory separated by strides.
[0069] The enqueuing controller 706 , is responsible for controlling the forwarding of the received data elements into D address queues 708 . Specifically, the address queues 708 store memory addresses of the data elements in hardware rather than the values of the data elements themselves. In block 806 of the flow chart 800 , the enqueuing controller 706 receives the set of memory addresses generated by the modulo address generator 704 , and in block 808 of the flow chart 800 , forwards the memory addresses into the corresponding address queues 708 , while concurrently adding control information into a control queue 710 . The control information is used to synchronize reception on a receiving dequeuing controller 712 .
[0070] The address queues 708 feed into a plurality of address decoders 714 respectively which in turn feed into a plurality of data queues 716 respectively. Specifically, in block 810 of flow chart 800 , the address decoders 714 decode the memory addresses of the data elements in the address queues 708 , into their respective data elements, and queue the decoded data elements into the data queues 716 respectively.
[0071] In block 812 of the flow chart 800 the dequeuing controller 710 receives the queued data elements from the data queues 714 , and receives the control information from the control queue 708 , and forwards to a reverse permutaton 716 , based at least on the received control information.
[0072] In block 814 of the flow chart 800 , the reverse permutaton 718 performs the inverse operation of the modulo address generator's 704 forward permutaton, to restore the data received from the dequeuing controller 712 . Upon doing so, in block 816 of the flow chart 800 , the restored data is forwarded to data out 720 .
Exemplary Use Cases
[0073] As described with respect to FIG. 1 , the multicast network and memory transfer optimizations disclosed herein may be applied to neural network operations. One or more multicast networks may be used to forward permutations of data elements stored in memory banks to a plurality of execution units. If multiple multicast units are used, then those units may use different permutations to feed into execution units. In one embodiment, different multicast units may relate to different partitions of a tensor.
[0074] In this way, the multicast network and the memory transfer units may be thought of discretely and separately from the context of a neural network hardware accelerator, each with applications potentially unrelated to neural network hardware acceleration.
[0075] By way of example, the multicast network and memory transfer optimizations may be used in other hardware acceleration contexts, such as graphical processing including the calculation of linear algebra operations, tensor operations specific to graphics and quaternion operations.
[0076] In the case of memory transfer optimizations, the application need not be specific to particular operations, but may be used simply in a memory controller. For example, where partitions and/or vectors of a data elements stored in contiguous memory are to be transferred, the memory transfer optimizations may be applied. Furthermore, because the multicast network optimizations may copy and permute data elements arbitrarily, used in conjunction with the memory transfer operations may provide the basis for a full memory controller.
Conclusion
[0077] Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.
|
Neural network specific hardware acceleration optimizations are disclosed, including an optimized multicast network and an optimized DRAM transfer unit to perform in constant or linear time. The multicast network is a set of switch nodes organized into layers and configured to operate as a Bene{hacek over (s)} network. Configuration data may be accessed by all switch nodes in the network. Each layer is configured to perform a Bene{hacek over (s)} network transformation of the -previous layer within a computer instruction. Since the computer instructions are pipelined, the entire network of switch nodes may be configured in constant or linear time. Similarly a DRAM transfer unit configured to access memory in strides organizes memory into banks indexed by prime or relatively prime number amounts. The index value is selected as not to cause memory address collisions. Upon receiving a memory specification, the DRAM transfer unit may calculate out strides thereby accessing an entire tile of a tensor in constant or linear time.
| 6
|
BACKGROUND OF THE INVENTION
Close to 70% of kidney stones in man are composed partially or predominantly of calcium oxalate. There is no satisfactory drug specific for the treatment of calcium oxalate renal lithiasis, nor for prophylactic use by patients prone to recurrent attacks of this disease.
The most common treatment for renal lithiasis due to calcium oxalate consists of surgical removal of stones, control of the diet to restrict calcium or oxalate, and ingestion of large quantities of water to dilute the urine. Attempts at chemotherapy have included the administration of magnesium oxide, calcium carbimide, orthophosphate, cellulose phosphate, isocarboxazide, thiazide diuretics, allopurinol and succinimide. Limited success has been realized by these drug approaches. No drug which specifically inhibits the biosynthetic formation of oxalic acid has previously been developed for the treatment of calcium oxalate renal lithiasis.
The immediate metabolic precursor of the majority of the oxalate in the urine of a typical patient is glyoxylic acid. In turn its most important precursor is glycolic acid. The enzyme glycolate oxidase is able to carry out the oxidation of glycolic acid, through glyoxylic acid, to oxalic acid. Inhibition of this enzyme will, therefore, reduce the concentration of oxalic acid in the kidney and bladder, reducing the probability that calcium oxalate crystallization will occur. Thus inhibitors of glycolate oxidase provide a specific approach to the prevention and treatment of calcium oxalate renal lithiasis.
Liao, et al, Arch. Biochem. Biophys., 154, 68-75 (1973) have shown that phenyllactic acid and n-heptanoic acid, which are inhibitors of glycolate oxidase, inhibit oxalate biosynthesis in isolated perfused rat liver. These compounds are not sufficiently potent to be useful as drugs.
The preparation of 3-hydroxy-4-phenyl-3-pyrroline-2,5-dione ##STR1## has been described by Harlay, J. Pharm. Chim., 24, 537-48 (1936). 3-Hydroxy-4-aryl-3-pyrroline-2,5-diones are described in U.S. Pat. No. 3,349,263 as intermediates in the preparation of antiphlogistic substances. A number of 3-hydroxy-4-substitutedphenyl-3-pyrroline-2,5-diones are reported by G. S. Skinner et al., J. Am. Chem. Soc., 73, 2230 (1951). (In this paper these compounds are referred to as pyrrolidine-2,3,5-trione derivatives). 3-Hydroxy-4-(4-bromo-1-naphthyl)-3-pyrroline-2,5-dione is described by G. S. Skinner et al., J. Am. Chem. Soc., 70, 4011 (1948).
SUMMARY OF THE INVENTION
It has now been found that novel compounds of the formula: ##STR2## wherein n is 0 to 2;
R is; ##STR3## wherein
R 1 and R 2 on the pyridine ring are independently hydrogen, loweralkyl containing 1 to 4 carbons or halogen and pharmaceutically acceptable salts thereof, are potent inhibitors of glycolate oxidase. They are, therefore, useful in the treatment and prevention of calcium oxalate kidney and bladder stone formation.
Preferred compounds are those wherein n is 0 having the structure: ##STR4## wherein
R 1 and R 2 are independently hydrogen, halogen or loweralkyl containing 1 to 4 carbons.
Still further preferred compounds are those wherein R 1 and R 2 are hydrogen having the structure: ##STR5##
Still further preferred compounds are those having the structure: ##STR6##
DETAILED DESCRIPTION
About 70% of all renal calculi contain oxalate as the main component of the matrix. In the majority of patients the condition is associated with a higher than average level of metabolically produced oxalate. The major pathway for biosynthesis of oxalate can be represented as follows: ##STR7## Glyoxylate is the major immediate forerunner of oxalate. An inhibitor of glycolate oxidase (G.O.) will inhibit both the conversion of glyoxylate to oxalate as well as the production of glyoxylate from glycolate. By reducing oxalic acid levels in the urine with the compounds of this invention, the formation of oxalate calculi will be reduced or prevented.
Compounds of formula (I) are potent inhibitors of glycolate oxidase and thus are useful in restricting oxalate levels in the blood and urine. Further, they are useful in the treatment and prevention of renal disease due to calcium oxalate stone formation in the kidney and bladder. They may be useful in the treatment of the genetically inherited diseases termed Hyperoxaluria types I and II in which very high levels of metabolic oxalic acid are present.
Compounds of formula (I) have been unexpectedly found to block the contractions of guinea pig ileum induced by Slow Reacting Substance of Anaphylaxis (SRS-A). They are ineffective against contractions caused by histamine, which demonstrates specificity against SRS-A. SRS-A is considered a major mediator in human allergic asthma. Thus the compounds of formula (I) are useful in the treatment of allergy, especially allergic asthma.
Compounds of formula (I) can be prepared according to the following scheme: ##STR8## wherein
R 1 and R 2 are as defined above.
The compounds (I) wherein the heterocyclic substituent is at the 2-position of the thiazole ring are prepared generally by the method of Fairfull, Lowe and Peak, J. Chem. Soc., 742 (1952). The nitrile (II), prepared by known methods, is reacted with excess hydrogen sulfide gas in the presence of excess triethylamine in a basic organic solvent such as pyridine. When the reaction is complete, the reaction mixture is poured into ice-water and the thiobenzamide (III) collected by filtration.
When n=0 the ethyl 4-thiazolylacetates (IV) are prepared by the classic Hantzsch procedure using the thiobenzamide (III) and ethyl 4-chloroacetoacetate. When n=1 or 2 the homologous chloro- or bromomethyl ketones are utilized.
Stirring the esters (IV) in concentrated ammonium hydroxide and dioxane or ammonia in methanol or ethanol for varying lengths of time, and temperature yield the corresponding amides (V).
Preparation of the pyrrolinediones from the amides (V) is accomplished by two different routes.
1. When n=0 the amides react with diethyl oxalate in a solvent such as DMF in the presence of strong base (generally alkali metal alkoxide) under an inert atmosphere. Acidification provides the desired hydroxypyrrolinedione derivative.
2. When n=0, 1 or 2, the intermediate amide is converted to the nitrile by dehydration using prior art procedures (e.g. thionyl chloride in DMF or pyridine, or p-toluenesulfonyl chloride in pyridine or DMF). The nitrile is reacted with diethyl oxalate and strong base (alkali metal alkoxide) in a solvent such as DMF or toluene. The resulting 3-cyano-2-ketoacid ethyl ester is converted to the desired 3-hydroxy-3-pyrroline-2,5-dione derivative by dissolving in sulfuric or methanesulfonic acid, allowing the mixture to stand at room temperature overnight, and then pouring into ethanol containing 5-10% water.
Alternatively, the 3-cyano-2-ketoacid ethyl ester intermediate may be converted to the iminoether using cold ethanolic hydrogen chloride for 20-48 hours. The iminoether hydrochloride on heating in refluxing chloroform is converted to the hydroxypyrrolinedione derivative.
For compounds of this invention wherein the hydroxypyrrolinedione moiety is attached at the 5-position of the thiazole ring, the above procedures are followed with the exception that for the thiazole ring-forming step there is utilized instead of the χ-haloketone, the isomeric χ-halo aldehydic ester intermediate. For example, in place of 4-chloroacetoacetic ethyl ester, 4-oxo-3-bromobutyric acid ethyl ester is employed.
The following examples, given by way of illustration and not to be construed as limiting, further clarify the invention.
EXAMPLE 1
General Method for the Preparation of 3-Hydroxy-4-substituted-3-pyrroline-2,5-diones from Thiazoleacetamide Intermediates
A mixture of the substituted acetamide (10 mmole), diethyl oxalate (1.533 g, 10.5 mmole) and dry dimethylformamide (20 ml) is stirred under nitrogen or argon and cooled in an ice-bath. Potassium t-butoxide (2.464 g, 22 mmole) is added in two equal portions 15 minutes apart and the reaction mixture is stirred for about 30 minutes in the ice-bath and then at room temperature overnight. The reaction mixture is poured into ice-water (100 ml). If the potassium salt of the product dissolves, the aqueous mixture is extracted with ethyl acetate (2×35 ml) and then acidified with 6 N hydrochloric acid in order to precipitate the product. The product is either collected by filtration or by extraction with ethyl acetate.
If the potassium salt is not soluble when the reaction mixture is quenched in ice-water, then it is necessary to acidify the resulting suspension and collect the product by filtration. The crude product is generally less pure when obtained in this way.
Compounds may be solvated after recrystallization (with either DMF, dioxane, isopropanol or acetonitrile) and require drying at 110° C./0.05 Torr in order to remove the solvate.
EXAMPLE 2
Preparation of 3-Hydroxy-4-[2-(4-pyridyl)thiazol-5-yl]-3-pyrroline-2,5-dione
Pyridine-4-thioamide (1.38 g, 0.01 mole) and 3-bromo-4-oxobutyric acid ethyl ester (3.1 g., 0.015 mole) in ethanol (50 ml) are heated at reflux for six hours. After cooling the solvent is evaporated and the residue is neutralized with sodium bicarbonate solution and then extracted with chloroform (300 ml.). The chloroform solution is washed with water, dried with (MgSO 4 ) and evaporated to yield crude 2-(4-pyridyl)-thiazole-5-acetic acid ethyl ester. Purification is carried out by dissolving in acetone and adding petroleum ether to induce crystallization. When this ester intermediate is treated with methanol solution saturated with ammonia gas (25 ml./g. of ester) for 3 days at room temperature 2-(4-pyridyl)thiazol-5-ylacetamide is obtained after partial evaporation of the methanol. Purification is carried out by recrystallization from ethanol. When the amide is treated according to the procedure in Example 1, there is obtained 3-hydroxy-4-[2-(4-pyridyl)thiazol-5-yl]-3-pyrroline-2,5-dione.
When the above procedure is carried out starting with 3-chloro or 3-bromopyridine-4-thioamide, but substituting 4-chloro-3-oxobutyric acid ethyl ester for the 3-bromo-4-oxobutyric acid ethyl ester, there are obtained 3-hydroxy-4-[2-(3-chloro-4-pyridyl)thiazol-4-yl]-3-pyrroline-2,5-dione and 3-hydroxy-4-[3-bromo-4-pyridyl)thiazol-4-yl]-3-pyrroline-2,5-dione respectively.
EXAMPLE 3
3-Hydroxy-4-[2-(4-pyridyl)thiazol-4-yl]-3-pyrroline-2,5-dione
When pyridine-4-thioamide is reacted with 6-chloro-5-oxohexanenitrile, according to the procedure of Example 2 (in place of 3-bromo-4-oxobutyric acid ethyl ester) there is obtained 4-[2-(4-pyridiyl)thiazol-4-yl]-butanenitrile. To a solution of this nitrile (2.29 g., 0.01 mole) in dimethylformamide (30 ml.) is added diethyloxalate (1.74 g., 0.012 mole), and potassium t-butoxide (2.48 g., 0.022 mole). The mixture is stirred overnight. Following evaporation under vacuum to one-half volume, chloroform (500 ml.) is added plus water (200 ml.), and the mixture acidified with conc. HCl to pH 2-3. The chloroform is separated, washed well with water, and evaporated to yield 2-oxo-3-cyano-5-[2-(4-pyridyl)thiazol-5-yl]pentanoic acid ethyl ester. The ester (3.24 g., 0.01 mole) is dissolved in methanesulfuric acid (30 ml.) and stirred for 24 hours. To the acidic mixture is added 80% ethanol-water. After standing for 2 hours, the ethanol is removed under vacuum. The residual aqueous mixture is neutralized with pyridine to pH 2-3, and the title product obtained on filtration.
EXAMPLE 4
2-[2-(4-Pyridyl)thiazol-4-yl]acetonitrile
To 2-[2-(4-pyridyl)thiazol-4-yl]acetamide (2.19 g., 0.01 mole) in pyridine (30 ml.) is added gradually p-toluenesulfuryl chloride (1.91 g., 0.01 mole). After stirring for one hour the mixture is poured into excess ice-water to give the title compound.
The physical constants of certain intermediates and end-product hydroxypyrrolinediones of this invention are tabulated below:
__________________________________________________________________________ ##STR9## ##STR10## ##STR11##RCN Calc. Fd. Calc. Fd. Calc. Fd.__________________________________________________________________________ ##STR12## N C H Cl 8.96 53.75 5.48 11.33 8.89 53.71 5.30 11.26 N C H 16.99 58.28 5.30 16.86 58.49 5.28 N C H 13.95 55.80 3.68 14.22 55.60 3.64 MP 94-96° C. MP 208-210° C. MP 288° C. ##STR13## N C H 11.28 58.04 4.87 11.43 58.29 4.91 N C H 19.17 54.78 4.14 18.87 54.72 4.26 N C H 15.38 52.74 2.58 15.66 52.57 2.71 MP 197-199° C. MP 290° C. (dec.) ##STR14## N C H 9.84 50.61 4.60 10.04 50.43 4.62 N C H 19.17 54.78 4.14 19.03 54.78 4.20 N C H 15.38 52.74 2.58 15.62 52.97 2.44 MP 123-125° C. MP 175-177° C. MP 269-270° C. ##STR15## Oil N C H 25.44 49.08 3.66 25,38 49.07 3.61 N C H 20.43 48.17 2.21 20.44 48.05 2.24 MP 169-171° C. MP 289-291° C. (dec.) ##STR16## N C H 11.02 47.22 3.96 11.12 47.46 3.95 N C H 18.65 42.65 3.13 18.53 42.71 3.08 N C H 15.05 43.00 1.80 15.21 42.81 1.92 MP 88-90° C. MP 175-177° C. MP 279-280° C.__________________________________________________________________________ (dec.) NOTE: The compounds of this invention may also be termed 3(substituted thiazolyl)4-hydroxy-3-pyrroline-2,5-dione derivatives.
Included within the scope of the invention are the pharmaceutically acceptable salts of formula (I) compounds. The compounds of formula (I) are strong organic acids with a pKa in the range 2-4. Thus salts are readily formed with the usual inorganic cations such as sodium, potassium and ammonium. Salts with organic amines such as trimethylamine, triethylamine, n-butylamine and the like are also very stable. The neutralization can be carried out by a variety of procedures known to the art to be generally useful for the preparation of such salts. The choice of the most suitable procedure will depend on a variety of factors including convenience of operation, economic considerations, and particularly the solubility characteristics of the particular free base, the acid, and the acid addition salt.
The compounds of formula (I) are utilized for the stated utilities by formulating them in a composition such as tablet, capsule or elixir for oral administration. Sterile solutions or suspensions can be used for parenteral administration. About 10 to 200 mg of a compound of formula I or a physiologically acceptable salt is compounded with a physiologically acceptable vehicle, carrier, excipient, binder, preservative, stabilizer, flavor, etc., in a unit dosage form as called for by accepted pharmaceutical practice. The amount of active substance in the composition is such that dosage in the range indicated is obtained. The total daily dose will be in the 30 to 2000 mg range, and preferably in the range of 50 mg to 1000 mg.
Illustrative of the adjuvants which may be incorporated in tablets, capsules and the like are the following: a binder such as gum tragacanth, acacia, corn starch or gelatin; an excipient such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid and the like; a lubricant such as magnesium stearate; a sweetening agent such as sucrose or lactose; a flavoring agent such as peppermint, oil of wintergreen or cherry. When the dosage unit form is a capsule, it may contain in addition to materials of the above type a liquid carried such as a fatty oil. Various other materials may be present as coating or to otherwise enhance the pharmaceutical elegance of the preparation. For instance, tablets may be coated with shellac, sugar or the like. A syrup or elixir may contain the active compound, sucrose as a sweetening agent, methyl and propyl parabens as preservatives, a dye and a flavoring such as cherry or orange flavor.
Sterile compositions for injection can be formulated according to conventional pharmaceutical practice by dissolving or suspending the active substance in a conventional vehicle such as water for injection, a naturally occurring vegetable oil like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or a synthetic fatty vehicle like ethyl oleate or the like. Buffers, preservatives, antioxidants and the like can be incorporated as required.
|
Novel 4-(substituted thiazolyl)-3-hydroxy-3-pyrroline-2,5-diones are disclosed which inhibit glycolic acid oxidase and thus are useful in the treatment and prevention of calcium oxalate renal lithiasis.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of and priority to European Patent Application No. 13 195 600.5 filed Dec. 4, 2013, the entire disclosure of which is incorporated by reference herein.
TECHNICAL FIELD
The present disclosure relates to a method and apparatus for repairing composite components, especially fiber-reinforced polymer or plastic components with continuous fibers.
BACKGROUND
The use of composite materials in the design and manufacture of aircraft and spacecraft is becoming increasingly prevalent due to the low-weight and relatively high-strength properties achievable with those materials, among which fiber-reinforced polymer composites, such as carbon fiber reinforced polymers (CFRP), are especially preferred. An important issue with the use of fiber-reinforced polymer composite materials in modern aircraft production concerns the repair of such components; i.e. when those components are found to have a defect or if they sustain damage due to an inadvertent impact. Clearly, it will generally be preferable to repair a component having a small defect or minor damage rather than replace an entire component, especially for larger or more complex components.
Current techniques for repairing damaged CFRP components in the aircraft industry involve removing an affected area (e.g. a damaged area or a defective area) from the component and inserting a ply doubler. This has the notable disadvantage, however, that elongate or continuous reinforcing fibers of the component extending through the affected area are cut or severed. In order to achieve a corresponding load-carrying or load-transfer capability in this area, therefore, the repair is required to substantially reinforce the component in this area.
SUMMARY
The method and apparatus of the disclosure herein are directed to redressing this problem and are especially suitable for use in the aircraft and aerospace industries. It will be noted, however, that the method and the apparatus of the disclosure herein are not limited to the aircraft and aerospace industries, but may be used in a range of applications where fiber-reinforced polymer composites are employed.
According to one aspect, therefore, the disclosure provides a method of repairing a component of a fiber-reinforced polymer composite, especially with elongate or continuous reinforcing fibers in a polymer matrix, the method comprising:
providing a controlled atmosphere around an affected area of the component; heating the component in the affected area within the controlled atmosphere to cause pyrolysis or depolymerization of the polymer matrix in the affected area, thereby to remove the polymer matrix from the affected area; and introducing polymer resin into a space left by the matrix removed by pyrolysis or depolymerization to refill the affected area.
For the sake of clarity, it will be appreciated that the term “affected area” used in relation to the present disclosure may be understood to include a damaged area, being an area of the component that may have been subject to a damaging influence, such as a physical impact, and/or a defective area, being an area of the component that may include some physical defect, such as an inclusion, e.g. due to a manufacturing process.
The repair method of the disclosure has the advantage that the polymer matrix material can be removed from the affected area of the component while leaving the reinforcing fibers in that area intact. That is, the elongate or continuous reinforcing fibers in the affected area are not severed or cut or removed but rather remain substantially unchanged in the space left upon removal of the matrix by pyrolysis or depolymerization. For this reason, the polymer resin introduced into that space can again be infused into those fibers, which are later then able to transmit loading through that area of the component as before. This can provide a very high quality repair with physical and structural properties at the repaired area being essentially the same as an unaffected area of the component.
In a further embodiment, the step of providing a controlled atmosphere around the affected area of the component includes locally enclosing or isolating the affected area of the component, for example, by arranging the affected area within a treatment chamber or cavity. Further, the step of providing a controlled atmosphere preferably includes filling a chamber or cavity that locally encloses or isolates the affected area with a relatively inert or non-reactive gas or gas mixture, such as nitrogen gas. In this way, the chamber or cavity of inert or non-reactive gas or gas mixture forms the controlled atmosphere around the affected area, within which a pyrolysis or depolymerization of the polymer matrix may take place. An unwanted oxidization or burning of the matrix material can thereby be avoided as the repair method of the disclosure is carried out.
In a further embodiment, the step of heating the component in the affected area comprises applying energy locally to the affected area to heat the polymer matrix. In this regard, the localized application of energy preferably involves applying one or more of: a direct heat source, such as a stream of hot gas, and/or indirect heating via microwave energy, such as a microwave beam, or laser energy, such as a laser beam. The polymer resin matrix of the component in the affected area is preferably heated to a temperature in the range of about 300° C. to 700° C., more preferably about 450° C. to 600° C.
In another embodiment, the step of heating the component in the affected area includes controlling or regulating the temperature of the component in the affected area. This may, for example, include sensing a temperature on or adjacent to the affected area of the component and adjusting the degree of heating to maintain the temperature within a range of pre-defined upper and lower limits. The heating step preferably also includes substantially confining or limiting the heating to the affected area. In one embodiment, this may be achieved by insulating or isolating other regions of the component from the locally applied energy, such as by cooling a periphery of the affected area.
In a further embodiment, the method comprises the preliminary step of providing at least one hole or bore which penetrates through the component in the affected area. Each hole or bore may, for example, be drilled through the affected area. The at least one hole or bore then enables the controlled atmosphere to penetrate through the component, and also enables heat provided directly (e.g. in a hot gas) to penetrate through the affected area and into a central region of the polymer matrix.
In another embodiment of the disclosure, the method step of introducing polymer resin includes covering at least one side of the space in the affected area left by the pyrolyzed or depolymerized matrix with a molding tool to form a mold cavity; and infusing or injecting polymer resin (i.e. in liquid or fluid form) into the mold cavity to re-fill the space. As may be expected, the molding tool will preferably follow a desired contour of the component in the affected area. After the fluid polymer resin has been infused into the reinforcing fibers in the space created, the resin is then preferably cured in the mold cavity. The curing step will typically take place in an autoclave or oven as is known in the art.
In a further embodiment of the disclosure, the method may further include the step of preparing a peripheral edge around the space left by removal of the polymer matrix by pyrolysis or depolymerization to form a profile or shape with which the new resin introduced into the mold cavity may form a mechanical connection in the component. For example, preparation of the peripheral edge could include machining or modifying the edge region to form one or more slot, groove, shoulder, or other profile or shape to assist integration of the newly introduced polymer resin in the component.
The material of the polymer matrix is usually a polymer resin such as a thermosetting resin, and can be selected from the group consisting of epoxy, polyester, vinyl ester, and nylon resins. As noted above, the reinforcing fibers can be selected from the group of carbon fibers, glass fibers and aramid fibers. Thus, the fiber-reinforced polymer (FRP) can be a carbon fiber reinforced polymer (CFRP), and/or a glass fiber reinforced polymer (GFRP), and/or an aramid fiber reinforced polymer (AFRP).
According to another aspect, the present disclosure provides an apparatus for use in repairing an affected area of a component of fiber-reinforced polymer composite, especially having elongate or continuous reinforcing fibers in a polymer resin matrix, the apparatus comprising:
a casing with a treatment chamber or cavity configured to surround or encompass the affected area of the component; an inlet into the casing for introducing a controlled atmosphere into the treatment chamber or cavity surrounding or encompassing the affected area; and a heating device for local application of energy to the affected area within the treatment chamber or cavity to effect pyrolysis or depolymerization of the polymer matrix in the affected area.
In another embodiment, the casing may be configured to enclose and/or isolate the affected area of the component. In this regard, walls of the casing define the treatment chamber or cavity. Furthermore, the casing is desirably configured to enclose and/or isolate the affected area at opposite sides of the component. To this end, the casing may have a first part and a second part for respectively mounting at opposite sides of the component, wherein the first and second parts of the casing together define the treatment chamber or cavity. In this regard, the casing may include a mounting mechanism for mounting the casing on or adjacent to the component, e.g. such that a first part of the casing is mounted to cover one side of the affected area and a second part of the casing is mounted to cover an opposite side of the affected area.
In another embodiment, the apparatus further comprises an insulator device for substantially confining or limiting heat generated by the heating device to the affected area. To this end, the insulator can include a cooling arrangement for cooling at or around a periphery of the casing which surrounds or encompasses the affected area so as to insulate other parts of the component from the heat generated by the heating device.
In another embodiment, the apparatus further comprises a molding tool for covering at least one side of the space in the affected area from which the pyrolyzed or depolymerized matrix is removed. Thus, the molding tool is configured to form a mold cavity with the component, and the molding tool typically follows a desired contour of the component in the affected area.
According to a further aspect, the present disclosure provides a component that is repaired by a method and/or apparatus of the present disclosure according to any one of the embodiments described above. In another aspect, the disclosure provides a vehicle, such as an aircraft or spacecraft, with an airframe or fuselage structure including at least one component that has been repaired by a method or apparatus of the disclosure according to any of the embodiments described above.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present disclosure and the advantages thereof, exemplary embodiments of the disclosure are explained in more detail in the following description with reference to the accompanying drawings, in which like reference characters designate like parts and in which:
FIG. 1 is a schematic perspective view of a component of a fiber-reinforced polymer composite having a damaged area;
FIG. 2 is a cross-sectional side view of the component of FIG. 1 in a direction X-X showing the damaged area;
FIG. 3 is a cross-sectional side view of the component of FIG. 1 in the direction of arrows X-X and shows a bore or hole formed through the damaged area;
FIG. 4 is a cross-sectional side view of an apparatus of a preferred embodiment of the disclosure deployed with the component of FIG. 1 ;
FIG. 5 is a cross-sectional side view of the apparatus of FIG. 4 in use;
FIG. 6 is a series of images t1 to t5 illustrating stages in the use or operation of the apparatus of FIG. 4 ;
FIG. 7 is a cross-sectional side view of the component of FIG. 1 showing a region of removed polymer matrix;
FIG. 8 is a cross-sectional side view of the component of FIG. 7 showing preparation of the region of removed polymer for application of new matrix material;
FIG. 9 is a cross-sectional side view of the component of FIG. 1 showing the repaired region; and
FIG. 10 is a schematic illustration of an aircraft having a fuselage or airframe structure which includes one or more composite component repaired by a method or an apparatus according to the disclosure.
DETAILED DESCRIPTION
The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate particular embodiments of the disclosure and together with the description serve to explain the principles of the disclosure. Other embodiments of the disclosure and many of the attendant advantages of the disclosure will be readily appreciated as they become better understood with reference to the following detailed description.
It will be appreciated that common and/or well understood elements that may be useful or necessary in a commercially feasible embodiment are not necessarily depicted in order to facilitate a more abstracted view of the embodiments. The elements of the drawings are not necessarily illustrated to scale relative to each other. It will further be appreciated that certain actions and/or steps in an embodiment of a method may be described or depicted in a particular order of occurrences while those skilled in the art will understand that such specificity with respect to sequence is not necessarily required. It will also be understood that the terms and expressions used in the present specification have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study, except where specific meanings have otherwise been set forth herein.
Referring first to FIG. 1 of the drawings, a composite component C is shown in the form of a curved CFRP panel that may, for example, form a section of a fuselage structure for an aircraft. The CFRP panel component C comprises multiple layers of elongate or continuous reinforcing fibers F (e.g. in the form of woven carbon fiber fabric sheets) embedded within a polymer resin matrix M and includes a damaged area A shown in a cross-section in FIG. 2 taken in the direction of the arrows X-X illustrated in FIG. 1 . The damaged area A may, for example, have been caused by a physical impact and could include a delamination of one or more layers of the carbon fibers F within the polymer matrix M and/or a fracture in the polymer matrix M itself.
In performing or conducting a repair of the damaged area A according an embodiment of this disclosure, a preliminary step includes forming (for example, by drilling) at least one hole or bore B through the component C in the damaged area A, as shown in FIG. 3 . The hole or bore B is typically relatively fine or small and in the case of a small damaged area A, only one such hole or bore B may be required, e.g. centrally of the damaged area A. In a larger damaged area A, however, two or more such holes or bores B may optionally be formed. Each hole or bore B thus provides fluid communication through the panel component C in the damaged area A.
With reference now to FIGS. 4 and 5 of the drawings, an apparatus 1 for use in repairing the damaged area A of the panel component C is illustrated deployed and in operation in the damaged region A of the panel component. The apparatus 1 comprises a casing 2 having a first part 2 ′ mounted on a first (e.g. front) side of the panel component C and a second part 2 ″ mounted on a second, opposite (e.g. rear) side of the panel. The casing 2 is configured to enclose and/or isolate the damaged area A of the panel component and the first and second parts 2 ′, 2 ″ of the casing 2 together form or define a treatment chamber or cavity 3 which substantially surrounds or encompasses the affected area A of the panel.
Further, the apparatus 1 includes an inlet 4 in the casing 2 for introducing a gas or a gas mixture into the treatment chamber or cavity 3 to provide a controlled and essentially inert atmosphere 5 within that chamber or cavity 3 . In this regard, nitrogen gas (N 2 ) is particularly preferred for the controlled atmosphere. The at least one hole or bore B formed through the damaged area A in the panel component C enables the nitrogen gas (N 2 ) to pass through the component C into the second or rear portion of the treatment chamber 3 defined by the second casing part 2 ″, thereby enabling the treatment chamber 3 in the casing 2 to be filled with nitrogen gas (N 2 ) and thus provide the non-reactive atmosphere 5 throughout the treatment chamber 3 . As will be understood by persons skilled in the art, the rear part 2 ″ of the casing 2 may include an outlet (not shown) for the gas (N 2 ) to exit the chamber 3 and then be recirculated back to the inlet 4 to be re-introduced into the casing 2 .
As can be seen in FIGS. 4 and 5 of the drawings, the method and apparatus 1 of the disclosure involves a localized heating of the panel component C in the damaged area A within the controlled atmosphere 5 contained within the casing 2 . The heating mechanism 6 according to this preferred embodiment of the disclosure may comprise a physical heat source, such as a stream of hot gas, which may be precisely directed onto the damaged area A of the component C. Indeed, it is contemplated that the hot gas stream 6 may also comprise the nitrogen gas used to generate the controlled atmosphere 5 . Alternatively, or in addition, the heating mechanism 6 may be configured to apply energy in other forms in a localized or focused manner onto the damaged area A. For example, that heating energy may be in the form of a microwave beam and/or a laser beam, which may also be introduced into the casing 2 via the inlet 4 , as described previously. As will be appreciated, however, the apparatus 1 may include a separate inlet, introduction point, or source for the energy to be applied to the damaged area A.
With reference to drawing FIG. 5 , the particular embodiment illustrated includes a hot gas stream 6 as the energy source for directly heating the damaged area A within the treatment chamber 3 . In this connection, the stream of hot gas 6 may penetrate the panel component C through the at least one hole or bore B drilled through the damaged area A as a preliminary step. As such, the hot gas, typically having a temperature in a range of 400° C. to 600° C., can pyrolyze or depolymerize the polymer resin of the composite matrix M both at the first side and the second side as well as through the core of the panel component C within the casing 2 of the apparatus. As noted above, the second part 2 ″ of the casing 2 may include an outlet (not shown) for the hot gas 6 to be recirculated in the treatment chamber 3 —i.e. back to the inlet 4 to be re-introduced into the casing 2 .
The first and second casing parts 2 ′, 2 ″ of the apparatus 1 may be mounted on and secured to the panel component C by non-contact fastening elements 7 , such as strong magnets. In this way, a strong magnetic attraction between the fastening elements 7 on opposite side of the panel component C operates to hold the first and second parts 2 ′, 2 ″ of the casing 2 fixed in position on opposite sides of the panel C without the need for any physical penetration or damage to the panel. As resilient sealing members (not shown) are typically also desired to avoid any gas leak from the atmosphere 5 generated within the treatment chamber 3 , the resilient sealing members are typically provided between the first and second casing parts 2 ′, 2 ″ and the panel component C, respectively, which also serve to avoid any superficial stretching or damage to the panel C by the strong magnetic attraction of the non-contact fastening elements 7 .
In order to limit or confine the heating of the polymer resin matrix M to the damaged area A enclosed by the casing 2 , the apparatus 1 also incorporates an insulator device 8 which is configured to provide cooling to the panel component around a periphery of the damaged area A. In this regard, each of the first and second parts 2 ′, 2 ″ of the casing 2 includes a cooling circuit or channel 9 for circulating a cooling liquid in thermal contact around a periphery of the damaged area A. This cooling circuit 9 thus prevents an undesired extension of the pyrolysis or depolymerization of the resin matrix M beyond a predetermined extent.
With reference now to FIG. 6 of the drawings, a series of images t1 to t5 illustrate the progress (i.e. over time) of the pyrolysis or depolymerization that occurs with the method and apparatus 1 according this preferred embodiment. In this regard, the image t1 illustrates the damaged area A in the panel component C together with the hole or bore B formed centrally through the damaged area (i.e. as shown in FIG. 3 ) before the apparatus 1 is mounted on the panel component C. The image t2 in FIG. 6 then represents that the apparatus 1 of FIGS. 4 and 5 (shown in miniature next to the image t2) is mounted onto the panel C as described above. The darkened region in the middle of the damaged area A represents a start or early stage of heating within the controlled atmosphere 5 of the chamber 3 in the casing 2 by the introduction of a hot gas stream 6 (or other localized heating, such as a microwave beam) onto and through the damaged area A. Regions of the panel component C remote from damaged area A, however, are thermally insulated from the heating with the apparatus 1 via the cooling circuit 9 in the casing 2 , as is represented by the dark circular ring R spaced from the damaged area A.
The image t3 of FIG. 6 shows that the heated region of resin matrix M in and around the damaged area A has grown, as represented by the central darkening of the polymer matrix M. In other words, the resin matrix M in the damaged area now typically has a highly elevated temperature (e.g. in a range of about 450° C. to 600° C.) in the controlled atmosphere 5 of the treatment chamber 3 due to the heat source 6 directed onto the damaged area A. In the image t4 of FIG. 6 , it can be seen that a pyrolysis or depolymerization of the resin matrix M progresses to such an extent under a continuous influence of the heating mechanism, that the polymer matrix M is slowly but increasingly removed from the panel component C in the damaged area A. In this regard, the pyrolyzed matrix material may be removed or carried away from the damaged area A by the gas stream 5 , 6 to an outlet (not shown) in the rear casing part 2 ″, from which it is then exhausted from the casing 2 . The reinforcing fibers F in the layers of woven carbon fiber fabric embedded within the polymer matrix M, however, remain essentially unaffected by the elevated temperature in the matrix material. As such, the degradation and removal of the polymer matrix M by this pyrolysis or depolymerization simply exposes the reinforcing fibers F in this area A of the panel component. Finally, the image t5 of FIG. 6 shows completion of the pyrolysis or depolymerization of the resin matrix M as the heating and removal phase reaches a limit or confinement defined by the cooled region generated by the cooling circuit 9 of the insulator device 8 in the apparatus 1 .
FIG. 7 of the drawings then illustrates the panel component C (i.e. again in the cross-section X-X) after the state shown in image t5 of FIG. 6 has been reached. Specifically, the polymer matrix material M in and immediately surrounding the damaged area A has been removed from the panel component C to create a space 10 but the reinforcing fibers F in the various layers that were previously embedded within that resin matrix M remain substantially intact.
Referring now to FIG. 8 of the drawings, a molding tool 11 including a cover member 12 may be applied over an outer side of the panel component C such that it covers the space 10 in the damaged area A from which the polymer matrix M has been removed by the pyrolysis performed with the apparatus 1 , as described above. The molding tool 11 forms a surface contour in the cover member 12 which essentially corresponds with a desired outer contour of the panel component C and, together with the space 10 , forms a mold cavity 13 in the damaged region A for introducing new polymer resin to re-impregnate or infuse the exposed reinforcing fibers F. Thus, the method of this embodiment further includes introducing new polymer resin N into the space 10 in the panel component C created by removal of the matrix material M in order to refill and re-impregnate those reinforcing fibers F. To assist integration of the newly introduced polymer resin N in the component C, a peripheral edge 14 surrounding the space 10 could be prepared (e.g. machined) to provide a profile or shape, such as one or more slot or groove, with which the resin N introduced into the mold cavity 13 may form a mechanical connection in the component C. As a final step, the polymer resin N introduced into the mold cavity 13 and conforming to the desired shape or contour of the panel C can then be cured (for example, in an autoclave or an oven as is known in the art) to complete the repair procedure. FIG. 9 of the drawings illustrates the panel component C again in a cross-section taken in the direction of arrows X-X after the curing of the newly introduced polymer resin and therefore after the entire repair procedure has been completed.
Finally, with reference to FIG. 10 , a schematic illustration of an aircraft P is shown having an airframe which includes a fuselage H, wings W, and an empennage E. The airframe of the aircraft P incorporates one or more panel component repaired with a method and/or an apparatus 1 according to a preferred embodiment of the disclosure, for example, as described above with reference to FIG. 1 to FIG. 9 .
Although specific embodiments of the disclosure have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations exist. It should be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing summary and detailed description will provide those skilled in the art with a convenient road map for implementing at least one exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims and their legal equivalents. Generally, this application is intended to cover any adaptations or variations of the specific embodiments discussed herein.
In this document, the terms “comprise”, “comprising”, “include”, “including”, “contain”, “containing”, “have”, “having”, and any variations thereof, are intended to be understood in an inclusive (i.e. non-exclusive) sense, such that the process, method, device, apparatus or system described herein is not limited to those features or parts or elements or steps recited but may include other elements, features, parts or steps not expressly listed or inherent to such process, method, article, or apparatus. Furthermore, the terms “a” and “an” used herein are intended to be understood as meaning one or more unless explicitly stated otherwise. Moreover, the terms “first”, “second”, “third”, etc. are used merely as labels, and are not intended to impose numerical requirements on or to establish a certain ranking of importance of their objects.
|
A method of repairing an affected area of a component of a fiber-reinforced polymer composite, especially having elongate or continuous reinforcing fibers in a polymer matrix, is disclosed. The method includes: providing a controlled atmosphere around the affected area of the component; heating the component in the affected area within the controlled atmosphere to cause pyrolysis or depolymerization of the polymer matrix in the affected area and thereby to remove the polymer matrix from the affected area; introducing polymer resin into a space left by the pyrolyzed or depolymerized matrix to refill the affected area.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part application of application Ser. No. 10/965,384 filed Oct. 14, 2004.
BACKGROUND OF THE INVENTION
[0002] The invention concerns a procedure for feeding balls into the projectile chamber of a handgun, in particular the projectile chamber of a paintball gun. A ball container is connected with the projectile chamber via a feeder tube. The balls are fed from the ball container into the projectile chamber via the feeder tube by means of a motor. The invention further concerns a device designed to carry out the procedure.
[0003] A device in which the balls are fed into the projectile chamber in this manner is described in detail, for example, in U.S. application Ser. No. 10/965,384 filed Oct. 14, 2004 submitted by the same Applicant, the disclosure of which is incorporated by reference into the present application. It has turned out to be a problem to control the motor in such a way as to allow fast feeding of the balls and to provide the feeding force at the right moment.
SUMMARY OF THE INVENTION
[0004] The invention is based on the object of providing a procedure and a device that allow fast and reliable feeding of the balls into the projectile chamber and that avoid unnecessary operation of the motor.
[0005] According to the invention, the motor is controlled as a function of the movement of the balls in the feeder tube. In this way it is possible to suitably control the feeding force supplied by the motor as a function of the actual status of the balls in the feeder tube.
[0006] Information about the balls is needed in order to perform the control operations as a function of the movement of the balls. In order to obtain the information, the device according to the invention may comprise a sensor to monitor the movement of the balls in the feeder tube and to provide status reports on the presence or absence of balls in the feeder tube. By mounting the sensor on the device itself, and not on the weapon, the device can be operated in conjunction with various weapons.
[0007] The sensor may comprise a light barrier arranged on the feeder tube. When there is no ball situated in the light path, the light barrier is not interrupted, but it is interrupted when a ball is situated in that location.
[0008] In an advantageous embodiment of the invention the sensor is arranged close to the end of the feeder tube pointing towards the projectile chamber. The balls located in this zone are just about to enter the projectile chamber and direct information can be obtained.
[0009] The device may further comprise a spring element for storing the drive energy of the motor. The energy stored in the spring element can be used to feed several balls into the projectile chamber without it being necessary to start up the motor. Drive energy supplied by the motor while the balls are not moving can be stored in the spring element. In order to protect the spring element from becoming overloaded, the spring element may be connected to the motor via a slip clutch. If the motor supplies more energy than can be stored in the spring element, the excess energy can be dissipated via the slip clutch.
[0010] The sensor is preferably designed in such a way that it reports the two statuses “ball present” and “no ball present”. A change in status occurs when, after a certain period of time during which it has reported one of the statuses, the sensor reports the other status. A resting phase occurs when the row of balls present in the feeder tube is stationary relative to the feeder tube. In the reports generated by the sensor, a resting phase is characterized by the fact that no change in status is reported for a period of time that is longer than the period of time required to feed two successive balls into the projectile chamber during a burst of firing.
[0011] A change in status following immediately after a resting phase is referred to as a first change in status. Changes in status following a first change in status, without any intervening resting phase, are referred to as further changes in status.
[0012] The motor is preferably switched on for a start-up period following a first change in status. The start-up period lasts for a defined length of time which is adapted to the interplay between the feeder device and the handgun.
[0013] After the balls have started to move in the feeder tube, it takes a certain amount of time until the sensor detects the first change in status. This is because the balls are of a certain size and must cover a distance dependent on this size before any change in status occurs from “ball present” to “no ball present”, or vice versa. This period is referred to as the first period of ball movement that triggers the first change in status. The start-up period is advantageously longer than the first period of ball movement. The excess operating time of the motor compared with the duration of the movement takes account of the fact that, after it has been idle, a certain amount of time is needed to start the motor up again.
[0014] The start-up period is preferably at least twice as long as the first movement period. In particular, the length of the start-up period may be between 60 ms and 100 ms, and preferably between 70 ms and 90 ms.
[0015] Depending on how many balls are discharged during a burst of firing, the first change in status may be followed by further changes in status. After each further change in status the motor advantageously continues to operate for a certain period of working time. Unlike in the case of the start-up period, the motor is not set in motion but continues to operate because a working period follows immediately after the start-up period or after a preceding working period. At the start of a working period the motor is thus already operating and no acceleration phase is any longer needed. For this reason, a working period can be shorter than the start-up period. The total period of time for which the motor is operating while a burst is being fired is determined by the total of the start-up period and the working periods.
[0016] In order for the sensor to report a further change in status following a previous change in status, the balls must move a certain distance inside the feeder tube. The period of time during which the balls are in motion and trigger a further change in status is referred to as the further period of ball movement. The working periods are preferably longer than the further periods of ball movement. As a result, the motor remains in operation for a longer period of time than the balls are moving in the feeder tube. The period of time during which the motor continues to operate, while the balls, however, are once more at rest, is referred to as the run-on time. During the run-on time the motor can resupply the spring element with the energy which the spring element had discharged in order to set the balls in motion before the first change in status.
[0017] The sensor can be arranged in such a way that, during the resting phase, a ball is present in front of the sensor. In this case, the first change in status is a change from “ball present” to “ball not present”. The second change is a change from “ball not present” to “ball present”. In this case, the sensor is set up in such a way that it reports two changes in status when the balls move by the length of one ball in the feeder tube. When the balls move by the length of one ball in the feeder tube, the operating period of the motor is thus extended by two working periods. The length of these working periods can be between 20 ms and 60 ms, and is preferably between 30 ms and 50 ms. In an alternative embodiment, the sensor can also be set up in such a way that it reports only one change in status per ball. In this case, the working periods chosen should be twice as long.
[0018] Depending on what is practical, the sensor can also be arranged in such a way that no ball is present in front of the sensor during the resting phase. The sequence described is then reversed.
[0019] The more shots that are fired in a burst, the longer will be the run-on time, because for each individual shot the working period is longer than the movement period. Since the spring element has only a limited capacity for storing the drive energy supplied during the run-on period, the latter period can be limited to a maximum duration. The maximum duration of the run-on time is preferably between 170 ms and 400 ms, and furthermore preferably between 320 ms and 360 ms.
[0020] Before the device is put into operation, all the balls are present in the ball container and the feeder tube is empty. In order to get the device ready for use, the feeder tube must be filled with balls. For this purpose, when the device is started up, the motor can be switched on for a preparatory period of time which is preferably sufficiently long for the feeder tube to become completely filled with balls. The preparatory period may have a predetermined duration. Independent of the predetermined duration, or in addition to it, the end of the preparatory period can be determined by the fact that the sensor arranged at the end of the feeder tube reports a change in status, i.e. the presence of a ball.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The invention is described in the following, on the basis of an advantageous embodiment and making reference to the attached drawings.
[0022] FIG. 1 shows the device which is the subject of the invention being used;
[0023] FIG. 2 shows a partially cut-away view of the ball container with the feeder;
[0024] FIG. 3 shows a cross section through the ball container, looking down on the feeder;
[0025] FIG. 4 shows a diagrammatic view of a feeder tube filled with balls in three different configurations; and
[0026] FIG. 5 shows the temporal sequence of reports from the sensor and of the operation of the motor for three different bursts of fire.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] A shooter shown in FIG. 1 is using a weapon 1 , for example an air rifle used to fire paintballs, which is connected via a feeder channel, which is designed here in the form of a flexible feeder tube 2 , to a ball container 3 . The ball container 3 holds balls which are fed by means of a feeder 8 in an unbroken sequence through the feeder tube 2 to the projectile chamber 11 of the gun 1 . During this process, a spring force is applied to the balls so that in each case, when a ball has been fired and the empty projectile chamber 11 opens up, a new ball is fed from the feeder tube 2 into the projectile chamber. The ball container 3 is attached to the belt 4 of the shooter. In an alternative embodiment, the ball container may be firmly attached to the weapon via a rigid feeder channel.
[0028] As shown in FIG. 2 , the ball container 3 is cylindrical in shape and is provided with a lid 5 which is connected via a diagrammatically arranged pressure spring 6 to a pressure plate 7 . Under the action of the spring 6 the pressure plate 7 forces the contents of the container away from the open end of the container, which is closed off by the lid 5 , and towards the other end of the container. At this other end is located the feeder 8 which transports the balls 14 into the outlet channel 9 of the ball container 3 . The outlet channel 9 is attached to the inlet end of the feeder tube 2 .
[0029] The feeder 8 can be caused to rotate in the direction indicated by the arrow 10 by means of an electric motor, not depicted here, arranged in the lower area of the ball container 3 . The motor is connected via a spring element and a slip clutch, neither of which are depicted here, to the feeder 8 . Rotation of the motor drive shaft is transmitted via the spring element to the feeder 8 . As soon as the feeder tube 2 is completely filled with balls, the feeder 8 is prevented from rotating any more. If further drive energy is supplied by the motor while the feeder 8 is stationary, this causes the spring element to become tensioned, so that the spring element stores the drive energy of the motor. If the spring element is tensioned to the maximum extent, further drive energy supplied by the motor is dissipated via the slip clutch. The features of this drive mechanism with spring element and slip clutch are described in detail in U.S. application Ser. No. 10/965,384 filed by the same applicant. A control unit 18 which controls the motor as a function of the reports received from the sensor 16 is arranged in the lower area of the ball container 3 .
[0030] If shots are fired from the rifle 1 , the first balls 14 can be conveyed into the projectile chamber of the weapon 1 by means of the energy stored in the spring element. However, because the energy stored in the spring element is sufficient only to convey a few of the balls 14 , the motor must be controlled in such a manner that it provides new drive energy in a timely fashion. The procedure which is the subject of the invention is concerned with controlling the motor.
[0031] A sensor 16 is arranged at the end of the feeder tube 2 adjoining the weapon 1 and is used to determine whether a ball 14 is present in this area of the feeder tube 2 . The sensor 16 comprises a light barrier whose light beam runs in the cross-sectional plane of the feeder tube 2 . The light beam is interrupted if a ball 14 is present at that location, and it is not interrupted if no ball is present there. The motor is controlled as a function of the status reports put out by the sensor 16 .
[0032] In FIG. 4 , one end of the feeder tube 2 adjoins the inlet to the projectile chamber 11 of the weapon 1 . A light barrier 17 in the sensor 16 intersects the feeder tube 2 in a direction perpendicular to the plane of the drawing. During the resting phase depicted in FIG. 4A , the feeder tube 2 is completely filled with balls 14 , and the frontmost ball 141 is situated at the entrance to the projectile chamber 11 of the weapon 1 . The entrance to the projectile chamber 11 is closed, and all the balls are at rest within the feeder tube 2 . The series of balls 14 contained in the feeder tube 2 is acted on by the spring force transmitted via the feeder 8 . The light barrier 17 is interrupted by the ball 141 and the sensor 16 reports the presence of a ball.
[0033] After a shot is fired by the weapon 1 , the inlet to the projectile chamber 1 opens up, and the frontmost ball 141 , driven by the force of the spring, moves into the projectile chamber 11 . Once the ball 141 has partially entered the projectile chamber 11 , in the status as depicted in FIG. 4B , the light barrier 17 detects a first change in status, namely that there is no longer a ball present in the area of the light barrier 17 . As the ball 141 continues to move into the projectile chamber 11 , the next ball 142 enters into the area of the light barrier 17 , interrupting the latter as shown in FIG. 4C . The sensor 16 reports a further change in status.
[0034] The control of the motor as a function of the changes in status reported by the sensor 16 is depicted in diagrammatic form in FIG. 5 . FIG. 5A shows the sequence occurring when a single shot is fired; FIG. 5 b shows the sequence occurring when three shots are fired in a burst; and FIG. 5C shows the sequence occurring when twenty shots are fired in a burst. In each case, in FIGS. 5A, 5B , 5 C, the status of the sensor 16 is shown above the time axis in Diagram 12 and the status of the motor is shown above the time axis in Diagram 13 . Both the sensor and the motor alternate only between the states 0 and 1 . In state 1 a ball is present in front of the sensor, and in state 0 no ball is present in front of the sensor. In state 0 the motor is stationary and in state 1 it is in operation. All the numerical data shown in FIG. 5 indicate time in ms.
[0035] FIG. 5A shows the temporal sequence when a single shot is fired from the weapon 1 . The point in time S designates the starting point at which, following the firing of the shot, the entrance to the projectile chamber 11 opens up and the ball 141 starts to move into the projectile chamber 11 . As soon as the status shown in FIG. 4B is reached, the sensor reports at time 151 that the first change in status has occurred following a resting phase. The first change in status at time 151 is reported to the control unit 18 which thereupon causes the motor to start operating for a start-up time of 80 ms. As the ball 141 penetrates further into the projectile chamber 11 , the status shown in FIG. 4C is reached, where the ball 142 enters the zone of the light barrier 17 . At time 152 the sensor reports a further change in status. The control unit 18 causes the motor to continue operating after the further change in status at time 152 for a working period of 40 ms duration immediately following the start-up period. Since the sensor 16 no longer reports any further changes in status after time 152 , the motor is switched off after the first working period.
[0036] A period of time which triggers the first change in status elapses between the point in time S, when the movement of the balls 14 in the feeder tube 2 commences, and the time 151 , when the balls 14 are located in position 4 B. It is assumed here that the length of this period of time is 25 ms. Once the first change in status has occurred, the motor is set in operation for a start-up time of 80 ms. The start-up time is more than twice as long as the movement period that triggers the first change in status. This takes account of the fact that it requires a certain amount of time to set the motor in motion.
[0037] The period of time between the first change in status 151 and the further change in status 152 corresponds to the time required by the balls 14 in the feeder tube 2 to move from status 4 B to status 4 C. The length of this period of movement by the balls 14 , which triggers the further change in status 152 , is also assumed to be 25 ms. The working period associated with the movement period 151 to 152 is at 40 ms longer than the movement period. This difference between the working period and the movement period results in a run-on time during which, on the one hand, the balls are returned from status 4 C to the position shown in 4 A, and the spring element is tensioned.
[0038] The overall operating duration of the motor when a shot is fired is made up of the start-up time of 80 ms and a working period of between 40 ms and 120 ms. After the last reported change in status at time 152 , the motor continues to run for a further 95 ms.
[0039] FIG. 5B shows the temporal sequence 12 of the changes in status reported by the sensor 16 and the temporal sequence 13 of the operation of the motor for the case in which a burst of three shots is fired. Exactly as in the case when a single shot is fired, the sensor 16 reports the first change in status at time 151 and a further change in status at time 152 . After the first change in status 151 the motor is set in motion for a start-up period of 80 ms; after the further change in status 152 , the motor continues to operate for a working period of 40 ms. Following the changes in status 153 to 156 , the motor continues to run in each case for a further working period of 40 ms, with each successive working period following immediately after a preceding working period. The overall operating time of the motor when a burst of three shots is fired is made up of the start-up time of 80 ms and the five working periods, each of 40 ms, for a total of 280 ms. Following the last reported change in status 156 the motor runs on for 155 ms. The run-on time is sufficient to bring the balls 14 back to the resting phase 4 A and to fully tension the spring element.
[0040] When a burst of twenty shots is fired, as shown in FIG. 5 c , the sensor 16 reports a first change in status 151 followed by 39 further changes in status 152 to 1540 . After the first change in status 151 , the motor is set in motion for a start-up time of 80 ms. For each of the further changes in status 152 to 1540 , the motor continues to run for working periods of 40 ms. The movement periods of the balls 14 which trigger the changes in status 151 to 1540 add up to an overall duration of 975 ms. The total amount of time made up of the start-up period of 80 ms and 39 working periods each of 40 ms is 1640 ms, which would give a calculated run-on time of 665 ms. However, the operating duration of the motor required to convey the balls 14 back to the starting status 4 A and to fully tension the spring element is substantially shorter than 665 ms. For this reason, the run-on duration is limited to a maximum length of 340 ms. If the calculated run-on time, as the difference arising from the sum of the start-up period and the working periods as well as the movement periods, adds up to more than 340 ms, this excess portion of the run-on time is ignored. The run-on time remains fixed at 340 ms regardless of how many further changes in status the sensor 16 reports.
[0041] At the time of start-up the ball container 3 is filled with balls 14 and there are no balls in the feeder tube 2 . In order to fill the feeder tube 2 with balls, the motor is switched on for an adequately long period of time. As soon as the sensor 16 at the end of the feeder tube 2 close to the projectile chamber 11 reports the presence of a ball 14 , this means that the feeder tube 2 is filled with balls. After receiving the report from the sensor 16 , the control unit 18 allows the motor to continue running for a short period of time to ensure that the spring element is fully tensioned. This completes the preparatory period and the weapon 1 is ready to be used.
|
The procedure for feeding balls ( 14 ) to the projectile chamber ( 11 ) of a handgun ( 1 ), in particular to the projectile chamber of a paintball weapon, whereby the balls ( 14 ) are fed by means of a motor from a ball container ( 3 ), through a feeder tube ( 2 ) into a projectile chamber ( 11 ), is characterized by the fact that the motor is controlled as a function of the movement of the balls ( 14 ) in the feeder tube ( 2 ). The feeding of the balls ( 14 ) to the projectile chamber ( 11 ) is controlled in accordance with the procedure which is the subject of the invention. The invention has the advantage that the motor is controlled as a function of the actual conditions prevailing inside the feeder tube ( 2 ).
| 5
|
FIELD OF THE INVENTION
The present invention relates to the field of synchronizing signals. Specifically, embodiments of the present invention relate to a device and method for emulating a phase-locked loop.
BACKGROUND ART
There are many applications in which it is desirable to create one or more signals that are phase-locked to a reference signal that is at a different frequency from the signal or signals. For example, a device in a network may synchronize an internal clock to a network clock in order to allow internal components that run at different frequencies than the network clock to be able to communicate on the network.
Standards for the accuracy of the internal clock, as well as the degree to which it is synchronized to the reference network clock, have been defined by the American National Standards Institute (ANSI). For example, ANSI has defined performance requirements regarding clocks in digital networks in the document entitled, “Synchronization Interface Standards for Digital Networks,” ANSI/T1.101-1998. In particular, that standard defines four stratum levels (and additional substrata). Stratum 1 has the most stringent requirements and the clock may be a completely autonomous source of timing. On the other hand, stratum-2, stratum-3, and stratum-4 may track an input clock at the same or a higher stratum level. Stratum-4 has the least stringent timing requirements.
One type of device within a network that may need to synchronize to a network reference clock is customer premises equipment (CPE). For example, CPEs often derive a reference clock from the network to drive their backplane TDM (Time Division Multiplexing) bus and may also pass one or more clocks downstream to other devices. Being at the lower end of the network, CPEs generally are not subject to the most stringent clock standards and as such, may only need to meet the requirements of stratum-4 or stratum-4E. Thus, CPEs may synchronize to a network clock that is a stratum-4 clock or higher.
Conventionally, a phase-locked loop may be used to frequency and phase-lock to a clock such as a network clock, while meeting stratum-4 or stratum-4E requirements for the internal synchronized clock. The phase-locked loop may generate multiple clocks that are at frequencies other than the network clock, but phase-locked to it. However, conventional phase-locked loops have several drawbacks.
One problem with conventional digital phase-locked loops is that they are generally designed to lock to a specific reference frequency. For example, the digital phase-locked loop may have a reference oscillator that is either some integral multiple or very close to an integral multiple of the desired frequency. The reference frequency to which it locks must be at or very near the frequency of the reference oscillator. Frequently, this is on the order of Megahertz. If the reference frequency is not near the frequency for which the phase-locked loop was designed, then it will not function and a different phase-locked loop will be required. Sometimes, a custom phase-locked loop that is able to synchronize to the desired frequency must be built.
A further drawback with conventional phase-locked loops is that they add considerable cost to the system. For example, analog phase-locked loops require external components such as resistors and capacitors to implement loop filters to tune to the desired frequency, thus adding considerable expense.
Additionally, the external components may be temperature sensitive and hence the designer must factor in possible temperature variations. If the designer fails to properly do so, the phase-locked loop may fail to accurately synchronize to the reference.
Therefore, it would be advantageous to provide a method and device for providing a phase-locked loop to synchronize an output signal to a reference signal. It would be further advantageous if the method and device is able to phase-lock to a network reference clock. It would be further advantageous that the output signal is a clock that is ANSI stratum-4 compliant. It would be still further advantageous that the above method and device is cost efficient. It would be even further advantageous if the method and device is not highly sensitive to temperature variations.
SUMMARY OF THE INVENTION
Embodiments of the present invention provide a method and device for emulating a phase-locked loop that may synchronize an output signal to a reference signal. Embodiments of the present invention phase-lock to a network reference clock. Embodiments of the present invention provide a clock signal that is ANSI stratum-4 compliant. Embodiments of the present invention are cost efficient. Embodiments of the present invention are not highly sensitive to temperature variations.
A device for emulating a phase-locked loop is disclosed. The device comprises a correction table for storing a digital pattern describing how a frequency of a signal is to be altered. The device also has first logic for receiving a sample signal and altering its frequency based on the correction table output to produce a desired output signal that is near a desired frequency. The first logic accomplishes this by dividing the frequency of the sample signal by a first or a second integer based on the correction table output. Further, the device has second logic for adjusting the frequency of the output signal to the approximate frequency of a reference signal. Additionally, the device has comparison logic for comparing the reference signal with the adjusted output signal and modifying the output of the correction table to substantially phase-lock the output signal to the reference signal.
Another embodiment provides for a method of emulating a phase-locked loop. The method comprises receiving a base signal and a frequency modification signal into logic for altering a frequency of a signal. To produce an output signal, the frequency of the base signal is divided by a first integer if the frequency modification signal is a first value and divided by a second integer if the frequency modification signal is a second value. The frequency of the output signal is altered to substantially match a frequency of a reference signal. The altered output signal fed back and compared to the reference signal. Then, the frequency modification signal is modified in response to the comparison to substantially phase lock the output signal to the reference signal.
These and other advantages of the present invention will no doubt become obvious to those of ordinary skill in the art after having read the following detailed description of the preferred embodiments which are illustrated in the various drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a device for emulating a phase-locked loop, according to an embodiment of the present invention.
FIG. 2 is an exemplary table comprising frequency compensation information, according to an embodiment of the present invention.
FIG. 3 is a timing diagram illustrating signal formation and cycle-to-cycle jitter, according to an embodiment of the present invention.
FIG. 4 A and FIG. 4B are diagrams illustrating synchronization of a signal to a reference signal, according to embodiments of the present invention.
FIG. 5 is a flowchart illustrating steps of a method of emulating a phase-locked loop, according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description of the present invention, a method and device for emulating a phase-locked loop, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be recognized by one skilled in the art that the present invention may be practiced without these specific details or with equivalents thereof. In other instances, well-known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the present invention.
An embodiment of the present invention is a device for emulating a phase-locked loop (PLL). The emulated PLL is able to phase-lock one or more output signals to an input reference signal. In one embodiment, the input reference signal is a network clock, although various embodiments of the present invention may phase-lock to other reference signals. In one embodiment, the one or more output signals are clocks used to drive components in CPEs and may be sent downstream.
Basic operation of the embodiment of FIG. 1 may be as follows. In this embodiment, the input is an 8 kHz reference input 101 and the clock 1 and clock 2 outputs are a 4.096 MHz clock 102 and an 8.192 MHz clock 103 , which the device 100 phase-locks to the reference signal 101 . However, the present invention is well suited to synchronizing to other references at other frequencies and producing outputs at other frequencies. The device has a 100 MHz free-running clock source 115 for producing a free-running clock 117 that the device 100 divides in frequency to produce the output clocks 102 , 103 . The frequency of the free-running clock 117 is generally not an exact integer multiple of the output clocks 102 , 103 . To produce an output clock 102 , 103 , the frequency of the free-running clock 117 is sometimes divided by a first integer at other times divided by a second integer. For example, to produce the 4.096 MHz clock 102 , the free-running clock 117 is divided in frequency by 24 for 212 out of 512 free-running clock cycles and by 25 for the rest of the cycles.
The correction table 120 contains a pattern of zeros and ones that are input to the frequency divide logic 125 . The pattern is designed to cause the frequency divide logic 125 to modify the frequency of the free-running clock 117 (e.g., a base clock) to a suitable frequency and output this as the 4.096 MHz signal, for example. The 4.096 MHz clock 102 is fed into frequency adjustment logic 130 , where its frequency is adjusted to substantially match the reference signal's 101 frequency. This frequency-adjusted signal 131 is fed back into the comparator 135 .
Since the 8 kHz input reference signal is asynchronous with respect to the free-running clock 117 , the synchronization logic 105 synchronizes the input reference signal 101 to the free-running clock 117 . Finally, the synchronized reference clock 111 is fed into the comparator 135 and compared to the frequency-adjusted signal 131 . Based on this comparison, the correction table 120 output is modified so that the synchronized reference clock 111 and the frequency adjusted signal 131 are substantially frequency and phase-locked. For example, if the frequency adjusted signal 130 lags the synchronized reference clock 111 , the output of the correction table 120 is modified by converting a one to a zero. In this fashion, the output clocks 102 , 103 are phase-locked to the reference signal 101 .
FIG. 1 will now be discussed in more detail. The reference signal 101 received into the device 100 may be an 8 kHz pulse that is used as a timing reference. The free-running clock source 115 , in this embodiment, is implemented with a 25 MHz Stratum-4 clock 113 that is multiplied in frequency by four by a delayed lock loop (DLL) 114 to produce a 100 MHz free-running clock 117 . Other frequencies than 100 MHz are suitable. The DLL may be a type of phase-locked loop. However, the methodology of producing the 100 MHz free-running clock 117 is not limited to the logic shown. For example, a more accurate clock, such as a Stratum-3 clock may be used. However, as CPEs generally require only a Stratum-4 clock, a more accurate clock is generally not required.
Furthermore, the free-running clock 117 may be received to the device 100 from any convenient source. For example, CPEs will generally have at least one clock source available for other purposes. The output clocks 102 , 103 may have a frequency that is not a whole integer fraction of the free-running clock 117 . For example, in one embodiment, the free-running clock is 100 MHz and the output signal is either 4.096 MHz or 8.192 MHz. The accuracy (e.g., parts per million or ppm) and jitter characteristics may be determined by the depth of the sampling time and the frequency of the free-running clock 117 .
The reference signal 101 and free-running clock 117 are input to the synchronization logic 105 , which in this embodiment comprises a pair of D flip-flops 110 . However, the synchronization logic 105 may be implemented in other fashions. Thus, the synchronization logic 105 outputs the reference signal 101 synchronized to the free-running clock 117 (e.g., a synchronized reference signal 111 ).
The correction table 120 contains a pattern of ones and zeroes that carry information to produce the output clocks 102 , 103 from the free-running clock 117 . The correction table output, which serves as a frequency modification signal 137 , is fed into the enable of the frequency divide logic 125 . The frequency divide logic 125 may issue a signal 139 to the correction table 120 to cause a transfer of one or more bits from the correction table 120 . As discussed herein, the frequency modification signal 137 may be modified to adjust the output clocks 102 , 103 and hence to establish precise output clocks that are phase-locked to the reference signal 101 . More details of the composition of the correction table 120 are discussed herein with respect to FIG. 2 .
The frequency divide logic 125 may be implemented with a counter that toggles the output clocks 102 , 103 after a pre-determined number of free-running clock 117 cycles have transpired. The pre-determined number may be a first integer or a second integer, based on the frequency modification signal 137 . For example, if the frequency modification signal 137 is currently a ‘0’, the frequency divide logic 125 may establish the period of the output clock 102 as 24 free-running clock cycles. On the other hand, if the frequency modification signal 137 is currently a ‘1’, the frequency divide logic 125 may establish the period of the output clock 102 as 25 free-running clock cycles. The frequency divide logic 125 may obtain the next bit from the frequency modification signal 137 as needed after counting down the 24 or 25 free-running clock cycles from the previous bit. In one embodiment, the frequency divide logic 125 is implemented with a five-bit counter, which toggles the output clocks 102 , 103 after a suitable number of counts of the free-running clock 117 have passed. However, embodiments of the present invention are well-suited to implementing the frequency divide logic 125 in other fashions.
The frequency adjustment logic 130 may be implemented with a ten-bit counter. In particular, the 4.096 MHz output clock 102 may be fed into the frequency adjustment logic 130 clock input. The enable may be set at all times and the ten-bit counter may be set to toggle (up or down as appropriate) after every 512 counts of the 4.096 MHz output clock 102 . Thus, the frequency of the 4.096 MHz output clock 102 is divided by 512 to produce an 8 kHz clock that may be referred to as an frequency adjusted signal 131 . This signal 131 is fed back to the comparator 135 . The frequency adjustment logic 130 also outputs an 8 kHz frame synchronization pulse (e.g., FSC signal) 143 . The pulse width and hence duty cycle of these signals 131 , 143 may established by setting the 10-bit counter to toggle down a pre-determined number of 4.096 MHz output clock 102 cycles after it toggled up, for example. Thus, the duty cycle of the signals 131 , 143 need not be the same as the 4.096 MHz output clock 102 .
The various components in the device 100 may be implemented within a field programmable gate array (FPGA), an application specific integrated circuit (ASIC), etc. Just as the free-running clock 117 may already be available, a CPE may already have an FPGA or the like that is suitable to implement device 100 . Thus, unlike conventional solutions that require one or more additional components to be added to the system, embodiments of the present invention do not require additional components than already exist.
Referring now to FIG. 2, an exemplary correction table 120 is shown. In this embodiment, the correction table 120 has 128 bits that are arranged in a pattern that allows the output clocks 102 , 103 to maintain a 50% duty cycle. If other duty cycles are desired, a different pattern may be used. Given that the reference signal 101 is an 8 kHz clock and the free-running clock 117 is 100 MHz, during one reference clock frame (e.g., 125 microseconds) there will be 512 free-running clock 117 cycles. Thus, the 128 bit correction table 120 may be accessed by the frequency divide logic 125 four times per frame. The number of bits in the correction table 120 may be otherwise to allow for other free-running clock 117 frequencies, output clocks, etc. For example, the ratio of the frequency of the free-running clock 117 to the output clock 102 affects how many bits are needed to obtain a given accuracy.
In various embodiments of the present invention, the correction table 120 content is modified to allow the device 100 to synchronize to a different frequency reference signal 101 , to create a different frequency output signal, or to make both adjustments. For example, the correction table 120 may be implemented in RAM, flash memory, etc.
As discussed herein, the 4.096 MHz output clock 102 may comprise either 24 or 25 free-running clock 117 cycles. Referring now to FIG. 3, some details relating to formation of the 4.096 MHz output clock 102 and its accuracy will be discussed. FIG. 3 shows a portion of an 8 kHz reference signal 101 and a 4.096 MHz output clock 102 near the top of the figure. At the bottom is a magnified region 302 showing a portion of two exemplary 4.096 MHz output clocks 102 compared to a 100 MHz free-running clock 117 .
FIG. 3 shows the upper exemplary 4.096 MHz output clock 102 a having twelve free-running clocks 117 for all of its phases. However, the lower 4.096 MHz output clock 102 b is shown having thirteen 100 MHz free-running clock 117 cycles for the negative phase of its first cycle. In one embodiment, the positive phase of the output clock 102 always has twelve free-running clocks 117 cycles. It is the negative phase that is either twelve or thirteen clock cycles. Maintaining the positive phase at the same width may provide timing benefits for devices that sample the 4.096 MHz output clock 102 . For example, in an embodiment in which the device 100 is used in customer premise equipment in a communications network, most of the devices in the CPE sample on the falling edge of the 4.096 MHz output clock 102 , so the positive clock phase is maintained at twelve free-running clock cycles. However, the opposite could be true to benefit other devices.
Still referring to FIG. 3, there may be a cycle-to-cycle jitter 310 of 1/frequency of the free-running clock 117 . Thus, in FIG. 3 the jitter 310 is shown as ten nanoseconds. Therefore, embodiments of the present invention are able to produce a output clocks 102 , 103 that have a jitter within acceptable tolerance by selecting an appropriate frequency for the free-running clock 117 . The quality of the free-running clock 117 itself will also affect the quality of the output clocks 102 , 103 . Thus, if desired, the free-running clock 117 maybe produced from a higher quality clock. However, for most applications in present CPEs that require a stratum-4 quality clock, the quality of the output clocks 102 , 103 will be sufficient if the free-running clock 117 is derived from a stratum-4 level clock.
As discussed herein, the synchronized reference clock 111 is compared to the frequency adjusted signal 131 to phase and frequency lock those signals. FIG. 4A illustrates an 8 kHz synchronized reference clock 111 is being compared with a frequency adjusted signal 131 that was produced by the frequency adjustment logic 130 . In this case, the frequency adjusted signal 131 is lagging the 8 kHz synchronized reference clock 111 .
The comparison may be performed as follows. The comparator logic 135 may count the number of free-running clock 117 cycles that exist in one (or more) cycles of the synchronized reference clock 111 . To this, the comparator logic 135 compares the number of free-running clock 117 cycles that exist between one (or more) cycles of the frequency adjusted signal 131 . Based on this comparison, the comparator logic 135 modifies the output of the correction table 120 . In this fashion, the output clocks 102 , 103 are adjusted.
For example, in order to synchronize the frequency adjusted signal 131 to the 8 kHz reference clock pulse 111 , which ultimately synchronizes the output clocks ( 102 , 103 ) with the synchronized reference clock 111 , the comparator logic 135 may replace zeros with ones in the output of the correction table 120 . This may be accomplished through the use of ORed logic, for example. On the other hand, if the frequency adjusted signal 131 was leading the 8 kHz synchronized reference clock 111 , then the comparator logic 135 may replace ones with zeroes in the output of the correction table 120 . In this fashion, the 4.096 MHz output clock 102 is phase-locked to the synchronized reference signal 111 .
The accuracy of the output clocks 102 , 103 may be improved by averaging out multiple frames of the synchronized reference clock 111 and calculating the deviation therefrom. As an example, for each additional frame that is sampled and compared, the accuracy may be improved by +/−80/n ppm, where n is the number of frames. For example, sampling 16 frames provides corrections to the output clocks' 102 , 103 accuracy by +/−80/16 ppm or +/−5 ppm. ANSI standards may require an accuracy of +/−32 ppm for a stratum-4 clock source. Therefore, embodiments of the present invention produce an output clock 102 , 103 that achieve accuracy well within ANSI stratum-4 standards.
In the embodiment shown in FIG. 4B, the output clock 102 , 103 is intentionally made to slightly lag the synchronized reference signal 111 . The amount by which it lags may be relatively small as compared to the amount of accuracy required by ANSI stratum-4, such that the output clocks 102 , 103 are still ANSI stratum-4 compliant. In this embodiment, since the output tends to lag the input, the logic can be made simpler because the adjustment only needs to be made in one direction.
A mechanism for achieving synchronization via the embodiment of FIG. 4B may be as follows. Prior to synchronization, the 8 kHz reference signal 101 may be monitored for 4 consecutive frame cycles for a stable signal. Once a stable 8 kHz reference is found, the 4.096 MHz output clock 102 is biased by +160 ppm (sped up) to allow the edges of the reference signal 101 and the frequency adjusted signal 131 to line up. Once the edges are synchronized, the 4.096 MHz output clock 102 is biased −160 ppm (slowed down) until the edges are no longer synchronized. This negative feedback mechanism will keep the two edges synchronized. This provides a pull-range of +/−160 ppm, centered on the free-running clock 117 frequency (which can be +/−30 ppm).
An embodiment of the present invention is a method of emulating a phase-locked loop. Referring now to process 500 in FIG. 5, in step 510 a clock signal (e.g., 100 MHz free-running clock 117 ) is received into frequency divide logic 125 . For example, the free-running clock 117 is input into a clock input of a counter. The frequency divide logic 125 also receives a digital signal containing frequency modification information is received into the frequency divide logic 125 . For example, a signal from the correction table 120 is input to an enable input of the frequency divide logic 125 .
In step 520 , the frequency divide logic 125 produces an output clock 102 or 103 by dividing the frequency of the free-running clock 117 by either a first or a second integer depending on the frequency modification signal 137 . For example, the frequency divide logic 125 produces a 4.096 MHz clock 102 by dividing the frequency of the 100 MHz free-running clock 117 by 24 if the correction table output is a ‘1’ and dividing the frequency of the 100 MHz free-running clock 117 by 25 if the correction table output is a ‘0’. Referring again to FIG. 2 this may be accomplished by toggling a flip-flop according to the timing shown in FIG. 2 .
In step 530 , the frequency of the output clock 102 is adjusted so that it substantially equals the input reference 101 . For example, the frequency adjustment logic 130 divides the frequency of the 4.096 MHz clock 102 by 512 to produce an 8 kHz frequency adjusted signal 131 . An appropriate pulse width for the frequency adjusted signal 131 may be achieved as described herein.
In step 540 , the frequency adjusted signal 131 is fed back to comparator 135 and compared to the synchronized reference signal 111 . The frequency modification signal 137 is modified in response to the comparison to substantially frequency and phase lock the frequency adjusted signal 131 to the reference signal 101 . In this fashion, the output clocks 102 , 103 are phase-locked to the reference signal 101 .
The preferred embodiment of the present invention, a method and device for emulating a phase-locked loop, is thus described. While the present invention has been described in particular embodiments, it should be appreciated that the present invention should not be construed as limited by such embodiments, but rather construed according to the below claims.
|
The device has a correction table for storing a digital pattern describing how a frequency of a signal is to be altered. The device also has first logic for receiving a sample signal and altering its frequency based on the correction table output to produce a desired output signal that is near a desired frequency. The first logic accomplishes this by dividing the frequency of the sample signal by a first or a second integer based on the correction table output. Further, the device has second logic for adjusting the frequency of the output signal to the approximate frequency of a reference signal. Additionally, the device has comparison logic for comparing the reference signal with the adjusted output signal and modifying the output of the correction table to substantially phase-lock the output signal to the reference signal.
| 7
|
RELATED APPLICATION
[0001] This application claims priority from U.S. Provisional Application No. 60/578,451, filed Jun. 9, 2004, entitled ULTRASONIC PROCESS AND APPARATUS WITH PROGRAMMABLE SWEEP FREQUENCY, invented by J. Michael Goodson. This provisional application is expressly incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to ultrasonic processing methods and apparatus involving one or more ultrasonic transducers energized by an ultrasonic driving signal, and relates more particularly to improving performance by sweeping the driving signal through one or more user-programmable frequency ranges or bandwidths at one or more user-programmable sweep rates.
[0004] 2. Description of the Relevant Art
[0005] An ultrasonic generator supplies an ultrasonic frequency driving signal to drive one or more ultrasonic transducers, which vibrate to supply ultrasonic energy to a cleaning fluid in a tank or to a wire bonding or welding tool, depending on the application. It is known that ultrasonic activity in a cleaning tank will generally benefit from a process of sweeping the frequency of the driving signal at a predetermined rate throughout a predetermined frequency range. With prior generators, however, it was difficult to select or change the range and sweep rate because those parameters were defined by electrical components such as resistors and capacitors that were difficult for a user or operator to access or change.
SUMMARY OF THE INVENTION
[0006] The present invention is an ultrasonic processing apparatus and method having an ultrasonic generator with user-programmable process parameters, including frequency range and sweep rate. Applications for the invention include various ultrasonic processes and apparatus, including cleaning, wire bonding, and plastic welding using ultrasonic transducers.
[0007] The ultrasonic generator of the present invention includes a programmable memory device that permits a user or operator to program the frequency range of the driving signal produced and output by the generator, and also to program the rate at which the generator sweeps through the frequency range. The programmed frequency range may be a single or multiple frequency ranges. In addition to programming the frequency range and sweep rate, a user may also program process times and power settings.
[0008] In particular, the ultrasonic generator of the present invention includes a user interface adapted for a user to specify parameters that define a frequency range and a sweep rate for the driving signal, a programmable memory coupled to the user interface for storing the frequency range and sweep rate parameters, and an output circuit responsive to the frequency range and sweep rate parameters for generating the driving signal in the frequency range and at the sweep rate specified by the user.
[0009] More broadly, the present invention encompasses an ultrasonic system that includes a piezoelectric transducer, an ultrasonic generator coupled to the transducer for supplying a driving signal at a predetermined frequency range and sweep rate, input means for a user to input parameters to specify the predetermined frequency range and sweep rate, and memory means for storing the parameters that specify the predetermined frequency range and sweep rate.
[0010] The ultrasonic process of the present invention includes the steps of programming an ultrasonic generator with parameters specifying a frequency range and a sweep rate of a driving signal output by the generator to one or more ultrasonic transducers used in the ultrasonic process, storing the frequency range and sweep rate parameters in a memory or storage device, and generating a driving signal having a frequency within the specified frequency range and varying at the specified sweep rate.
[0011] The ultrasonic process of the present invention also includes the steps of providing one or more sandwich style ultrasonic transducers, providing an ultrasonic generator coupled to the one or more transducers and capable of generating a driving signal to power the transducers, inputting parameters that specify two or more frequency ranges and two or more sweep rates, wherein each frequency range specifies a range of frequencies of the driving signal output by the generator and wherein each sweep rate specifies a rate of change of the frequency of the driving signal, storing the frequency ranges and sweep rates in a memory or storage device, selecting one of the stored frequency ranges and one of the stored sweep rates, and controlling the generator to generate the driving signal according to the selected frequency range and selected sweep rate.
[0012] The features and advantages described in the specification are not all inclusive, and particularly, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification and claims hereof. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and may not have been selected to delineate or circumscribe the inventive subject matter, resort to the claims being necessary to determine such inventive subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic view of a cleaning tank and attached ultrasonic transducer with a generator that supplies the driving signals to the transducer for creating ultrasonic vibrations in a cleaning fluid in the tank.
[0014] FIG. 2 is a graph of the driving signal frequency and time.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] The drawings depict various preferred embodiments of the present invention for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the invention described herein.
[0016] The present invention is an ultrasonic processing apparatus and method having an ultrasonic generator with a user-programmable frequency range and a user-programmable sweep rate. The invention allows a user or operator to easily select or change the range or bandwidth of frequencies in which the generator outputs the driving signal that powers the ultrasonic transducer or transducers. The invention also allows the user or operator to easily select or change the sweep rate at which the frequency of the driving signal changes within the selected range or bandwidth. In other words, the sweep rate indicates how quickly the generator “sweeps” the driving signal frequency between the minimum and maximum frequencies that define the selected frequency range or bandwidth. In addition to programming the frequency range and sweep rate, the invention also permits a user to program process times, power settings, and multiple frequency ranges and sweep rates.
[0017] The generator of the present invention has a user interface that permits a user to program or otherwise specify the frequency range or bandwidth and the sweep rate for the output driving signal to provide an improved ultrasonic cleaning process. The user inputs one or more frequency ranges and sweep rates, and these parameters are stored in a memory or storage device and used to control the generator output. The generator generates and outputs the driving signal according to the programmed frequency range and sweep rate specified by the user. The frequency range can be specified by the user as minimum and maximum frequencies, or can be specified by a center frequency plus a deviation or bandwidth or sweep width above and below the center frequency. The sweep rate is typically specified by how many times per second the frequency is swept throughout the user-programmed frequency range.
[0018] The user interface for controlling the generator is preferably implemented in computer hardware and software. The user inputs the frequency range and sweep rate through a typical computer interface using a keyboard, mouse, and display monitor, or by using an integrated hand-held or portable computing device, which may be hard wired to the generator or connected by a wireless interface. In one implementation, the monitor would display numerous choices for frequency ranges, specified by minimum and maximum frequencies or center frequencies plus plus-or-minus deviations or bandwidth. The display prompts the user to select one or more sets of parameters. The monitor would also display numerous choices for the sweep rate, specified by a frequency such as, for example, 50 Hz, and prompts the user to select one or more sweep rates. In the same way the user may input other parameters for controlling the generator, including power level, process times, and multiple frequency ranges. The parameters input by the user are stored in a memory and/or storage device, such as a disk drive or RAM, and used to control the generator.
[0019] For example, in an application involving ultrasonic cleaning, the ultrasonic transducer or transducers may be mounted on the bottom or sides of a tank, or enclosed in an immersible container or mounted on the end or ends of an ultrasonic rod or push-pull transducer and submerged in water or other cleaning fluid in the tank. Preferably, the transducers are sandwich type transducers, having one or more piezoelectric crystals sandwiched between end masses and clamped with a compression screw. Alternatively, the piezoelectric crystals of the transducer may be directly bonded to a quartz or ceramic tank in a cleaning application. The programmable frequency generator of the present invention may be used to drive ultrasonic transducers in applications other than cleaning, such as plastic welding and wire bonding.
[0020] The present invention allows a user to program or otherwise select the frequency range and sweep rate output by the generator that drives the transducer or transducers. This capability permits a user to easily experiment with the frequency range and sweep rate so that optimum values for particular applications can be readily found.
[0021] The sweeping mechanism of the present invention is incorporated into a programmable ultrasonic generator, which supplies the driving signal that excites the ultrasonic transducer or transducers. The generator includes a user interface including knobs, screws, dials, software, keys or a keyboard, a graphical user interface using a mouse, or other input devices that permit the user to set the frequency range over which the generator operates and also to set the rate at which the generator sweeps through the programmed range. The controls for user programming the frequency range and sweep rate may be analog or digital.
[0022] The purpose of this invention is to incorporate a programmable capability in the ultrasonic generator so that the user can use different combinations of bandwidth and sweep rate, as well as other process parameters such as power levels and processing times, and store them in a memory chip or other storage device so that the user can develop different formulations and return to the exact formula from time to time and always get an exact repeatable formulation.
[0023] An advantage of the invention is that it allows the user to program the programmable generator and easily try numerous formulations to develop the best formulas. Another advantage is that the memory capabilities may accommodate as many formulas or processes as the user would like to retain in memory. For example, ten programmable memories would provide the user with ten different frequency ranges and sweep rates that can be stored and used.
[0024] Another advantage of the invention is that a user need not disclose proprietary formulations or processes and can keep them confidential from other users, other employees, the vendor of the generator, and any other third parties who may be observing the operation of the generator. This enhances the ability to keep formulations secret.
[0025] Yet another advantage is that the user can develop and store different formulations for different products that are being processed, each benefiting from a customized program.
[0026] As shown schematically in FIG. 1 , a cleaning system 10 utilizing the present invention includes a cleaning tank 12 containing a cleaning liquid or solution 14 and one or more pieces 16 to be cleaned using ultrasonics. Ultrasonic energy is supplied to the cleaning liquid through the tank by one or more ultrasonic transducers 18 affixed to (or immersed in) the tank 12 . Typically, a transducer 18 has a sandwich-type construction, with a head mass 20 in contact with the tank, a piezoelectric (PZT) crystal or element 22 , a tail mass 24 , and a compression fastener or bolt 26 . The transducer 18 is driven by a driving signal supplied over electrical wires 28 by a programmable generator 30 . The generator 30 is programmed by a user or operator through a user input or interface 32 to set the frequency range or bandwidth and the sweep rate of the driving signal output by the generator, and any other process parameters. The generator includes a memory 34 , which is a memory chip, disk drive, or other memory or storage device that stores the frequency ranges, sweep rates, and any other process parameters programmed by the user, and is accessed by the generator circuitry to control the frequencies of the driving signal. The user interface may include a hand-held device for the user to input the process parameters to the programmable generator 30 . The user interface 32 may be hard wired to the rest of the programmable generator 30 , or may be connected through a wireless interface (not shown). If the user interface 32 is a hand-held wireless device, the memory 34 may reside in the hand-held device.
[0027] As shown in FIG. 2 , during operation the programmable generator 30 changes the frequencies of the driving signal over time. For example, the driving signal output by the generator may start at a minimum frequency 40 at time T 0 and then ramp up linearly to a maximum frequency 42 at time T 1 and then ramp back down to the minimum frequency at time T 2 . The minimum and maximum frequencies are defined by the frequency range or bandwidth programmed by the user and stored in the memory 34 of the generator 30 . The rate at which the frequency varies, or the corresponding time period, is determined by the sweep rate programmed by the user and stored in the memory 34 of the generator 30 . The generator can be programmed to vary the frequencies of the driving signal according to other programs or functions and need not be limited to linear variations which form a triangular wave or saw tooth pattern shown in FIG. 2 . The frequency/time function can be, for example, sinusoidal, exponential, and other functions, as well as linear. The sweep rates need not be the same for sweeping upwards and downwards. The user can also set the number of periods and can establish rest times when the generator shuts off the driving signal, and any other processing variables.
[0028] The generator 30 includes the ability to record user-selected frequency ranges and sweep rates, however they are defined by the user, to facilitate experimentation and determination of optimum values for those parameters. The generator 30 and its user input 32 may permit the programming of parameters without displaying them during later operation in order to maintain the confidentiality of the parameters. The programmable generator 30 may output driving signals to several transducers or groups of transducers, by controlling a single or multiple power supplies, each of which outputs a driving signal.
[0029] Some ultrasonic transducers may operate within more than one frequency ranges. For example, a wire bonding transducer may have resonant frequencies near 58 KHz and 110 KHz. In such a case, the present invention permits the user to specify frequency ranges and sweep rates at both operational frequencies. For example, the user may set a first center frequency of 57.5 KHz and a first bandwidth of +/−0.5 KHz and a second center frequency of 110.2 KHz and a second bandwidth of +/−1.1 KHz. In this case, the user-programmable parameters would include two or more frequency ranges.
[0030] The parameters input by the user may include more than the frequency range and sweep rate. One such parameter is the desired power level of the driving signal. Processing times is another such parameter.
[0031] The frequency range may be selected or defined in part by a phase lock loop circuit. An ultrasonic transducer may have a nominal frequency for operating at its lowest or highest impedance, depending on the application. However, individual transducers may vary from the nominal frequency, or may vary with time due to thermal or aging effects. Some generators use a phase lock loop control to determine the operating frequency. The present invention can be implemented in such generators using the phase lock loop circuit to control the center frequency by having the user program the plus and minus deviations or bandwidth relative to that center frequency.
[0032] From the above description, it will be apparent that the invention disclosed herein provides a novel and advantageous ultrasonic processing apparatus and method having an ultrasonic generator with a user-programmable frequency range and a user-programmable sweep rate. The foregoing discussion discloses and describes merely exemplary methods and embodiments of the present invention. As will be understood by those familiar with the art, the invention may be embodied in various other forms without departing from the spirit or essential characteristics thereof. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
|
An ultrasonic generator includes a user interface adapted for a user to specify parameters that define a frequency range and a sweep rate for the driving signal, a programmable memory coupled to the user interface for storing the frequency range and sweep rate parameters, and an output circuit responsive to the frequency range and sweep rate parameters for generating the driving signal in the frequency range and at the sweep rate specified by the user. An ultrasonic process includes the steps of programming an ultrasonic generator with parameters specifying a frequency range and a sweep rate of a driving signal output by the generator to one or more ultrasonic transducers used in the ultrasonic process, storing the frequency range and sweep rate parameters in a memory or storage device, and generating a driving signal having a frequency within the specified frequency range and varying at the specified sweep rate.
| 1
|
FIELD OF THE INVENTION
[0001] The present invention relates generally to removal of paints and sealants and more particularly to non-destructive and efficient apparatuses and methods for such removal.
BACKGROUND
[0002] Several methods are known for removing paint and generally such methods can be divided into three categories: mechanical, thermal and chemical.
[0003] Mechanical abrading processes are known in the art. Scraping is usually accomplished with either a putty knife or a paint scraper, or both. Putty knives range in width from one to six inches and have a beveled edge. A putty knife is used in a pushing motion going under the paint and working from an area of loose paint toward the edge where the paint is still firmly adhered. Paint scrapers are commonly available in 1 5/16, 2½, and 3½ inch widths and have replaceable blades. In addition, profiled scrapers can be made specifically for a particular purpose. A paint scraper is used in a pulling motion and works by raking the damaged areas of paint away. Scrapers may be formed from steel, aluminum, wood, Mycarta, and nylon, the desired choice being a softer material than the substrate being scraped to avoid marring for appearance or structural reasons.
[0004] Both the putty knife and paint scraper, particularly the paint scraper with its hooked edge, must be used with care to avoid “scribe scratches.” For example, when using metal scrapers to remove paint and sealant from aircraft skin, scribe scratching has been recognized as a significant problem, causing hairline cracks and fissures that can ultimately grow into larger cracks and threaten the structural integrity of the aircraft. The preferred methods for using scrapers on aircraft are discussed in the Aircraft Structural Repair Manuals (SRM) or FAA Advisory Circulars, AC 65-16A and AC 43.205. The following government documents document and discuss solutions to the issues of fatigue cracks subsequent to scribe mark scratches: The Federal Aviation Bulletin, FSAW 03-10B (amended), dated Mar. 31, 2004 “Fuselage Skin ‘Scribe Mark’ Damage on a Boeing 737 Aircraft; The Transport Canada Airworthiness Notice B071, Edition 1-3 Nov. 2004, “Paint and Sealant Removal Process.”
[0005] Other mechanical methods to remove paint include sanding, sandblasting, water blasting, plastic media blasting, and the like. All of these methods are characterized by modifying the surface being worked through surface abrasion, and in addition, they tend to be slow and labor intensive.
[0006] It is also known to use thermal methods, such as an electric heat plate and electric heat gun. Thermal methods have limited applications.
[0007] Finally, paint can be removed chemically. Solvent-base strippers have formulas that generally contain combinations of organic solvents such as methylene chloride, isopropanol, toluol, xylol, and methanol. Thickeners such as methyl cellulose and various additives such as paraffin wax are added to prevent the volatile solvents from evaporating before they have time to soak through multiple layers of paint. Some solvent-base strippers are quite thin and therefore unsuitable for use on vertical surfaces while others, called “semi-paste” strippers, are formulated for use on vertical surfaces or the underside of horizontal surfaces. More recently, paint removers have been formulated using a mixture of water and benzyl alcohol.
[0008] Chemical Paint Removers have several problems in their use. Paint removers, especially older formulations containing methylene chloride, are subject to extensive health and environmental restrictions. Since they are sprayed on the surface and allowed to work, applicator personnel must wear complete personal protective equipment while using the materials and the Volatile Organic Component (VOC) of the sprayed material is closely monitored in the U.S. Clean Air Act. Finally, at the conclusion of the stripping operation using chemicals, significant amounts of liquid/solid waste are generated and must be safely disposed.
[0009] A paint removal system that addresses some of the above-noted problems is desirable.
SUMMARY OF THE INVENTION
[0010] The present invention provides a cost-effective and minimally destructive apparatus and method for removing paint and other coatings from a surface.
[0011] In one form thereof, the present invention provides an apparatus for removing a substance from a surface. The apparatus comprises a tape having a masking material adapted to adhere to the surface and a stripper, wherein applying the masking material and the stripper can be performed in a single step.
[0012] In a preferred embodiment, the apparatus comprises a matrix impregnated with the stripper and a bladder in which the stripper is impregnated. The matrix and bladder are disposed centrally with respect to a lengthwise axis of the tape and the masking material is disposed on lateral sides of the tape. A backing material is removably adhered to the tape.
[0013] In another preferred embodiment, the apparatus comprises an elongated tape having the masking material disposed along lateral sides thereof and the stripper disposed between the masking material. The tape is wound on a roll and includes a removable backing.
[0014] In another form thereof, the present invention provides a method of removing a substance from a surface. The method comprises masking a portion of the surface with masking material to protect it from a stripper and applying the stripper to an unmasked portion of the surface. These steps are performed at substantially the same time.
[0015] One advantage of the present invention is that it saves time. The stripper and masking material can be applied at the same time, in a single step, as opposed to two separate steps. Use of this invention allows airplane operators to perform the removal step within their maintenance hangers during other routine checks, rather than requiring the aircraft to be dispatched to a specialized facility for removal of paint and sealant. The invention is envisioned as being supplied to the user as a complete kit required for whatever model of aircraft is being examined for scribe marks. Current practice is to mask the aircraft as though it were being completely stripped of paint and sealant. This invention can eliminate that labor intensive step in the process.
[0016] Another advantage of the present invention is that it allows less stripper to be used because the stripper material, which is typically volatile, is covered, which greatly reduces evaporation. Less stripper is used, saving material costs and also reducing the amount of waste and thus reducing disposal costs. Efficiency of the stripper improves, since the solvent that penetrates the paint is being held next to the surface in the channel, rather than evaporating into the atmosphere. In addition to increased efficiency, the reduction in evaporation will mean less contribution from the stripper to total VOC output of the facility, thereby providing considerable pollution prevention advantages.
[0017] From a similar pollution prevention perspective, the present invention will significantly reduce the “cleanup” phase of the stripping operation, where considerable amounts of solvent and contaminated water waste are generated. Since the paint and sealant adhere to the fiberglass mesh matrix at the conclusion of stripping, all of the contributors to pollution, viz., stripper, paint and sealant, will be confined to one item that may be disposed of accordingly.
[0018] Another advantage of the present invention is that, since only the stripper and mesh pad are in contact with the surface being examined, no adhesive residues are left that might interfere with the inspection process
BRIEF DESCRIPTION OF DRAWINGS
[0019] The above-mentioned and other advantages of the present invention, and the manner of obtaining them, will become more apparent and the invention itself will be better understood by reference to the following description of the embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
[0020] FIG. 1 is a perspective view in partial cross-section of a substance removal apparatus embodiment of the present invention;
[0021] FIG. 1A is an enlarged perspective view of the portion of the apparatus indicated in FIG. 1 .
[0022] FIG. 2 is a fragmentary perspective view of the apparatus of FIG. 1 applied to a lap joint;
[0023] FIG. 3 is a perspective view partially broken away of an alternate embodiment of the present invention;
[0024] FIG. 4 is a fragmentary perspective view of an alternate embodiment of the present invention;
[0025] FIG. 5 is a sectional view of an alternate embodiment of the present invention;
[0026] FIG. 6 is a sectional view of an alternate embodiment of the present invention, and.
[0027] FIG. 7 is an enlarged perspective fragmented view in partial cross-section of another embodiment in accordance with the present invention.
[0028] Corresponding reference characters indicate corresponding parts throughout the several views.
DETAILED DESCRIPTION
[0029] The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention.
[0030] Referring now to FIGS. 1 and 1A , apparatus 10 for removing a substance from a surface is provided as a tape 12 having masking material provided as strips 14 . A stripper segment or matrix 16 is provided in the center of tape 12 , between strips 14 . Stripper segment 16 further includes a fibrous material layer 18 . Adjacent to and in contact with fibrous layer 18 is bladder 20 , which in the illustrated embodiment includes a liquid stripper that, during use of apparatus 10 as explained below, will impregnate or saturate fiber layer 18 with a liquid chemical stripper (not shown). Bladder 20 is preferably configured to rupture upon the application of a force to it such that the liquid therein saturates layer 18 , as explained below. Neoprene is one suitable material for bladder 20 . A rectangular shell 22 forms a channel and houses therein layer 18 , and bladder 20 . Shell 22 is preferably made of a quasi-rigid material such as Mylar®. Optional beads 24 join masking material 14 to shell 22 . The beads 24 may be made of rubber or other suitable polymer. A removable backing 26 covers tape 12 as shown. Tape 12 is wound on a roll 28 .
[0031] With reference to FIG. 1A , masking material 14 is preferably provided as a conventional masking tape having an adhesive 30 applied on one side thereof. One tape suitable for use with apparatus 10 is an aluminum adhesive tape meeting MIL-T-23397B, one (1) inch wide, available from 3M Corporation, Grade 417 Aluminum Foil Tape, 900 Bush Avenue, St Paul Minn., 55133. The adhesive provided on the tape should sufficiently adhere to the surface being stripped such that it forms a liquid-proof seal with the surface, thereby rendering bead 24 optional. In embodiments where bead 24 is employed, masking material 14 is attached thereto by means of heat welding, sonic welding, adhesives or other suitable fastening means.
[0032] Shell 22 is also joined to bead 24 by any of a variety of suitable fastening means. As alluded above, shell 22 is relatively rigid for the reasons described below. A suitable material for shell 22 meets MIL-P-22270 and is available from Dupont Discovery Films, 1 Discovery Drive, Hopewell Va., 23860. The approximate desired thickness for shell 22 is 10 mils. An alternative packaging material is an oxygen barrier bagging material, commonly known as “mylar” bags and consisting of a mylar/aluminum sandwich. For improved puncture resistance, nylon may be substituted for polyester. These products are manufactured by and available from IMPAK corporation, 2460 East 57 th St, Los Angeles, Calif. 90058.
[0033] Also, while shown as rectangular in the illustrated embodiment, shell 22 may have a curved or rounded profile. Shell 22 is preferably non-porous such that the stripper liquid contained therein cannot escape by leakage or evaporation.
[0034] The bladder 20 can be a tube or oval shape for easy fitting into the shell. The tubes containing the stripper are filled using standard liquid filling techniques and are placed in the semi-rigid matrix or shell 22 . Preferably, the bladder will have the same cross-sectional dimensions as the shell and will fit snugly into shell 22 . Once inserted into the shell, the fibrous matrix 18 for absorbing the stripper is fitted into the shell and glued to the shell with a chemically resistant epoxy adhesive. Tygon® extruded tubing is suitable for bladder 20 and is available from Prince Rubber and Plastics, 137 Arthur Street, Buffalo N.Y. 14207.
[0035] The liquid which fills bladder 20 can be any of a variety of commercially available strippers, depending upon the particular paint, sealant or coating that is to be removed with the stripper. For removing coatings on commercial aircraft, the stripper should be capable of removing both a polyurethane topcoat, epoxy primer and common polysulfide sealants, such as sealants meeting MIL-S-8802. One such stripper is Eldorado Solutions, PR-3133, Eldorado Solutions, Carmel Ind.
[0036] Fibrous materials suitable for layer 18 can be any material that is inert to the stripper and that tends to spread the stripper material evenly over the surface contacted upon contact. The term “inert” is intended to mean that the fibrous material does not substantially chemically react with the stripper composition and is capable of maintaining mechanical integrity for a period at least as long as the shelf life of apparatus 10 . Examples of suitable materials for fibrous layer 18 include polymers, such as polypropylene and polyethylene; woven and non-woven fabrics, such as felts, cotton and wool; and glass fibers such as fiberglass. One of skill in the art would readily recognized many materials that would perform suitably for fibrous layer 18 .
[0037] Backing 30 may be polyvinyl chloride (PVC), nylon, paper with a metallized interior to prevent chemical migration, mylar with aluminized backing, or any other material having the following characteristics: ability to form into a channel for insertion of bladder and fibrous matrix; rigid, yet deformable that can be crushed with a nylon hand scrapper; chemically resistant to migration of the stripper for sufficient time (e.g., less than 24 hours), and compatible with the other materials used for apparatus 10 , such as the adhesive on the aluminum tape. One such preferred material is an extruded PVC backing. The ready availability of these extrusions and the ability to form complex internal geometry for the bladder and matrix to fit into it make it a desirable alternative. One such manufacturer for backing 30 is Fukuvi USA, 7631 Progress Court, Huber Heights, Ohio 45242.
[0038] With reference now to FIG. 2 , in use, tape 12 is applied to a surface such as aircraft skin 34 , particularly, over lap joint 36 . Most aircraft have many lap joints such as joint 36 having rivets 38 securing the joints. Sealant as well as paint is typically applied to the joints. To check the integrity of the lap joints years or even decades after the plane is manufactured, the paint and sealant must first be stripped from the joints. As alluded above, however, metal scrapers that are commonly used tend to gouge or “score” the aircraft skin, which may ultimately cause larger cracks.
[0039] Tape 12 is centered over the lap joint desired to be stripped and then applied to the skin 34 in the same manner as a conventional piece of tape. After the tape is applied, pressure is applied as indicated by arrows 40 to shell 22 , which ruptures the bladder, which in turn causes the liquid stripper to saturate the fibrous layer 18 . The fibrous layer then meters the stripper fluid, i.e., spreads it evenly over the surface of the skin desired to be stripped. Beads 24 prevent the stripper fluid from spreading laterally and thus define a border or periphery beyond which the stripper does not reach.
[0040] After the requisite time has elapsed, tape 12 is removed from aircraft skin 34 . Ideally, the stripper has caused the paint and sealant to delaminate from the aircraft skin and stick to fibrous layer 18 , but otherwise remain intact. In such event, the paint and sealant are removed as a single layer along with tape 12 . In many cases, however, this will not be possible, in which event manual wiping and perhaps some light scraping after removal of tape 12 is required to remove the residual paint and/or sealant. In any event, one of skill in the art can now readily appreciate that the masking material and stripper are applied at substantially the same time, in a single step.
[0041] Turning now to FIG. 3 , an alternate embodiment of apparatus 100 is shown having a backing 102 , a circular fibrous layer 104 , and a masking material 106 surrounding the fibrous layer. Apparatus 100 can be used for stripping spots of a surface at desired locations. Apparatus 100 is simply applied to the spot desired to be stripped in a manner similar to that described above with reference to apparatus 10 .
[0042] FIG. 4 illustrates another embodiment in which apparatus 200 includes stripping areas 202 that are evenly spaced for use in applications where the areas desired to be stripped are also evenly spaced. The underside of apparatus 200 (not shown) includes a liquid stripper material that is preferably contained in a bladder and/or fibrous material, and also includes a removable backing layer as described above.
[0043] In FIG. 5 , an embodiment is shown in which apparatus 300 includes a tape 302 , a backing material 304 and a liquid stripper-impregnated fibrous matrix 306 sandwiched therebetween. The optional bladder is not provided in this embodiment. Instead, the backing material 304 and tape 302 form a liquid impervious seal 308 which maintains the stripper material within fibrous matrix 306 until the backing material is removed and apparatus 300 is applied to a surface desired to be stripped.
[0044] FIG. 6 illustrates an embodiment in which apparatus 400 includes a tape 402 and a shell 404 , both of which are joined to beads 406 . A backing material 408 is hermetically sealed to tape 402 . A bladder 410 is housed in shell 404 and contains the liquid stripper. Apparatus 400 is applied in the same fashion as apparatus 10 , except there is no fibrous matrix provided in apparatus 400 . Beads 406 help prevent liquid stripper from spreading laterally outside of the area intended to be stripped.
[0045] In another embodiment shown in FIG. 7 , the apparatus comprises a fiberglass mat 18 adjacent to a Tygon® bladder 20 filled with stripper. Bladder 20 in turn is surrounded by a PVC channel or shell 22 which has been secured to aluminum tape 14 flanking the channel with another layer of tape 14 a . That is, unlike the embodiment in FIG. 1 that has a single tape 14 , this embodiment includes two tape layers 14 , 14 a laminated together. The contents of the PVC channel 22 are protected from weather by a removable paper backing (not shown). The adhesive pull strength of the upper layer of tape 14 a is about one half of the tape 14 adhering to the desired surface, thus allowing the operator to remove the channel 22 , stripper bladder 20 and mesh matrix 18 while leaving the outer tape masking 14 adhered to the surface. Since chemical removal of paint and sealant may not be complete, this embodiment allows the user to do minor “touchup” work prior to removing layer 14 and performing the inspections noted above.
[0046] While a preferred embodiment incorporating the principles of the present invention has been disclosed hereinabove, the present invention is not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
|
A cost-effective and minimally destructive apparatus and method for removing paint and other coatings from a surface. The apparatus comprises a tape having a masking material adapted to adhere to the surface and a stripper, wherein applying the masking material and the stripper can be performed in a single step.
| 2
|
BACKGROUND OF THE INVENTION
1. Technical Field
This invention generally relates to diffusers and, more particularly, to a diffuser used in a centrifugal compressor. Specifically, the present invention relates to a diffuser having a valve that selectively opens and closes the outlets of the diffuser to create an unsteady wave pattern that will simultaneously diffuse a centrifugal impeller outflow and turn it to an axial direction.
2. Background Information
A centrifugal compressor employs an impeller that rotates inside a stationary flowpath that is typically formed by an inlet, a shroud, a diffuser, and a discharge duct. The impeller draws a stream of gas through the inlet in a direction that is generally parallel to the axis of rotation of the impeller. A plurality of impeller blades then act upon the stream to impart kinetic energy to the stream. The stream exits the impeller in a direction that is orthogonal or substantially orthogonal to the impeller's axis of rotation. The diffuser then acts on the stream to convert the kinetic energy of the stream to static pressure before discharging the flow to a duct. Typically, the flow discharged from the diffuser must be redirected to a direction substantially parallel to the axis of rotation of the impeller before being delivered to subsequent components.
The flow discharging from centrifugal impeller has significant velocity components in the tangential and radial directions. The tangential velocity component is primarily a result of work input by the impeller. The radial component is a function of the mass moving through the impeller and the flow path area and static conditions at the impeller trailing edge.
Conventional diffusers operate in a steady flow environment and employ conservation of mass and momentum principles to recover kinetic energy from the impeller discharge flow by reducing the absolute Mach number of the flow. As Mach number is reduced, the static pressure and density of the flow increase. To accomplish Mach number reduction, the diffuser accepts the impeller discharge flow and directs it through a single or plurality of passages wherein the area and radius increase with the distance along the passage.
Upon discharge from the diffuser, the flow still possesses radial and tangential components of velocity. These components are redirected to an axial direction through a high-radius duct as the flow is delivered to subsequent components. De-swirl vanes may be located in this duct to remove some of the remaining tangential velocity component.
Many configurations are known for steady flow diffusers. For instance, steady flow diffusers are known in the art as vaned diffusers, vane-island diffusers, channel diffusers, cascade diffusers, pipe diffusers, conical diffusers, vaneless diffusers, scroll diffusers, volute diffusers, and the like.
Vaned, vane-island, channel, and cascade diffusers use flat, wedge-shaped, or curved vanes that are arranged to form channels within the diffuser. Each vane provides a pressure surface for one channel and a suction surface for an adjacent channel. The channels are bounded on the two remaining sides by generally parallel solid surfaces that are typically referred to as the hub and shroud surfaces. The two remaining sides of the channel are open so that flow can enter and exit the channel. The pressure and suction surfaces typically diverge to create an increasing flow area along the channel. The increasing area causes a decrease in Mach number as flow moves through the passage. The centerline of each channel is aligned with the absolute angle of impeller discharge flow produced at a particular operating condition. In some situations, the vanes may be rotated so that channel alignment can be maintained at several operating conditions.
The pipe diffuser, or conical diffuser, is a channel-type diffuser where the channel cross section has a circular rather than rectangular shape. The circular cross section in combination with increasing area along the passage gives each passage a conical shape. The leading edge of each passage typically intersects with the leading edge of an adjacent passage creating a scalloped profile.
The flow through a vaneless diffuser is bounded on only the two sides adjacent to the impeller hub and shroud surfaces. The vaneless diffuser is essentially a channel diffuser without vanes. No attempt is made to contain radial or tangential velocity components in a vaneless diffuser. Instead, the flow is allowed to swirl out to higher radii and the tangential velocity is reduced through conservation of angular momentum. Radial velocity is reduced as flow area increases with radius.
The volute or scroll diffuser is formed by a single channel wrapped about the impeller in the direction of rotation. The cross-sectional area of the channel increases with the distance along the flow path. As in the vaneless diffuser, volute diffusers are based on the premise that the angular momentum of the flow remains constant as radius increases. However, flow in the volute diffuser is bounded in all directions except the direction that follows the helical path leading away from the impeller.
The efficiency of any process that uses a centrifugal compressor depends at least partially on the efficiency of the compressor. The efficiency of the compressor depends at least partially on the efficiency of the diffuser in the compressor. A diffuser that loses pressure when converting the kinetic energy of the stream lowers the efficiency of the compressor and thus the efficiency of the process that employs the compressor. Most applications that require centrifugal compressors, especially aircraft gas turbine engine applications, place a size constraint on the compressor. These size limitations cause the outside diameter of the diffuser and discharge duct to be limited. Diffuser performance tends to vary inversely with the level of compactness and thus the size constraints lead to process inefficiencies.
Many systems employing a diffuser require the flow discharged from the diffuser to be substantially parallel to the axis of rotation of the impeller. Components must thus be provided to redirect the flow from the radial and tangential discharge directions to an axial direction. This is commonly achieved with ducts. Such ducts are undesirable because they occupy additional space and typically have a relatively large radius thus increasing the overall diameter of the diffuser. Ducts also lead to pressure losses that lower the efficiency of the diffuser. It is thus desired in the art to provide a centrifugal compressor diffuser that efficiently redirects the impeller discharge flow to an axial flow while maintaining compact overall dimensions. The diffuser should be able to effectively recover kinetic energy from all velocity components present in the impeller discharge flow.
Prior art diffusers employ a steady flow process to accomplish diffusion. The rate at which diffusion and direction changes can take place is limited by natural forces. As flow proceeds through a diffuser passage, the pressure along the passage increases by virtue of the diffusion that occurs along the passage. Concurrently, frictional and viscous forces cause a boundary layer of low energy fluid to develop along the solid surfaces of the diffuser passage. The growth rate of a boundary layer is accelerated by a pressure gradient.
Conditions adverse to effective diffusion result from boundary layer growth. First, boundary layers reduce the flow area available in a passage thus limiting the velocity reduction of the free stream. Second, the kinetic energy of fluid in the growing boundary layer is eventually reduced to the point that it cannot overcome the pressure gradient caused by diffusion. When this occurs, the boundary layer separates from one or more of the solid surfaces and significant pressure losses result. Depending on the structure of the separation, the flow may reverse direction over a portion of the passage and flow back into the impeller. Or, a separation bubble may form that contains recirculating fluid. Both events result in a loss of energy that would otherwise convert to a static pressure increase. The remaining outbound flow is forced through an even smaller flow area that further limits the diffusion that is accomplished. The separated flow eventually leads to a condition that precipitates compressor surge.
Prior design practice recognizes an optimum passage divergence angle of seven to eight degrees. This is a shallow angle that requires a relatively long passage to produce the area ratio needed for effective diffusion. Boundary layer thickness is also a function of passage length. A longer passage increases boundary layer loss. Longer passages also preclude a compact diffuser. A larger divergence angle can be used, but at the risk of causing flow separation. With such constraints in mind, most designers compromise between length and effectiveness. Such a compromise does not recover maximum kinetic energy from the flow.
Diffuser channel alignments and unrecovered kinetic energy result in a tangential component of velocity in the discharge flow. Some designs employ turning vanes in the discharge duct to recover some of this energy. However, boundary layers that develop along the additional tangential distance traveled by the flow, as well as on the turning vanes, cause additional losses.
A radial velocity is also present in a diffuser discharge flow. A duct is required to turn the radial flow to an axial direction for delivery to downstream components. The duct begins at the outermost radius of the diffuser and continues in a radial direction before turning to an axial direction. If the turn is too short, a flow separation will occur along the convex flow surface. More gradual turns require more radial distance working against the size constraint imposed on most diffusers. The gradual turns also produce additional loses as the flow travels through them. It is thus desired in the art to provide a diffuser that redirects the flow without such gradual turns and with reduced boundary layer formation.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an objective of the present invention to provide a compact, efficient centrifugal compressor diffuser.
Another objective of the present invention is to provide a centrifugal compressor diffuser that efficiently delivers the discharge flow in a direction parallel to the axis of rotation of the impeller.
Another objective of the present invention is to provide a centrifugal compressor diffuser that discharges the flow at a relatively small radius.
Another objective of the present invention is to provide a centrifugal compressor diffuser that discharges the flow in an axial direction through an area having a maximum radius that is equal to or less than the maximum radius of the diffuser.
Another objective of the present invention is to provide a centrifugal compressor diffuser that efficiently recovers kinetic energy from all the velocity components present in the impeller discharge flow.
Another objective of the present invention is to provide a centrifugal compressor diffuser that brings all components of velocity present in the flow to rest in order to recover kinetic energy contained therein while maintaining an acceptable discharge flow rate.
Another objective of the present invention is to provide a centrifugal compressor diffuser that efficiently recovers kinetic energy from the flow to cause an increase in the static pressure of the discharged flow.
Another objective of the present invention is to provide a centrifugal compressor diffuser that employs an unsteady flow process to simultaneously diffuse and redirect the flow discharging from a centrifugal impeller.
Another objective of the present invention is to provide a centrifugal compressor diffuser that employs a valve to control the unsteady flow process by periodically closing the outlet chamber to trap the discharge flow and generate compression waves.
Another objective of the present invention is to provide a centrifugal compressor diffuser that employs a valve to control the unsteady flow process by periodically opening the outlet chamber to generate expansion waves and discharge the trapped flow.
Another objective of the present invention is to provide a centrifugal compressor diffuser that employs an unsteady flow process that limits boundary layer development in the diffuser.
These and other objectives and advantages of the invention are achieved by a diffuser for use with an impeller having an inlet and an outlet, the diffuser including a plurality of vanes disposed at the outlet of the impeller; a wave chamber disposed between adjacent vanes, each wave chamber having an inlet and an outlet; and a valve plate having at least one valve opening; the value opening selectively opening and closing the outlet of at least one wave chamber.
Other objectives and advantages of the invention are achieved by a method of diffusing a fluid flow delivered from the outlet of an impeller in a radial and tangential direction, the impeller rotating about an axis of rotation; the method including the steps of delivering the fluid flow from the outlet of the impellerto a plurality of wave chambers, each of the wave chambers having a maximum outer radius; and redirecting the fluid flow from the radial and tangential outlet directions to an axial direction substantially parallel with the axis of rotation within the wave chamber inside the maximum outer radius of the wave chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention, illustrative of the best mode in which applicants have contemplated applying the principles of the invention, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
FIG. 1 is an elevational view of the diffuser of the present invention taken downstream of the impeller looking back upstream;
FIG. 2 is a sectional view taken along line 2 — 2 of FIG. 1 showing the valve plate of the present invention positioned immediately downstream of the impeller;
FIG. 3 is an elevational view taken along line 3 — 3 of FIG. 2;
FIG. 4A is an enlarged elevational view of a portion of the diffuser showing a pair of adjacent wave chambers in the center of the figure; the valve in a closed position with respect to the right hand chamber of the pair;
FIG. 4B is a sectional side view taken along 4 B— 4 B of FIG. 4A;
FIG. 5A is a view similar to FIG. 4A showing the valve in an initial open position;
FIG. 5B is a sectional side view taken along line 5 B— 5 B of FIG. 5A;
FIG. 6A is a view similar to FIG. 4A showing the valve in a fully open position;
FIG. 6B is a sectional side view taken along line 6 B— 6 B of FIG. 6A;
FIG. 7A is a view similar to FIG. 4A showing the valve in its final open position;
FIG. 7B is a sectional side view taken along line 7 B— 7 B of FIG. 7A;
FIG. 8 is an enlarged elevational view of one of the valve openings of the valve;
FIG. 9 is a view similar to FIG. 8 showing a first alternative embodiment of the valve openings; and
FIG. 10 is a view similar to FIGS. 8 and 9 showing a second alternative embodiment of the valve openings.
Similar numerals refer to similar parts throughout the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The diffuser of the present invention is indicated generally by the numeral 10 in the accompanying drawings. Diffuser 10 surrounds the discharge of an impeller 12 rotatably disposed in a shroud 14 . Impeller 12 is driven by a shaft 16 having an axis of rotation 18 located along the longitudinal centerline of shaft 16 . A valve plate 20 is mounted on shaft 16 and rotates with shaft 16 and impeller 12 . Diffuser 10 further includes a plurality of wave chambers 22 disposed at the outlet of impeller 12 . Each wave chamber 22 is bounded by a pair of vanes 24 . As will be discussed in detail below, diffuser 10 employs an unsteady flow process to simultaneously diffuse and redirect the flow discharging from impeller 12 . The unsteady process occurs within wave chambers 22 and is controlled by valve plate 20 on the downstream side of each wave chamber 22 . The preferred embodiment of the invention is described below to provide an example of the invention and the best mode in which the inventors now contemplate the invention. It should be understood, however, that the preferred embodiment and other embodiments described herein are only examples and that the components of diffuser 10 may be modified and altered depending on the specific application of diffuser 10 .
Impeller 12 includes a plurality of blades 26 mounted on shaft 16 and arranged to draw fluid into impeller 12 at an inlet 28 and discharge the fluid at an outlet 30 . The fluid is brought into impeller 12 in a flow direction that is substantially parallel to axis 18 as depicted by the arrow labeled with the numeral 32 in FIG. 2 . Impeller blades 26 act on the fluid flow and impart kinetic energy to the flow. The flow exits impeller 12 at outlet 30 in a direction substantially perpendicular to axis 18 (with radial and tangential flow components) as indicated by the arrows labeled with the numeral 34 in FIG. 2 . In accordance with one of the objectives of the present invention, diffuser 10 redirects outlet flow 34 from a direction substantially perpendicular to axis 18 to a direction substantially parallel with axis 18 as depicted by the arrows labeled with the numeral 36 in FIG. 2 . In accordance with another objective of the present invention, diffuser 10 accomplishes the redirection of flow in an area that is less than the outer radius 38 of diffuser 10 . This configuration results in a compact diffuser that increases the pressure of the flow while redirecting the flow in a desired direction.
Outlet 30 of impeller 12 is surrounded circumferentially by wave chambers 22 . Each wave chamber 22 is thus disposed radially outwardly of outlet 30 . Each wave chamber 22 is bounded by vanes 24 , valve plate 20 , and a solid surface such as shroud 14 . In the embodiment of the invention depicted in the drawings, shroud 14 extends radially outwardly from impeller 12 to form the shroud surface 40 of each wave chamber 22 and the outer radial surface 42 of each wave chamber 22 . In other embodiments of the present invention, other structures may form surfaces 40 and 42 .
Each vane 24 may be flat, wedge shaped, or curved as required in a specific application of diffuser 10 . In the embodiment of the invention depicted in the exemplary drawings, each vane 24 is wedge shaped and includes a leading edge 44 and a trailing edge 46 . Each vane 24 thus provides a suction side 48 for one chamber 22 and a pressure side 50 to the adjacent chamber 22 . Suction and pressure sides 48 and 50 diverge not only to create wedge shaped vanes 24 but also to increase the area along each wave chamber 22 as the radius increases. In accordance with one of the objectives of the present invention, each wave chamber 22 is bounded by outer radial surface 42 that prevents flow in wave chambers 22 from exiting wave chamber 22 in a radial direction. In the past, flow from chambers 22 would typically exit in a radial direction. In diffuser 10 of the present invention, flow exits each wave chamber 22 in a direction substantially parallel to axis 18 of impeller 12 .
The outlet of fluid from each wave chamber is controlled by valve plate 20 which includes a plurality of valve openings 52 . In the embodiment of the invention depicted in the drawings, valve plate 20 includes one valve opening 52 for every two wave chambers 22 . For instance, diffuser 10 includes eighteen wave chambers 22 and nine valve openings 52 . In accordance with one of the objectives of the present invention, valve plate 20 rotates with impeller 12 to selectively open and close the outlet to each wave chamber 22 . The outlet to a wave chamber 22 is considered to be open when a valve opening 52 is disposed between the vanes 24 of that wave chamber 22 and in fluid communication with wave chamber 22 . The outlet to wave chamber 22 is considered to be closed when no valve opening 52 is in fluid communication with wave chamber 22 . For instance, of the pair of wave chambers depicted in the center of FIG. 4A, chamber 54 is presently open and chamber 56 is presently closed. Other embodiments of the invention may contain a ratio of the number of wave chambers 22 to the number of valve openings 52 that is different from the two-to-one ratio depicted in the drawings.
Valve plate 20 controls the unsteady flow process by periodically closing wave chambers 22 to trap flow and to generate compression waves within chamber 22 . Valve plate 20 then opens chamber 22 to generate an expansion fan and to discharge flow from wave chamber 22 . In operation, flow proceeds from impeller 12 into wave chamber 22 where it stagnates against outer radial surface 42 creating a reflected compression wave in chamber 22 . The reflected compression wave moves upstream toward impeller 12 bringing the incoming flow to rest. Valve plate 20 then rotates valve opening 52 into fluid communication with wave chamber 22 and an expansion fan is created to begin discharging the trapped fluid in the direction of the expansion. The size and location of valve openings 52 are configured to cause cancellation of compression and expansion waves before pressure perturbations reach impeller 12 . Multiple compression and expansion waves produced by rapid cycling of the valve during the operation of diffuser 10 generates a wave pattern that continually diffuses the flow and redirects the flout to axial direction 36 . This flow pattern limits the development of boundary layers that adversely influence the flow through diffuser 10 . The configuration of diffuser 10 also allows the flow to be redirected to axial direction 36 from radial and tangential directions 34 in a compact diffuser.
For purposes of example, three alternative valve opening configurations are depicted in FIGS. 8, 9 , and 10 . It is understood that a wide variety of valve openings 52 may be used and the specific examples provided in FIGS. 8-10 are not to limit the present invention. In the embodiment of the valve opening depicted in FIG. 8, valve opening 52 is an offset design having an upper portion 60 and a lower portion 62 . Upper and lower portions 60 and 62 are connected together to form single valve opening 52 . Each valve opening 52 is sized as follows. First, the overall length 64 of vane 24 is determined. Next, the overall width 66 of wave chamber 22 taken at its greatest radius is determined. Valve opening 52 is then sized by setting its overall length 68 equal to 0.48 of overall length 64 and the length 70 of upper portion 60 equal to 0.24 of overall length 64 . Opening 52 is also offset by a distance 72 from the maximum radius of wave chamber 22 . Offset 72 is determined by the specific application of diffuser 10 . The width 74 of upper portion 60 may be 0.38 of overall width 66 with the 0.38 factor carried on throughout the length of opening 52 such that width 76 is 0.38 of width 78 and widths 80 and 84 are 0.38 of width 82 . In the embodiment of valve opening 52 depicted in FIG. 8, upper portion 60 leads lower portion 62 by 1.94°. The offset dimension 86 is the circumferential equivalent of 1.94° of an arc at the radius of width 84 .
In the embodiment of valve opening 52 depicted in FIG. 9, upper portion 60 and lower portion 62 are not connected and form individual openings in valve plate 20 . In this embodiment, upper portion 60 also leads lower portion 62 . Openings 60 and 62 may be dimensioned similarly to the embodiment depicted in FIG. 8 except that widths 76 and 80 are now 0.38 of widths 88 and 90 , respectively. The dimensions 88 and 90 are determined by appropriate calculations depending on the specific application of diffuser 10 . Similarly, the remaining length dimensions 92 and 94 are calculated by the designer of diffuser 10 .
A second alternative valve opening is depicted in FIG. 10 and indicated generally by the numeral 100 . Valve openings 100 form a plurality of valve openings in valve plate 20 and are sized according to the design principles; of diffuser 10 for a particular application. For instance, width 74 of opening 100 may be the 0.38 factor discussed above with respect to FIG. 8 or may be another factor. The lower width 102 is some factor of the overall width 104 and the overall length 106 of opening 100 is some factor of length 64 .
It is understood that openings 52 and 100 may have a wide variety of configurations and are not to be limited by the specific embodiments shown and described herein for purposes of example. The configuration and dimensions of openings 52 and 100 are sized and selected depending on the specific application of diffuser 10 . Design factors will include the conditions of the fluid flowing through diffuser 10 , the speed of impeller 12 , and the dimensions of impeller 12 and wave chambers 22 .
Turning now to FIGS. 4A-7B, the operation of diffuser 10 is now discussed with respect to one embodiment of the invention. Wave chamber 22 is closed by valve plate 20 in FIG. 4 A. Outlet flow 34 from impeller 12 thus fills wave chamber 56 and stagnates against outer radial surface 42 and the pressure builds in wave chamber 22 . A reflected compression wave moves upstream as indicated by the arrow labeled by numeral 120 in FIG. 4 B. Compression wave 120 brings incoming flow 34 to rest. The fluid downstream of compression wave 120 is at rest and therefore absent of boundary layers.
Valve plate 20 continues to rotate bringing upper portion 60 of valve opening 52 into fluid communication with wave chamber 22 as shown in FIGS. 5A and 5B. An expansion fan 122 begins to form at the outer radial portion of wave chamber 56 to begin discharging trapped fluid in the direction of the expansion through upper portion 60 of valve opening 52 .
Valve plate 20 continues to rotate as depicted in FIGS. 6A and 6B bringing the entire valve opening 52 into communication with wave chamber 22 . Expansion fan 122 is now fully developed allowing complete discharge of the flow in the axial direction 36 .
FIGS. 7A and 7B depict the end of the cycle where upper portion 60 has moved out of wave chamber 22 but lower portion 62 is still in fluid communication with wave chamber 22 . The fluid communication between lower portion 62 continues to allow fluid to escape from wave chamber 22 until valve plate 20 rotates farther to close wave chamber 22 as depicted in FIGS. 4A and 4B.
This cycle creates an unsteady flow through diffuser 10 to simultaneously accomplish diffusion and flow redirection. The flow that enters each wave chamber 22 is temporarily brought to rest by the action of the waves. Kinetic energy is recovered from all components of the flow and only kinetic energy needed to be deliver flow to downstream components is reintroduced into the fluid. Immediate axial delivery of the flow directly from diffuser 10 is made possible by the virtue of the fact that the fluid within chamber 22 is at rest and may be reaccelerated in any direction. The ducting that is normally required to return the flow through a gradual bend is thus eliminated. Recovery of residual swirl in the duct is also not needed because the component has been fully recovered in wave chamber 22 . The elimination of the radial ducting prevents pressure loss that occurs within the ducting and improves the compactness of diffuser 10 . Boundary layer development in diffuser 10 is limited by the periodic nature of flow through wave chamber 22 . Even though a boundary layer will begin to develop as flow enters wave chamber 22 , the boundary layer collapses when the fluid in wave chamber 22 is brought to rest against a closed portion of valve plate 20 . The same occurs during the discharge process. The loss is attributed to boundary layergrowth in diffuser 10 are thus lower than a steady flow diffuser.
Valve plate 20 operates in close proximity to wave chambers 22 to minimize leakage. Wave chamber 22 may also be sealed by any of a variety of seals known in the art such as labyrinth seals or face seals. Valve plate may be driven by impeller shaft 16 as depicted in the drawings or may be driven by a separate drive mechanism. It is also contemplated that a different valve assembly or multiple valve assemblies may be utilized to create the unsteady flow process instead of rotating valve plate 20 . Non-rotary valves may also be used to control the wave process. Alternate constructions of wave chambers 22 similar to the chambers of other steady flow diffuser types may also be used with the valves to create the unsteady flow. Other embodiments may also include a valve member that controls the wave chamber volume during the cycling of the valve. It is also contemplated that fuel may be injected into the wave chambers to produce combustion within the wave chambers during the cycling of the valves.
Accordingly, the improved wave augmented diffuser for centrifugal compressors is simplified, provides an effective, safe, inexpensive, and efficient device which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art.
In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.
Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.
Having now described the features, discoveries and principles of the invention, the manner in which the improved wave augmented diffuser for centrifugal compressors is construed and used, the characteristics of the construction, and the advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.
|
A wave augmented diffuser for a centrifugal compressor surrounds the outlet of an impeller that rotates on a drive shaft having an axis of rotation. The impeller brings flow in in an axial direction and imparts kinetic energy to the flow discharging it in radial and tangential directions. The flow is discharged into a plurality of circumferentially disposed wave chambers. The wave chambers are periodically opened and closed by a rotary valve such that the flow through the diffuser is unsteady. The valve includes a plurality of valve openings that are periodically brought into and out of fluid communication with the wave chambers. When the wave chambers are closed, a reflected compression wave moves upstream towards the diffuser bringing the flow into the wave chamber to rest. This action recovers the kinetic energy from the flow and limits any boundary layer growth. The flow is then discharged in an axial direction through an opening in the valve plate when the valve plate is rotated to an open position. The diffuser thus efficiently raises the static pressure of the fluid and discharges an axially directed flow at a radius that is predominantly below the maximum radius of the diffuser.
| 8
|
[0001] This is a division of U.S. patent application Ser. No. 14/033,020 filed Sep. 20, 2013 which is a continuation of U.S. patent application Ser. No. 11/017,277 filed Dec. 20, 2004, now U.S. Pat. No. 8,551,591 granted Oct. 8, 2013, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to braided structures and more particularly to conformable braided structures that are characterized by axial sites and bias sites, where the axial sites have a greater diameter than the bias sites. The conformable braided structures are mathematically designed to meet the perimeter and area requirements of target gap area to be filled in a structure.
[0004] 2. Background of the Invention
[0005] Resin transfer molding has been around for many decades, and its use has grown considerably in recent years. The process allows the economical manufacture of high quality composites. The term “composite” has been used principally to define a class of materials in which a matrix material, such as plastics (both thermosetting and thermoplastic), metals, or ceramics are reinforced by strengthening fibers in the form of a preform. Composites are advantageous since the final structure exhibits properties which are a combination of the properties of the constituent materials (i.e., the fiber reinforcement and matrix material).
[0006] In accordance with the process, a resin system is transferred at low viscosities and low pressures into a closed mold die containing a preform of dry fibers. The dry fibers, which may have the form of continuous strand mat, unidirectional, woven, or knitted preforms, are placed in a closed mold and resin is introduced into the mold under external pressure or vacuum. The resin cures under the action of its own exotherm, or heat can be applied to the mold to complete the curing process.
[0007] The resin transfer molding process can be used to produce low-cost composite parts that are complex in shape. These parts typically provide continuous fiber reinforcement, along with inside mold line and outside mold line controlled surfaces. It is the placement of the continuous fiber reinforcements in large structures that sets resin transfer molding apart from other liquid molding processes.
[0008] In the past, resin transfer molding was used for applications suitable to consumer product markets. However, in the last few years, through the development of high-strength resin systems and more advanced pumping systems, resin transfer molding has advanced to new levels. These recent developments have promoted resin transfer molding technology as a practical manufacturing option for high-strength composite designs, particularly in the aerospace industry.
[0009] In the aerospace industry, the most visible advantage to the resin transfer molding process lies in resin transfer molding's ability to combine multiple, detailed components into one configuration. For example, many traditional designs consist of many individual details that are combined as a subassembly. These subassemblies usually require labor-intensive shimming, bonding, mechanical fastening and sealing. Consequently, these subassemblies demonstrate high part-to-part variability due to tolerance build-up.
[0010] Resin transfer molding produces smooth surfaces. Being a product of the mold makes the surface quality of the part produced within the mold comparable to that of the tool's surface. Resin transfer molding also provides control of the fiber/resin ratio in the completed product. This advantage produces parts that are lightweight and high in strength.
[0011] However, when multiple detailed components having rounded edges are combined, the concavity of the edges causes gaps to be formed at the point where the components join together. Consider the geometries shown in FIGS. 1A and 1B , which are typical of the types of cross-sections that often need to be filled with “radius gap-filler” material during construction of a composite lay-up. One method to fill this volume with fiber is to lay-in individual ends of fiber. However, this method can be tedious and inefficient. An alternative method of filling this volume is to use a braided “gap-filler” component that holds multiple ends of the fiber together in a single piece. A drawback of this alternative is that gap filler is typically rigid and not easily conformable to varying cross-sections. Specialty braiders are available that can produce material to a specific geometry, but that geometry is then applicable only to a single application. Generic tubular braids are somewhat conformable to varying shapes, but geometric constraints of the braiding process make it difficult to obtain both the correct fiber volume and the correct perimeter for concave or complex shapes such as that of FIGS. 1A and 1B .
[0012] For example, consider again the geometry shown in FIG. 1A where the length of the sides of the concave gap or area 8 to be filled is indicated by 10 and 12 and the radius of the concave gap or area 8 to be filled is indicated by 14 . In this example assume that the length of the sides, 10 and 12 of the concave gap 8 to be filled is 0.500 in. each. Further, assume that the radius of the concave gap 14 is approximately 0.500 in.. In order to function as an acceptable gap filler that will be conformable to the shape of the gap, a braid must have roughly the same cross-sectional area (0.054 sq. in.) and perimeter (1.785 sq. in.) as the concave gap 8 in FIG. 1A . FIGS. 2A and 2B show the two extremes possible when trying to produce a circular or maypole braid to meet the area and perimeter criteria of FIG. 1A . In one case, as depicted in FIG. 2A where the braid radius 16 is 0.284 in., the perimeter is fixed at 1.785 in. and the area of the solid braid (0.253 sq. in.) is too high. In the other case, as depicted in FIG. 2B where the braid radius 16 is 0.131 in., the area is fixed at 0.054 sq. in. and the perimeter of the solid braid (0.283 in.) is too low.
[0013] In some cases it is possible to avoid the dilemma described above with conventional maypole braids via the use of mandrels. In fact, braids have the property of being conformable to mandrels of various cross-sections. However, this capability is limited in that the mandrel must have no concave geometry. Thus, one typically must attempt to braid around a convex geometry of the target perimeter, then deform this perimeter to the desired concave shape after braiding. However, the area bounded by the initial convex braid prior to deformation will always be higher than the target area of the concave geometry. This is shown in FIG. 3 by the circular cross-section of a braided sheath about an undersized core 18 with an idealized perimeter but also having a high internal void area 24 . As opposed to the solid braid in FIG. 2A in which the area of fiber is too large, the braid in FIG. 3 shows a solid core of fiber 22 sized appropriately to meet the area requirement. Any attempt to fill the void area 24 between the solid core of fiber 22 and the braided sheath 20 with unidirectional fibers would be futile, as the core would simply “fall out” of the sheath.
[0014] U.S. Pat. No. 6,231,941 discloses a radius or gap filler to fill concave areas as depicted in FIGS. 1A and 1B . As disclosed, a braided sleeve surrounds a number of unidirectional tows (untwisted filaments). The core of the unidirectional tows can be of uniform cross section, or can be varied in cross-section along its length so as to fit a particular gap. The radius filler is formed on a mandrel that includes a contoured surface that is substantially the same shape as depicted in FIG. 1A or FIG. 1B . The braided sleeve is braided around the unidirectional tows and is then soaked with a tackifier. The braided sleeve with the unidirectional tows therein is then placed on the mandrel surface and is vacuum bagged under a bladder. The bagged radius filler is then placed in an autoclave and heat is applied while vacuum is applied to the bladder. The bagged radius filler is heated until the tackifier on the braided sleeve is procured or semi-hardened. Since the tackifier is only semi-hardened, it acts as a binding agent to maintain consolidation and configuration of the braided sleeve until the final transfer molding of the component to be filled is performed. However, this process requires specially designed mandrels to construct the specific gap filler required which is a time consuming, laborious and expensive process.
[0015] Accordingly, a need exists for a braided gap filler that can be designed so that it is conformable to gaps with varying cross sections, that can be constructed using conventional braiding techniques.
SUMMARY OF THE INVENTION
[0016] It is the object of the present invention to provide a tubular structure that is conformable to concave gaps or complex shapes.
[0017] The present invention is directed to a tubular structure which includes a plurality of axial sites in circular relation to one another and a plurality of bias sites that interconnect the axial sites to form the tubular structure. The tubular structure's axial sites have a greater diameter than the structure's bias sites. Another aspect of the present invention relates to a method for forming the conformable braid. The method includes calculating the perimeter and the area of the gap that is to be filled by the braid. Next, based on the perimeter and area of the gap, the number of carriers on a braider and the diameter of the circular axial tows are calculated. Once the calculations are completed, the conformable braid is fabricated with a plurality of axial tows that form the sheath of the braid. Since the resulting sheath of the braid was designed based on the perimeter and area requirements of the gap to be filled, upon being conformed, the gap is filled by the braid.
[0018] A further aspect of the present invention relates to a method of reinforcing a woven structure. The method includes providing a tubular structure with a plurality of axial sites in circular relation to one another and a plurality of bias sites interconnecting the axial sites to form the tubular structure. The tubular structure's axial sites have a diameter which is greater than the diameter of the bias sites. Once provided, the tubular structure is inserted and conformed to at least one surface of the woven structure to be reinforced. Finally, the combination of the woven structure and the tubular structure is impregnated with a resin material.
[0019] The various features of novelty which characterize the invention are pointed out in particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying descriptive matter in which preferred embodiments of the invention are illustrated in the accompanying drawings in which corresponding components are identified by the same reference numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The following detailed description, given by way of example and not intended to limit the present invention solely thereto, will best be appreciated in conjunction with the accompanying drawings, wherein like reference numerals denote like elements and parts, in which:
[0021] FIG. 1A depicts a concave gap that is to be filled with fibers;
[0022] FIG. 1B depicts a complex gap that is to be filled with fibers that is formed when curved structures are joined;
[0023] FIG. 2A depicts a known solid circular braid with a perimeter equal to the perimeter of the gap to be filled in FIG. 1A ;
[0024] FIG. 2B depicts a known solid circular braid with an area equal to the area of the gap to be filled in FIG. 1A ;
[0025] FIG. 3 depicts a braided sheath with an undersized solid core that meets both the area and perimeter requirements of the gap to be filled in FIG. 1A ;
[0026] FIG. 4 depicts one aspect of the present invention with oversized axial sites;
[0027] FIG. 5 depicts a conformable braid, according to one embodiment of the present invention;
[0028] FIG. 6 depicts a standard triaxial design according to the prior art;
[0029] FIG. 7 depicts adjacent unbraided axial sites or tows during roll over, according to one embodiment of the present invention; and
[0030] FIG. 8 depicts adjacent braided axial sites or tows during roll over, according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] As previously described and illustrated in FIGS. 2A and 2B , it is difficult and almost impossible to design a conventional braided tubular structure that meets both the area and perimeter requirements of the concave gaps or complex shapes depicted in FIGS. 1A and 1B . Previously, in order to meet both the area and perimeter requirements of a complex gap, a structure 18 consisting of a braided sheath 20 surrounding an undersized solid fiber core 22 , would be constructed as depicted in FIG. 3 . In order to satisfy the area and perimeter requirements of FIG. 1A , the radius 26 of the braided sheath 20 would be 0.284 in. and the radius 28 of the fiber core 22 would be 0.093 in.. The area of the solid fiber core 22 satisfies the area requirement of FIG. 1A and the perimeter of the braided sheath 20 satisfies the perimeter requirement of FIG. 1A . However, as depicted in FIG. 3 , a void area 24 is created between the solid fiber core 22 and the braided sheath 20 . Any attempt to fill the void area 24 would be futile since the solid fiber core 22 would simply “fall out” of the sheath 20 . This could lead to delamination of the finished composite structure,
[0032] Therefore, the present invention relates to a tubular structure 32 comprised of large, unbraided, circular axial tows or sites 30 as depicted in FIG. 4 . The axial tows 30 are made up of the core material used for the solid fiber core 22 in FIG. 3 . By moving the fiber core material 22 to the axial sites 30 of the braid as depicted in FIG. 4 , the conformable braid 32 now consists of a sheath 34 without a core. The fiber area of the axial sites or tows 30 alone satisfies the entire area requirement of the gap to be filled depicted in FIG. 1A . Furthermore, the diameter of these axial sites 30 has been controlled such that the perimeter of the braid can be accurately predicted. The radius 36 of the braid 32 is 0.284 in.. As demonstrated by FIG. 3 , both the axial fiber area and the perimeter of the conformable braid 32 in FIG. 4 are in agreement with the targets defined by FIG. 1A . Hence, the conformable braid can be used to fill a target gap or complex shape and reinforce a structure.
[0033] The mathematical relationship of the area and the perimeter of the gap or complex shape to be filled is shown below for the simplified case of an axial tow having a circular cross-section:
[0000] A =( n/ 2)(π d 2 /4) (1)
[0000] P =( n/ 2) d (2)
[0000] where: A=desired area of gap filler
[0034] P=desired perimeter of gap filler
[0035] n=number of carriers (part of a braiding machine that carries the group of yarns or a single yarn, through the braid as it is made)on the braider
[0036] n/2=number of axial sites on the braider
(note standard braiders contain one axial site for every 2 carriers)
[0038] d=diameter of the axial tow
[0000] For a given area and perimeter, equations (1) and (2) define the size of the braider and axial tow required.
[0039] Using an example, if the requirements shown in FIG. 1A are substituted into equations (1) and (2) above, then the values of “n/2” and “d” calculate to be 46.3 in. and 0.0385 in., respectively. Since braiders come in discreet sizes, set the value of “n/2” to 48 which corresponds to a 96 carrier braider (a common size). Now using equation (2) above and an “n/2” equal to 48, re-calculate “d” 31 to be 0.037 in.. FIG. 5 shows the axial cross-section of the 96 carrier conformable braid 32 defined by this example. The size of the axial tows 30 turn out to be representative of what could be achieved using a single end of commercially available 12K carbon.
[0040] FIG. 6 depicts a prior art design using the same size braider and a standard, triaxial construction. For simplicity only the axial tow cross-sections 30 are shown. In order to make room for similarly sized bias fibers that must travel over and under or otherwise around the axials or tows 30 in FIG. 6 , spacing 38 must exist between the axial tows 30 as shown. Subsequently, in order for the circumference of the braid to be close to the target value, the size of the axial tows 30 in FIG. 6 must be smaller than those shown in FIG. 5 . Hence, it has been demonstrated that a standard braided equivalent to the conformable braid does not satisfy the criteria of having the majority of its fiber weighted in the axial direction. FIG. 6 depicts the cross-section of a solid fiber 22 that would still be required in the core of the braid in order to satisfy the FIG. 1A area requirement. As with FIG. 3 , it can be seen that the void volume 24 within this cross-section is significantly higher than the size of the core, such that the core and sheath are unlikely to behave as a single component as is the case with the conformable braid structure. This represents a problem both in terms of handleability, and in the likelihood for de-lamination to occur between core and sheath in the composite.
[0041] It is possible to form a structure similar to that of FIG. 3 using a traditional triaxial braid. However, the uniqueness of the conformable braid concept is that almost all of the required fiber volume is in the form of the axial tows or fibers. Thus, the bias fiber that holds the conformable braid together is extremely small in cross-section relative to the axial fiber. The function of the bias fiber in this case is to loosely hold the axial tows together such that the conformable braid still has the advantage of being a single piece that is easy to handle, but at the same time has a high percentage of axial fibers with the ability to roll over each other semi-freely thus allowing good conformability to the final gap or complex shape cross-section. Therefore, in one embodiment of the present invention, the bias fibers are not used to impart strength on the conformable braid but instead to simply hold the axial fibers together until the braid is inserted into the target gap or complex shape and the structure is impregnated with resin.
[0042] In another embodiment of the present invention, braided tows are utilized within the axial sites 30 of the conformable braid itself. Take for example two adjacent tows 40 as depicted in FIG. 4 . Triaxial braids traditionally incorporate either individual or multiple ends of fiber. These ends tend to take on elliptical cross-sections and the shape of these cross-sections is difficult to predict and control as depicted in FIG. 7 . By utilizing solid braids in the axial sites of the conformable braid as depicted in FIG. 8 , one can be confident that the cross-sectional shape of the axial tows is circular. Equations (1) and (2) then become far more accurate and thus the ability to design the conformable braid to a given combination of perimeter and area becomes more reliable. In addition, a key property of the conformable braid is the ability of the axial sites to roll over each other when conforming to a given geometry as depicted in FIGS. 7 and 8 . The circular geometry of the braided axial tows as depicted in FIG. 8 should lend itself better to this effect than the oval geometry of a non-braided axial tow as depicted in FIG. 7 because the oval geometry of the unbraided tows lead to higher frictional forces when the tows roll over each other. With the axial-site fiber being in braided form, frictional forces between individual filaments should be minimized, since the surface area to mass ratio of the axial site is far less for the braided configuration as shown in FIG. 8 .
[0043] The concept of using braids in the axial sites is applicable to other materials that, similarly to braids, have fairly rigid, circular cross-sections. The most apparent alternative of this may be pultruded rods.
[0044] Accordingly, it has been shown that a conformable braid where the fiber core material is moved to the axial sites can be designed to satisfy both the area and perimeter requirements of a concave or complex gap that needs to be filled prior to the introduction of a matrix material.
[0045] Although a preferred embodiment of the present invention and modifications thereof have been described in detail herein, it is to be understood that this invention is not limited to this precise embodiment and modifications, and that other modifications and variations may be effected by one skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.
|
A tubular structure which includes a plurality of axial sites in circular relation to one another and a plurality of bias sites that interconnect the axial sites to form the tubular structure. The tubular structure's axial sites have a greater diameter than the structure's bias sites.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a sluice arrangement for the sluicing out of clinker and uncombusted residue from combustion furnaces, i.e. the residual material which is discharged from the discharge end of a fuel-transporting grate, or from a rotary kiln.
The arrangement is well suited for furnaces fired with poor solid fuels, especially incinerator furnaces for household refuse, but may be used for any furnace where clinker and slags are discharged.
2. Description of the Prior Art
In one-furnace plants, the material in question usually is discharged either directly to a clinker or ash pit, or to conveyor means, transporting the material to the clinker or ash pit.
In multi-furnace plants, there may be separate clinker or ash pits for each furnace, or the material may fall onto conveyor means which discharge the material into a common clinker or ash pit.
The arrangement according to the invention is usable in one-furnace as well as multi-furnace plants at the place where the hot residual material discharged from one or more furnaces is transferred to the store which it is sooner or later removed from the plant.
From the prior art it is known to sluice out the residual matter, such as slags and clinker, through a siphon trap. The discharged material flows through a shaft, the end of which dips down under the water surface in a water-filled basin; the material is cooled through contact with the water and then settles on the bottom of the basin from where it is removed by suitable conveyor means such as a scraper conveyor.
This system has the advantage of ensuring an effective cooling of the discharge uncombusted material and providing for an effective seal, preventing false draught to the flue gas ducts. However, the erection as well as the operation costs are rather high. Also, it is rather water-consuming and difficult to repair during operation. Moreover, fine particles contained in the discharged material or split off from layer clinker dropping into the water may collect as a slurry-like mass on the surface of the water, from where it must be removed, and the conveyor means are subject to heavy wear.
It is also known to perform the sluicing-out without the use of a water trap, for instance by means of a screw conveyor mounted in a tube-formed guide, or by a system of push-pistons, pushed along a duct which has its base in the side wall of the ash pit, near the bottom, and whose cross section is the same as that of the pistons. These conveyor means can, however, hardly stand temperatures as high as 900°-1000°C which may well be reached, and by this known dry-sluicing it is furthermore difficult, or impossible, to attain a sufficient degree of tightness, which may unintentionally cause false draught through the ash pit to the flue ducts.
In instances in which the material which has fallen down in the pit contains voluminous elements such as scrap, which is common occurrence in incinerator plants for household refuse and the like, none of the above sluicing-out systems are suited, as such parts either cannot be sluiced away in the manner described, or will entail great risks of the system being jammed or damaged.
It is a purpose of the invention to procure a sluicing-out arrangement of the kind described in the preamble, and moreover an arrangement which does not have the defects outlined above, which can be installed at relatively low costs, and which permits a safe and particularly advantageous operation.
Furthermore, the invention includes a method for the operation of the above-mentioned arrangement and a pilot system for automatic control of the arrangement during this operation.
SUMMARY OF THE INVENTION
In the following text, the term "ash pit" has been used to name the shaft through which the uncombusted material leaves the proper furnace, be it either directly from the grate or a rotary kiln or after having been conveyed in the hot state to be discharged at a far remote place.
According to the invention, the arrangement comprises a steel plate duct having a cross section at least equal to that of the ash pit, being attached to the lower end of the ash pit in a downwards steeply slanting position, and being equipped with an upper and a lower mechanically operated swinging flap, the flaps in their closed positions forming a sluicing chamber within the duct, and in their open positions exposing the full cross section of the duct; in the side walls of the duct nozzles being mounted between the two flaps for spraying water into the sluicing chamber; a discontinuously working transport bucket being arranged for directly beneath the lower rim of the duct for chargewise removal of material discharged from the duct.
The arrangement according to the invention has been built on the well-known principle of a chamber sluice with two sluice gates. The arrangement thus offers the advantages of this system in the form of tightness during the sluicing out operation. By the application in question, it furthermore provides for the possibility of procuring -- when desired -- an unimpeded flow of fresh air up through the ash pit and into the furnace in a simple way, viz. by opening both gates.
By means of a limited quantity of water sprayed through the nozzles, the uncombusted material is cooled effectively, and present or developing dust laid, so that the sluiced-out material does not contain any great surplus of water and can be moved to a bin or pile in a correspondingly cleanly way.
In the operation step of the arrangement, the upper gate will be open and the lower one closed, so that the material discharged falls through the ash pit and down on the lower gate. After a certain time the next steps follow, whereby the upper gate is closed then the lower one is opened whereby the material contained in the sluice chamber will fall down in the conveyor means arranged below for further transport. During these two steps the material which has fallen down into the ash pit is held back by the closed, upper gate. After the emptying of the sluicing chamber, the lower gate is again closed and the upper one opened, and the cycle just described is repeated.
During normal operation of the furnace, it is important that only one of the gates or flaps is open at a time. Furthermore, it should only be possible to open the lower gate or flap for emptying when the conveyor bucket is placed directly under the discharge opening. According to this, the movement of the gates or flaps of the sluice chamber may, according to the invention, be controlled in such a way that one gate or flap cannot be opened without the other being closed, and the the lower one is only opened when the conveyor bucket is placed in its receiving position. This compulsory control of the movements of the gates or flaps may, of course, be abolished when it is desired that both of them should be opened to make a draught up through the ash pit; and according to the invention, the interdependence of movement may be abolished in such a way that both gates may be kept open at the same time and independent of the position of the transport bucket.
In order for instance to avoid damage to the parts working during the operating of the gate, especially in the case of refuse incineration where possibly heavy lumps of refuse during their fall may hit the gates, for instance during the opening/closing movements of the latter, this movement can according to the invention be carried out in a way know per se, by pneumatic means so that the effect of the possible impact is caught elastically. The use of pneumatic means entails the advantage that operation stops are avoided in the case of possible brief compressor stops due to the fact that the compressed-air receiver connected to the compressor acts as accumulator for the air compressed by the compressor.
The system according to the invention gives optimum safeguarding against the penetration of false air to the flue ducts of the furnace. Furthermore it makes it possible to work with a minimum consumption of water for cooling down uncombusted material and laying the dust which, in its turn, gives minimum pollution of buildings and sewer outfalls and makes it possible to feed a maximum quantity of air to the flue ducts of the furnace through the ash pit when this is desirable, for instance in case of priming of the boiler. The operation costs are small due to the small amount of movable components and the fact that they are relatively lightly loaded.
By a preferred operation method for the system, the lower flap is, according to the invention, closed, and the upper one open during a certain fill-up period, such as 5-15 minutes, during which time a comparatively small quantity of water is sprayed into the sluice chamber through the nozzles to lay the dust and keep the nozzles clean, whereas the transport bucket before the end of this period is brought to its receiving position under the discharge opening of the sluice. Thereafter the upper flap is closed and during a cooling period of for instance 1-2 minutes, a greatly increased quantity of water corresponding to the cooling of the slags to about 200°C, is sprayed into the sluice chamber. After this cooling period, the increased water feeding is stopped and the lower flap is opened and is kept open during a period of discharge, such as half a minute, whereupon after discharge into the transport bucket it is closed again and the upper flap is opened, and the bucket with the discharged material is removed. The procedure is then repeated. Furthermore, both flaps may be kept open at the same time without considering the above-mentioned functional interdependency, if required for instance in the case of priming of the boiler.
The above procedure is preferably controlled automatically by means of a suitable pilot system governing the movement of the movable parts, dependent on pre-selected periods and signals indicating the operational state of the incinerator.
Such a pilot system for a sluice system, in which the motive power for the operation of each of the flaps is controlled by a separate change-over device which by changing over effects the closing/opening respectively of the flaps, may according to the invention be arranged in such a way that the change-over devices for the motive power are governed by signal emitters which latter are actuated by the open/closed position of the flaps respectively and activate electric switches so that they, dependent on a signal from a signal emitter which in its turn is activated by the transport bucket in its receiving position, activate time relays to effect a switch of the above-mentioned change-over devices, and opening/closing respectively of the water feed to the sluice chamber in the working cycle as stated by the procedure.
According to the invention, such a pilot system may be connected to a mechanism effecting a compulsory action by the change-over devices, so that both flaps are swung in open position, which mechanism goes into action in the case of abnormal conditions, such as priming of a boiler in the furnace.
Further, the pilot system may, according to the invention contain an alarm mechanism, know per se and reacting on abnormal incidents in the control system.
A preferred embodiment of a pilot system according to the invention, serving the above pilot functions, is described in the specification below, and its different characteristics are listed in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further elucidated below where an embodiment of a sluice system according to the invention and the appurtenant pilot system have been described with reference to the drawing where:
FIG. 1 represents the sluice arrangement proper, in longitudinal section.
FIG. 2 the system -- as seen from the left in FIG. 1.
FIG. 3 a diagram of the automatic pilot system, and
Fig. 4 a diagram of the positions of the sluice gates in the course of a working cycle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The lower end of the end of the shaft 1 is provided with a knee section 2, made of steel plate, preferably with a lining of special wear-resistant cast iron plates.
The lower part of the knee section 2 ends within the upper part of a slanting duct 3, forming the sluice chamber.
The duct 3 is rectangular in cross section and made of steel plate and lined with wear-resistant cast iron plates. The downward facing side of the duct 3 is plane, and the lower end of the duct has an approximately even cross section. From about the middle of the duct, its cross section has been enlarged, giving space for a flap A, mounted on a swinging axle 5. The latter is supported in not shown bearings, arranged on each side of the side walls of the duct 3 at its top, and moreover positioned in such a way that the flap can swing either clockwise to a position -- shown in dotted line -- in the enlarged portion of duct 3, or counter-clockwise to a position -- shown in full line -- where it closes the mouth of knee section 2.
The duct 3 opens into a hopper 4, at the top of which is arranged a flap B similar to the way in which flap A has been mounted. Flap B is mounted on a swinging axle 6, carried by not shown bearings on each side of the hopper 4. Flap B can be swung either clockwise to the position shown in dotted line, or counter-clockwise to the position shown in full line, where it closes the month of the duct 3.
The movements of the two flaps A and B are brought about by two pneumatic cylinders A 1 and B 1 respectively, the piston of cylinder A 1 being hingedly connected to an arm 7 fixed to and extending from the axle 5, and the piston of cylinder B 1 being hingedly connected to an arm 8 fixed to and extending from the axle 6.
Below the sluice arrangement just described, a skip hoist 9 is provided with a bucket 11 running on rails 10. The bucket is shown in its end position ready to receive clinkers and the like residue discharged from the hopper 4. The bucket 11 and the rails 10 are so mounted that the upper rim of the bucket is almost level with the lower rim of the hopper. Thereby the risk that dust originating from the clinker and residue should spread and stir up from the bucket during the discharge operations is considerably minimized. To avoid the risk that residues, such as large clinker, not molten and partly molten metal parts, projecting above the rim of the bucket, should catch the wall of the hopper and be jammed, thereby damaging the hopper or the bucket or both, the lower portion 12 of the hopper wall facing the travelling direction of the filled bucket is formed as a swing flap connected at its upper edge to the upper part of said wall to its lower edge.
The sluicing arrangement, comprising the knee section 2, the duct 3 with flat A, the hopper 4 with flap B and the pneumatic cylinders A 1 and B 1 fixed to the upper wall of the duct 3, is suspended from the end of the shaft 1 and the furnace base in the following way. The upper end of knee section 2 is provided with a flange which is fastened to the brickwork of shaft 1 by vertical bolts. The knee section 2 is connected to the duct 3, which again is connected to the hopper 4, so that the parts then form a unit. The hopper 4, moreover, is carried by adjustable suspension rods 14.
In the side walls of the sluice chamber, i.e. the duct 3, nozzles 15 are provided through which water is sprayed over the contents of the chamber.
In the upper wall of the duct a tight fitting inspection door 16 is provided.
The operation of the sluice system is cyclic and has four steps as shown in FIG. 4, viz. step 1: both of the flaps A and B closed; step 2: upper flap A open, lower flap B closed; step 3: both flaps A and B closed; and step 4: upper flat A closed and the lower flap B open. Thus the positions of the flaps, as shown in FIG. 1 in line, correspond to the 1st or 3rd step. During step 1 the clinker and residue from the combustion falling down through shaft 1 collect in the knee section 2.
During step 2 the collected material falls down into the sluicing chamber, i.e. the duct 3.
During step 3 the quantity of water sprayed through the nozzles is considerably increased with the effect that the clinker and residue now resting in the sluicing chamber is properly cooled down.
During the entire cycle, a minimum quantity of water is fed to the water nozzles by means of an adjustment valve, the said quantity of water being just sufficient to lay the dust and keep the nozzles free of clogging by ashes and clinker dust.
The transition from one step to the next one is performed by operating adjustment valves controlling the introduction of compressed air to the cylinders A 1 and B 1 respectively. This adjustment is made by means of air pilot, the flow of which is controlled by a valve which is activated by the position of the pistons in the cylinders, and by signals from electric relays respectively. Also the supply of additional water to the nozzles in the sluice chamber is controlled by air pilot.
In a diagram in FiG. 3 is shown a pilot system (certain parts being left out) for automatic control of the sluicing arrangement. The system may be switched over to manual operation. In the diagram the shown positions of the pistons in the two cylinders A 1 and B 1 correspond to step 1. This step follows step 4, the discharge operation, at the end of which the lower flap is closed and step 1 -- as shown -- comes into play, being maintained for only a short time before under step 2, the upper flap A is opened.
As motive power is used compressed air entering through feed pipe L and flowing to a manually operated two-way valve V 1 , adjustable either to manual or automatic operating position. Valve V 1 is shown adjusted to automatic operation and allows compressed air to the main piping of the system L 1 , shown in bold line. From the system L 1 the compressed air can flow to the distribution pipes shown in fine line, according to the position of the various valves described in detail below.
The upper sluice flap A, and the lower one B, are moved for opening and closing separately by a pneumatic working cylinder A 1 respectively B 1 , whose functions are reversed by reversing valves V 4 and V 5 respectively, which are pneumatically operated and each adapted to make connection between a feed line and one or the other end of the cylinder, at the same time airing the other end of the cylinder. When the sluice flap A is in closed, respectively open position, the flap will engage the change-over valve V 7 , respectively V 8 , forcing it against a spring load, which returns the valve when the flap's position is changed.
In the same way flap B cooperates with similar valves V 9 and V 10 .
In their two positions, the above-mentioned change-over valves are adapted to connect a feed and discharge line, respectively close the feed line and air the discharge line.
A pneumatically adjustable change-over valve V 6 which is built like the change-over valves V 4 and V 5 , connects a feed line with either the change-over valve V 9 or a pneumatically operated electric switch V 27 .
In various places in the main line net and the distribution line net for the compressed air single-acting non-return valves V 20 , V 21 , V 22 and V 23 and double-acting non-return valves V 17 , V 18 , V 19 and V 25 with T-junctions have been inserted. Other valves and instruments belonging to the system will be mentioned in connection with the following description of the functions of the system during a full cycle of movement of the sluice flaps, the different positions of which during such a cycle appear from FIG. 4, as mentioned above.
Prior to the change-over from position 4 to position 1, where the lower flap B was open and V 10 activated, a compressed air impulse passed through V 10 and V 18 to V 6 which thereby was forced left to the position shown, its left end having been aired through V 8 . When B closes, and A is still closed as shown, both flaps are in position 1 (FIG. 4) and V 9 is activated by flap B. A compressed air impulse then passed from the main line through V 6 and V 9 to a delay air receiver R 1 and further to a spring-loaded, pneumatic change-over valve V 12 . When the pressure has been built up in R 1 with a delay of say 30 seconds V 12 will react and permit a compressed air impulse to pass on to V 24 and then to the change-over valve V 4 which changes over thereby allowing air from the main line to the bottom of cylinder A 1 with the effect that flap A will open, the other end of valve V 4 having been aired through V 17 and a spring-loaded change-over valve V 14 .
When thus the upper flap A is opened, whereby V 8 is activated, the flaps are in position 2. Generally speaking it is so that the working cylinders A 1 and B 1 when being changed over are aired through V 22 and V 23 respectively, and by the change-over valve V 1 when this valve is adjusted for automatic operation.
Through the now activated change-over valve V 8 a compressed air impulse passes to V 6 which changes over whereby the air receiver R 1 and a similar air receiver R 2 , inserted before a change-over valve V 13 , are aired, so that the corresponding change-over valves take up their original positions, as shown. Furthermore, through V 6 pressure is passed to a pneumatically operated electric switch V 27 , by which an electric current is switched on for the start of an adjustable timer T 1 which after the expiration of the adjusted period, for instance after 5-30 minutes, by means of an electric impulse activates the change-over valve V 14 causing a compressed air impulse to pass through V 17 to the change-over valve V 4 . This valve thereby moves to the position shown so that flap A will close, corresponding to position 3. When flap A is in closed position valve V 7 is activated and allows air to flow from the main line through valve V 6 -- now in position opposite the position shown -- through V 7 to a pneumatically operated electric switch V 28 to close a current through this switch. The current, however, will not flow before the conveyor bucket is in receiving position under the slag sluice, where it causes the closing of an electric switch, inserted in a series with V 28 . When the current flows through V 28 , an adjustable timer T 4 is started which immediately sends current to a magnet valve V 29 . This valve opens for the increased water supply to the nozzles 15 in the sluice chamber. After the adjusted period has expired, for instance after 1 to 300 seconds, T 4 switches off the current to V 29 which in its turn shuts off the increased supply of water and activates an electrically operated, spring-loaded change-over valve V 11 . Thereby a compressed air impulse passes through V 25 to the change-over valve V 5 which changes over to opening of the lower flap B, i.e. position 4.
In this position V 10 is activated and allows a compressed air impulse through V 18 and to V 6 which changes over to the position shown. By this, a compressed air impulse passes through V 6 to the delay air receiver R 2 and on to V 13 which for instance with a delay of 30 seconds is activated and permits a compressed air impulse to pass on to V 19 and on to the change-over valve V 5 which changes over to the position shown, i.e. closing the lower flap B. By this, V 9 is activated, and the cycle described starts again.
After the contents of the sluice chamber have been emptied into the transport bucket, and the lower flap B has been closed, the skip hoist is started, an electric switch K being closed by the closing of B, activating a relay U which reacts only at the moment when K closes the current, and which by its activation starts an adjustable timer T 5 . After the adjusted period has elapsed, for instance after maximum 30 seconds, T 5 will start the skip hoist.
In case the moving cycle of the sluice flaps for some reason or other is stopped, an alarm will go off after a certain time when an adjustable timer T 2 runs out. The latter will, however, normally, automatically be adjusted to its zero position before the adjustment period expires, as described below, to start its period afresh.
At the expiration of its period of adjustment, the timer T 1 starts an adjustable impulse relay T 3 which after say 1 to 180 seconds puts the running alarm clock T 2 back in its zero-position and restarts it. In case this zero-impulse fails to come through, T 2 -- after the expiration of its adjustment period, such as 2 to 60 minutes -- activates an alarm S through a pneumatic electric switch V 26 which is constantly switched on by means of the air pressure in the system's network. By adjusting the change-over valve V 1 to manual operation, the pressure in the line is abolished and V 26 is cut off, whereby the alarm is disengaged.
In case of priming, the priming thermostat of the boiler activates a spring-loaded change-over valve V 16 and a compressed air impulse passes through the latter and the non-return valves V 24 and V 25 respectively to the change-over valves V 4 and V 5 which thus change over to opening of both sluice flaps A and B.
By the switch-over to manual operation, the change-over valve V 1 is changed over from the position shown in the drawing to its other position. Hereby the main power net L 1 is cut off from connection with the feed line L and is aired, whereby the spring-loaded valve V 15 changes over from the position shown as it goes back to its original position by means of its restoration spring. By this, a compressed air impulse passes through the change-over valves V 17 and V 19 respectively to each of the change-over valves V 4 and V 5 which take up positions corresponding to the closing of the sluice flaps A and B, and furthermore a compressed air impulse passes through V 18 and V 6 which takes up positions as shown, whereby V 17 is aired and the contact is broken. By switching over to the automatics again, the system will thus start in position 1.
When V 1 is adjusted for manual operation, opening and closing of the sluice flaps A and B follow by manual operation of the valves V 2 and V 3 for A and B respectively. These valves can from the neutral position shown be changed over to one or another of the two active positions in which they-- through a network not shown -- establish direct contact between the feed line L and one end or other of the cylinders A and B respectively, as indicated by the letters x and y respectively z and u.
By adjustment to manual operation when the pressure in the network L 1 disappears, the switch V 26 will-- as mentioned earlier -- be disconnected so that the alarm S is not released even if the alarm clock T 2 is still running. Also the valve V 16 , which is activated by priming, remains inactive.
Instead of a single working cylinder, two parallel working cylinders may be in play for each sluice flap.
|
A sluice arrangement for sluicing out clinker and uncombusted residue from combustion furnaces such as rotary kilns and the like. A steel plate duct having a cross-section at least equal to that of an ash pit is attached to the lower end of the ash pit in a downwards steeply slanting position and is provided with an upper and lower mechanically operated swinging flap. By manually or automatically controlling the closed/opened positions of the flaps relative to each other an effective sluice is provided. A pilot system for the sluice wherein the motive power for operation of each of the flaps is controlled by separate changeover devices is also provided wherein the changing over effects the required closing/opening sequence of the flaps to provide an effective sluice.
| 5
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to fractional-N (fractional Number) phase-locked loop (PLL) circuits (hereinafter referred to simply as PLL circuits) that create multiple signals each with a different frequency. The present invention also relates to frequency division methods.
[0003] 2. Description of the Related Art
[0004] It is desired of PLL circuits employed in recent mobile communication devices to quickly switch the frequency of an output signal to a desired frequency so that the mobile communication devices are used with more convenience.
[0005] [0005]FIG. 1 is a diagram showing a structure of a conventional PLL circuit. As shown in FIG. 1, the PLL circuit includes an oscillator 1 , a prescaler 2 , a shift register 3 , a reference divider 4 , a swallow counter 5 , a main counter 6 , an accumulator 7 , a cancellation signal control circuit 8 , a phase comparator 9 , a charge pump 10 , a low-pass filter (LPF) 11 , and a voltage-controlled oscillator (VCO) 12 .
[0006] The reference divider 4 is connected to the oscillator 1 and the shift register 3 , and the accumulator 7 is connected to the shift register 3 . The cancellation signal control circuit 8 is connected to the accumulator 7 , and the phase comparator 9 is connected to the reference divider 4 and the main counter 6 .
[0007] The charge pump 10 is connected to the phase comparator 9 and the cancellation signal control circuit 8 , and the LPF 11 is connected to the charge pump 10 . The VCO 12 is connected to the LPF 11 . The prescaler 2 is connected to the VCO 12 , the swallow counter 5 , and the main counter 6 . The swallow counter 5 is connected to the prescaler 2 , the shift register 3 , and the accumulator 7 . The main counter 6 is connected to the prescaler 2 and the shift register 3 .
[0008] [0008]FIG. 2 is a circuit diagram showing a structure of the phase comparator 9 . As shown in FIG. 2, the phase comparator 9 includes inverting circuits 41 through 63 and NAND circuits 81 through 98 , and outputs pulse signals ΦP and ΦR on the basis of a phase difference between a supplied reference signal fr and comparison frequency signal fp.
[0009] In the PLL circuit of the above-described structure, the oscillator 1 supplies a reference clock signal CK with the natural frequency of a crystal oscillator to the reference divider 4 . The reference divider 4 , which is formed of a counter circuit, frequency-divides the reference clock signal CK by a division ratio set by data supplied from the shift register 3 . Then, the reference divider 4 supplies the reference signal fr generated by the division to the phase comparator 9 .
[0010] The main counter 6 supplies the comparison frequency signal fp to the phase comparator 9 , which outputs to the charge pump 10 the pulse signals ΦP and ΦR on the basis of the phase difference between the reference signal fr and the comparison frequency signal fp.
[0011] The charge pump 10 generates an output signal VOUT on the basis of the pulse signals ΦP and ΦR supplied from the phase comparator 9 , and supplies the output signal VOUT to the LPF 11 . The LPF 11 smoothes the supplied output signal VOUT by removing high-frequency components therefrom to generate an output signal DOUT. The LPF 11 supplies the output signal DOUT to the VCO 12 .
[0012] The VCO 12 outputs a signal fvco with a frequency corresponding to the voltage value of the output signal DOUT supplied from the LPF 11 , and outputs the signal fvco to the prescaler 2 .
[0013] The prescaler 2 frequency-divides the input signal fvco by M or M+1 (M: natural number) to generate a signal POUT, and supplies the signal POUT to the main counter 6 and the swallow counter 5 . The swallow counter 5 frequency-divides the signal POUT supplied from the prescaler 2 by N, and, if supplied with an overflow signal OVF from the accumulator 7 , frequency-divides the signal POUT by N+1 for a given period of time (N: natural number). The prescaler 2 sets the division ratio to M or M+1 depending on a signal MD supplied from the swallow counter 5 and the main counter 6 .
[0014] The above-described PLL circuit shown in FIG. 1 employs a fractional division setting method to enable fast phase lock, thus including the swallow counter 5 and the main counter 6 . In the above-described PLL circuit, a fraction F is supplied to the shift register 3 , which supplies a modulus QM for determining phase comparison timing in the phase comparator 9 and the fraction F to the accumulator 7 .
[0015] The accumulator 7 subtracts the fraction F from the modulus QM at every phase comparison timing in the phase comparator 9 , and supplies the overflow signal OVF to the swallow counter 5 when the subtraction result becomes zero.
[0016] Thus, in the PLL circuit of FIG. 1 functioning as a fractional-N synthesizer, the division ratio varies with time. Therefore, even after a frequency lock, the phase comparator 9 outputs the pulse signals ΦP and ΦR based on the phase difference to the charge pump 10 , which outputs the signal VOUT (a jitter) based on the supplied pulse signals ΦP and ΦR to the LPF 11 .
[0017] The LPF 11 outputs the signal DOUT, and the VCO 12 performs frequency modulation based on the signal DOUT. Therefore, the output spectrum of the VCO 12 includes an spurious output with a frequency that is a multiple of the frequency of the signal fvco which multiple is an integral multiple of a channel step (the fraction F).
[0018] In order to reduce the spurious output resulting from fluctuations in the signal VOUT output from the charge pump 10 , the PLL circuit of FIG. 1 includes the accumulator 7 and the cancellation signal control circuit 8 .
[0019] The cancellation signal control circuit 8 , based on a signal ACMD supplied from the accumulator 7 , generates a signal SPC having a pulse width proportional to the fluctuation width (a jitter width) of the signal VOUT and supplies the signal SPC to the charge pump 10 , thereby controlling the fluctuations in the signal VOUT output from the charge pump 10 to reduce the spurious output.
[0020] However, in the conventional PLL circuit of FIG. 1, it is necessary for the cancellation signal control circuit 8 to supply the signal SPC to the charge pump 10 with good accuracy in supply timing so as to effectively cancel spurious noise included in the jitter output of the charge pump 10 . This makes timing control in the cancellation signal control circuit 8 difficult and causes the cancellation signal control circuit 8 to be large in size.
SUMMARY OF THE INVENTION
[0021] It is a general object of the present invention to provide a PLL circuit and a frequency division method in which the above-described disadvantages are eliminated.
[0022] A more specific object of the present invention is to provide a simple PLL circuit for reducing spurious noise included in an oscillation output and a frequency division method by means of the simple PLL circuit.
[0023] The above objects of the present invention are achieved by a phase-locked loop ΦPLL) circuit performing a fractional division which circuit includes a phase comparator circuit comparing phases of two signals and outputting first and second phase difference signals based on a phase difference between the two signals, a phase difference signal modulation circuit modulating the second phase difference signals into third phase difference signals, and an oscillator circuit oscillating based on the first and third signals.
[0024] The above-described PLL circuit is simply structured and prevents a signal that is a source of spurious noise from being supplied to the oscillator circuit by modulating the second phase difference signals.
[0025] The above objects of the present invention are also achieved by a frequency division method including the steps of (a) generating first and second phase difference signals based on a phase difference between two signals, (b) modulating the second phase difference signals into third phase difference signals, and (c) generating a signal with a desired frequency by oscillating based on the first and third phase difference signals.
[0026] The above-described method prevents a signal that is a source of spurious noise from being supplied to the oscillator circuit by modulating the second phase difference signals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Other objects, features and advantages of the present invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings, in which:
[0028] [0028]FIG. 1 is a diagram showing a structure of a conventional PLL circuit;
[0029] [0029]FIG. 2 is a diagram showing a structure of a phase comparator shown in FIG. 1;
[0030] [0030]FIG. 3 is a diagram showing a structure of a PLL circuit according to an embodiment of the present invention;
[0031] [0031]FIG. 4 is a diagram showing a structure of a phase comparator shown in FIG. 3;
[0032] [0032]FIG. 5 is a circuit diagram for illustrating a structure of a delay circuit shown in FIG. 3;
[0033] [0033]FIG. 6 is a circuit diagram showing a structure of a selector circuit shown in FIG. 3;
[0034] [0034]FIG. 7 is a timing chart showing an operation of the PLL circuit of FIG. 3; and
[0035] [0035]FIG. 8 is another timing chart showing an operation of the PLL circuit of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] A description will now be given, with reference to the accompanying drawings, of an embodiment of the present invention. In the drawings, the same or equivalent elements are referred to by the same numerals.
[0037] Generally, spurious noise that matters in a fractional-N synthesizer results from a jitter output supplied from a phase comparator to a charge pump. In a PLL circuit according to the embodiment of the present invention, the generation of spurious noise is controlled by restricting the jitter output supplied to the charge pump.
[0038] That is, in the PLL circuit of this embodiment, a control circuits controls the output of a phase comparator and a delay in a delay circuit delaying the output of the phase comparator is controlled by a control signal output from an accumulator based on a fractional division phase difference or error, thereby modulating a signal indicating a phase difference and supplying the signal to a charge pump.
[0039] Therefore, this PLL circuit has the phase comparator controlled directly so as to dispense with such a large circuit as the cancellation signal control circuit 8 shown in FIG. 1. At the same time, the PLL circuit, while securing fast phase lock, can reliably reduce spurious noise generated in a fractional frequency division.
[0040] By simple comparison, the conventional PLL circuit of FIG. 1 is twice as large in size as the PLL circuit of this embodiment. A detailed description will now be given of the PLL circuit of this embodiment and a frequency division method by means of the PLL circuit.
[0041] [0041]FIG. 3 is a diagram showing a structure of the PLL circuit according to the embodiment of the present invention. As shown in FIG. 3, the PLL circuit of this embodiment is similar in structure to the conventional PLL circuit of FIG. 1, but differs therefrom in replacing the cancellation signal control circuit 8 shown in FIG. 1 with a delay circuit 22 , a control circuit 23 , and a selector circuit 24 .
[0042] As shown in FIG. 3, the control circuit 23 is connected to the main counter 6 , a phase comparator 20 is connected to the control circuit 23 , and the delay circuit 22 is connected to the phase comparator 20 and the accumulator 7 . The selector circuit 24 has its inputs connected to the control circuit 23 , the delay circuit 22 , and the phase comparator 20 and its output connected to a charge pump 21 .
[0043] In the PLL circuit of the above-described structure, the phase comparator 20 generates signals ΦP 1 , ΦR 1 , ΦP 2 , and ΦR 2 on the basis of control signals CNT and XCNT output from the control circuit 23 and the phase difference between the reference signal fr and the comparison frequency signal fp. As will be described later, the signals ΦP 1 and ΦR 1 are generated if there is no phase difference between the reference signal fr and the comparison frequency signal fp, and the signals ΦP 2 and ΦR 2 are generated if the phase difference exists between the reference signal fr and the comparison frequency signal fp. The phase comparator 20 supplies the signals ΦP 1 and ΦR 1 to the selector circuit 24 and the signals ΦP 2 and ΦR 2 to the delay circuit 22 and the selector circuit 24 .
[0044] At this point, the delay circuit 22 generates signals ΦDP 2 and ΦDR 2 by delaying the signals ΦP 2 and ΦR 2 by a delay corresponding to control signals SA and SB supplied from the accumulator 7 , and outputs the signals ΦDP 2 and ΦDR 2 to the selector circuit 24 . The selector circuit 24 generates signals ΦSP and ΦSR from the signals ΦP 1 , ΦR 1 , ΦP 2 , ΦR 2 , ΦDP 2 , and ΦDR 2 on the basis of the control signals CNT and XCNT supplied from the control circuit 23 , and supplies the generated signals ΦSP and ΦSR to the charge pump 21 .
[0045] Next, a description will be given of the phase comparator 20 shown in FIG. 3. FIG. 4 is a diagram showing a structure of the phase comparator 20 of FIG. 3. As shown in FIG. 4, the phase comparator 20 is similar in structure to the conventional phase comparator 9 of FIG. 2, but differs therefrom in additionally including NAND circuits 99 through 105 and inverting circuits 64 through 67 .
[0046] The NAND circuit 99 has its one input connected to the NAND circuit 89 and the other input supplied with the control signal CNT. The NAND circuit 100 has its one input connected to the output of the inverting circuit 51 and the other input supplied with the control signal XCNT. The NAND circuit 101 has its two inputs connected to the outputs of the NAND circuits 99 and 100 , respectively, and its output connected to an input of the NAND circuit 91 .
[0047] Further, the NAND circuit 102 has its one input connected to the output of the inverting circuit 61 and the other input supplied with the control signal XCNT. Similarly, the NAND circuit 103 has its one input connected to the output of the inverting circuit 61 and the other input supplied with the control signal CNT. The NAND circuit 104 has its one input connected to the output of the inverting circuit 63 and the other input supplied with the control signal XCNT. The NAND circuit 105 has its one input connected to the output of the inverting circuit 63 and the other input supplied with the control signal CNT.
[0048] The inverting circuit 64 is connected to the NAND circuit 102 and outputs the signal ΦP 1 , and the inverting circuit 65 is connected to the NAND circuit 103 and outputs the signal ΦP 2 . Similarly, the inverting circuit 66 is connected to the NAND circuit 104 and outputs the signal ΦR 1 , and the inverting circuit 67 is connected to the NAND circuit 105 and outputs the signal ΦR 2 .
[0049] Next, a description will be given of the delay circuit 22 shown in FIG. 3. FIG. 5 is a circuit diagram for illustrating a structure of the delay circuit 22 . As shown in FIG. 5, the delay circuit 22 delays the signals ΦP 2 and ΦR 2 supplied from the phase comparator 20 and generates the signals ΦDP 2 and ΦDR 2 . The delay circuit 22 includes inverting circuit 68 through 75 and NAND circuits 106 through 111 .
[0050] The delay circuits 22 adjusts a delay, as shown in the following table 1, on the basis of the signals SA and SB supplied from the accumulator 7 as an accumulator value (a fractional division error), with the result that the greater the fractional division phase difference, or the accumulator value, the greater the delay.
[0051] The accumulator value corresponds to the phase difference between the reference signal fr and the comparison frequency signal fp (that is, the fractional division error) of every timing at which the fraction F is subtracted from the supplied modulus QM.
TABLE 1 Accumulator value SB SA Gate delay 0 L L 4 gates 1 L H 6 gates 2 H L 8 gates 3 H H 10 gates
[0052] As shown in the table 1, if the accumulator value is 0, for instance, the levels of the signals SA and SB are both set to LOW (L). At this point, the NAND circuits 106 and 109 are inactivated. Therefore, if the accumulator value is 0, the signals ΦP 2 and ΦR 2 input to the delay circuit 22 are delayed for passing through the four NAND circuits 107 , 108 , 110 , and 111 , that is, the signals ΦP 2 and ΦR 2 are delayed by four gates. Similarly, the signals ΦP 2 and ΦR 2 are delayed by six gates, eight gates, and ten gates if the accumulator value is 1, 2, and 3, respectively.
[0053] In the above-described case, the accumulator value is a quaternary parameter expressed by two bits, but the accumulator value may be expressed by N bits (N: natural number) so that the delay may be adjusted more finely.
[0054] Next, a description will be given of the selector circuit 24 shown in FIG. 3. FIG. 6 is a circuit diagram showing a structure of the selector circuit 24 . As shown in FIG. 6, the selector circuit 24 includes AND circuits 31 through 34 and OR circuits 35 and 36 .
[0055] The OR circuit 35 has its two inputs connected to the AND circuits 31 and 33 , respectively, and the OR circuit 36 has its two inputs connected to the AND circuits 32 and 34 , respectively. The signal ΦP 1 is supplied to the AND circuit 31 , and the signal ΦR 1 is supplied to the AND circuit 32 . The signal ΦP 2 is supplied to the AND circuit 33 , and the signal ΦR 2 is supplied to the AND circuit 34 .
[0056] The signal ΦDP 2 is supplied to the AND circuit 33 , and the signal ΦDR 2 is supplied to the AND circuit 34 . The control signal CNT is supplied to the AND circuits 31 and 32 , and the control signal XCNT that is the reversal signal of the control signal CNT is supplied to the AND circuits 33 and 34 . The selector circuit 24 outputs the signals ΦSP and ΦSR from the OR circuits 35 and 36 , respectively.
[0057] Therefore, in the selector circuit 24 having the above-described structure, if the level of the control signal CNT is set to HIGH, the level of the control signal XCNT is set to LOW, thus inactivating the AND circuits 33 and 34 . Accordingly, if the level of the control signal CNT is set to HIGH, the selector circuit 24 selectively outputs the signals ΦP 1 and ΦR 1 as the signals ΦSP and ΦSR, respectively.
[0058] On the other hand, if the level of the control signal CNT is set to LOW, the AND circuits 31 and 32 are inactivated. Therefore, in this case, the selector circuit 24 outputs the logical product of the signals ΦP 2 and ΦDP 2 obtained in the AND circuit 33 and the logical product of the signals ΦR 2 and ΦDR 2 obtained in the AND circuit 34 as the signals ΦSP and ΦSR, respectively.
[0059] Next, a description will be given, with reference to timing charts shown in FIGS. 7 and 8, of an operation of the PLL circuit of the above-described structure according to this embodiment. The timing charts of FIGS. 7 and 8 show a case where the modulus QM is 8 and the fraction F is 1.
[0060] The phase comparator 20 is supplied with the reference signal fr shown in FIG. 7(c) from the reference divider 4 and the comparison frequency signal fp shown in FIG. 7(d) from the main counter 6 . Here, if the reference signal fr and the comparison frequency signal fp are phase-matched, for instance, at a time T 1 , the accumulator 7 supplied the overflow signal OVF to the swallow counter 5 at this time and the swallow counter 5 changes the division ration for the comparison frequency signal fp from M to M+1. Thereby, the comparison frequency signal fp is caused to have a given phase difference with respect to the reference signal fr, and, if the modulus QM is 8, is again phase-matched with the reference signal fr at a time T 2 after an eight-fr pulse-long period of time passes since the time T 1 .
[0061] On the other hand, the control circuit 23 generates the control signals CNT and XCNT shown in FIGS. 7 ( a ) and 7 ( b ) in accordance with a signal supplied from the main counter 6 when the main counter 6 counts up to a given number, and supplies the control signals CNT and XCNT to the phase comparator 20 and the selector circuit 24 . Here, in the case shown in FIG. 7, for instance, the control signal CNT has its level set to HIGH for a given period of time around each of the times T 1 and T 2 .
[0062] On the other hand, the phase comparator 20 of FIG. 4 generates the signals ΦP 1 , ΦR 1 , ΦP 2 , and ΦR 2 shown in FIGS. 7 ( e ) through 7 ( h ), respectively. Here, the signal ΦR 2 is a clock signal having a width proportional to the phase difference between the reference signal fr and the comparison frequency signal fp. Therefore, as shown in FIG. 7( h ), the clock width of the signal ΦR 2 gradually decreases over a period between the times T 1 and T 2 .
[0063] The delay circuit 22 of FIG. 5 delays the signals ΦP 2 and ΦR 2 shown in FIGS. 7 ( g ) and 7 ( h ) for a give period of time, and generates the signals ΦDP 2 and ΦDR 2 shown in FIGS. 7 ( i ) and 7 ( j ).
[0064] Thereby, the selector circuit 24 of FIG. 6 outputs signals N 1 and N 2 shown in FIGS. 7 ( k ) and 7 ( i ) from the AND circuits 31 and 32 , respectively. Since the AND circuits 31 and 32 are activated around the times T 1 and T 2 , the signals N 1 and N 2 consequently becomes identical to the signals ΦSP and ΦSR shown in FIGS. 7 ( o ) and 7 ( p ).
[0065] The AND circuits 33 and 34 shown in FIG. 6, contrary to the AND circuits 31 and 32 , are activated for a given period of time between the times T 1 and T 2 , and output signals N 3 and N 4 shown in FIGS. 7 ( m ) and 7 ( n ) in the given period of time, respectively.
[0066] The signal N 3 , which is generated from the logical product of the signals ΦP 2 and ΦDP 2 , is a pulse signal without a sufficient width. Therefore, the level of the signal N 3 is always set to LOW as shown in FIG. 7( m ). On the other hand, the signal N 4 , which is generated from the logical product of the signals ΦR 2 and ΦDR 2 , is a pulse signal having the width proportional to the phase difference between the reference signal fr and the comparison frequency signal fp as described above. Therefore, the level of the signal N 4 is set to HIGH over a period for which the levels of the signals ΦR 2 and ΦDR 2 are set to HIGH at the same time.
[0067] The selector circuit 24 outputs the signal ΦSP shown in FIG. 7( o ) from the OR circuit 35 by obtaining the logical add of the signals N 1 and N 3 , and the signal ΦSR shown in FIG. 7( p ) from the OR circuit 36 by obtaining the logical add of the signals N 2 and N 4 .
[0068] Therefore, with the phase of the comparison frequency signal fp not being locked onto the phase of the reference signal fr, that is, with the phase of the comparison frequency signal fp not being in a locked state, the signals ΦSP and ΦSR shown in FIGS. 7 ( o ) and 7 ( p ) are supplied to the charge pump 21 , which generates the output signal VOUT based on the supplied signals ΦSP and ΦSR.
[0069] As the phase of the comparison frequency signal fp shown in FIG. 7( d ) approaches that of the reference signal fr with the passage of time, the signal ΦR 2 generated by the phase comparator 20 has a smaller pulse width as shown in FIG. 8( d ). This makes no period of time for the signals ΦR 2 and ΦDR 2 shown in FIGS. 8 ( d ) and 8 ( f ) to have their levels set to HIGH at the same time. Therefore, the level of the signal N 4 generated in the AND circuit 34 shown in FIG. 6 is always set to LOW (L) as shown in FIG. 8( j ).
[0070] Accordingly, if the phase of the comparison frequency signal fp approaches that of the reference signal fr to be in the locked state, the signal ΦSR generated in the OR circuit 36 by obtaining the logical add of the signals N 2 and N 4 shown in FIGS. 8 ( h ) and 8 ( j ) has its level set to HIGH only at times T 1 and T 2 as shown in FIG. 8( l ), thereby eliminating such a pulse signal as shown in FIG. 7( p ) between the times T 1 and T 2 , which pulse signal is a source of spurious noise.
[0071] As described above, according to the PLL circuit of this embodiment, with the phase of the comparison frequency signal fp being in the locked position, a phase difference (error) signal (a pulse signal) generated based on the phase difference between the reference signal fr and the comparison frequency signal fp is cut off, so that a signal with a conventional frequency is supplied to the charge pump 21 . Therefore, spurious noise generated in a conventional fractional division is reduced.
[0072] Generally, a PLL circuit performing a fractional division generates the signal ΦR 2 based on a phase difference of its own and a phase difference produced in the process of locking the phase of the comparison frequency signal fp in a state where there is a large difference between the phases of the comparison frequency signal fp and the reference signal fr before the comparison frequency signal fp is in the locked state. However, with the comparison frequency signal fp being in the locked state, the PLL circuit of the present invention cuts off a given phase difference signal so as to generate the signal ΦSR based only on its own phase difference as a signal supplied to the charge pump 21 , thereby reducing spurious noise.
[0073] The present invention is not limited to the specifically disclosed embodiment, but variations and modifications may be made without departing from the scope of the present invention.
[0074] The present application is based on Japanese priority application No. 2000-320936 filed on Oct. 20, 2000, the entire contents of which are hereby incorporated by reference.
|
A phase-locked loop (PLL) circuit performing a fractional division includes a phase comparator circuit, a phase difference signal modulation circuit, and an oscillator circuit. The phase comparator circuit compares phases of two signals and outputs first and second phase difference signals. The phase difference signal modulation circuit modulates the second phase difference signals into third phase difference signals, and the oscillator circuit oscillates based on the first and third signals.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of copending International Application PCT/DE99/00147, filed Jan. 21, 1999, which designated the United States.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a device and a method for regulating a pressure in a high pressure accumulator for fuel injection systems having a pressure adjusting element which has a shut-off element which is actuated by an electromagnetic drive.
In the field of fuel injection systems for internal combustion engines, high pressure accumulator configurations which comprise essentially a high pressure pump, a high pressure accumulator, injection valves and an electronic control device with sensors have increasingly gained prominence in the last few years.
In order to be able to adapt the pressure in the high pressure accumulator, which determines the injection pressure, precisely and quickly to the respective operating conditions of the internal combustion engine, the high pressure accumulator is further provided with a pressure adjusting element or pressure control element by which excess fuel, which is not required to maintain the desired pressure in the high pressure accumulator, is fed back into the fuel tank.
The holding pressure in the pressure adjusting element is regulated by the electronic control unit of the internal combustion engine in accordance with an actual value which is measured by a pressure sensor in the high pressure accumulator and the set point value or desired value which is desired in the respective operating state of the internal combustion engine.
Since the solenoids or magnetic coils which are used in the pressure adjusting elements are made from a conductive material whose specific resistance is temperature-dependent, the current flowing through the solenoid, and thus also the armature force acting on the shut-off element, is influenced by the temperature of the solenoid. Due to the temperature-dependent resistance in the coil winding, the increase in temperature leads to a change in the current flowing through the solenoid and thus t a change in the resulting holding force in the pressure adjusting element. The holding force generally decreases because the coil materials which are used are usually conductors in which the resistance rises as the temperature increases, leading to a decrease in current.
However, since the change in the holding force of the shut-off element in the pressure adjusting element which is brought about by the temperature of the solenoid influences the pressure in the high pressure accumulator, the pressure adjusting element of the electronic control unit of the internal combustion engine must make an adjustment in order to be able to set the desired pressure in the pressure accumulator. However, this adjustment leads to a degradation of the control dynamics of the pressure adjusting element, so that the pressure which is optimum for the operating condition in the high pressure accumulator is achieved only with a delay. In order to prevent an excessively long delay in the regulation of the pressure in the high pressure accumulator, wide control range limits are generally used for prior art PI (proportional-integral) controllers for the pressure adjusting element, so that a sufficient adjustment speed is obtained during the regulation of the pressure. However, such high adjustment speeds increase the risk of overshooting when regulating the pressure, and thus adversely affect the stability of the regulating circuit. In addition, high adjustment speeds often lead to very high current peaks in the solenoid of the pressure adjusting element, which can cause damage.
The Published German Patent Application DE 195 48 278 A 1 discloses a method and a device for regulating a high pressure regulating valve connected to a high pressure accumulator. A current value which is detected in the electromagnetic drive of the high pressure regulating valve is compared with a setpoint current value which is derived from a desired setpoint pressure value. In case of a deviation, the value of the current which flows through the electromagnetic drive of the high pressure regulating valve is readjusted.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a method and a device for regulating a pressure in an accumulator injection system having an electromagnetically actuated pressure adjusting element which overcome the above-mentioned disadvantages of the heretofore-known methods and devices of this general type and which ensure that the control dynamics are at an optimum and at the same time reliably avoid damage to the electromagnetic drive of the pressure adjusting element.
With the foregoing and other objects in view there is provided, in accordance with the invention, in combination with a high pressure accumulator for a fuel injection system, a device for regulating a pressure in the high pressure accumulator, comprising a pressure adjusting element connected to the high pressure accumulator and having a shut-off element and an electromagnetic drive actuating the shut-off element; a first regulating device connected to the pressure adjusting element for performing a comparison between a pressure value obtained in the high pressure accumulator and a given setpoint pressure value, and, as a function of the comparison, determining a drive signal with a setpoint current value for the electromagnetic drive; and a second regulating device connected downstream of the first regulating device for comparing a current value of a current flowing through the electromagnetic drive with the setpoint current value and readjusting the current value in response to a deviation between the current value and the setpoint current value.
In accordance with another feature of the invention, the first regulating device is a pressure regulator and the second regulating device is a current regulator.
In accordance with yet another feature of the invention, the pressure regulator is a PI controlled pressure regulator.
In accordance with a further feature of the invention, the first regulating device determines a pulse-width-modulated drive signal and is configured for setting a pulse duty ratio for the pulse-width-modulated drive signal.
In accordance with an added feature of the invention, the electromagnetic drive includes a magnet armature and a current-conducting solenoid moving the magnet armature.
With the objects of the invention in view there is also provided, a method for regulating a pressure in a high pressure accumulator for a fuel injection system having a pressure adjusting element connected to the high pressure accumulator, the pressure adjusting element having a shut-off element actuated by an electromagnetic drive. The method comprises the steps of comparing a pressure value obtained in a high pressure accumulator with a given setpoint pressure value; determining a drive signal with a setpoint current value for an electromagnetic drive of a pressure adjusting element as a function of the comparing step; obtaining a current value of a current flowing in the electromagnetic drive; and adapting the current value of the current flowing through the electromagnetic drive to the setpoint current value.
In accordance with another mode of the invention, the drive signal with the setpoint current value for the electromagnetic drive is determined using a PI control.
In accordance with yet another mode of the invention, the drive signal for the electromagnetic drive is a pulse-width-modulated signal and the pulse-width-modulated signal is controlled by changing a pulse duty factor of the pulse-width-modulated signal.
According to the invention, a pressure adjusting element is set through the use of a cascade control. A first regulating device compares a pressure value, detected in a high pressure accumulator, with a setpoint value and, depending on this comparison, determines a drive signal with a setpoint current value for a solenoid of the electromagnetically actuated pressure adjusting element. A second, downstream-connected regulating device obtains a current value of the current that flows in the solenoid, compares it with the setpoint current value and makes an adjustment to the current value in the solenoid as a function of this comparison. Through the use of this cascade control of the electromagnetically driven pressure adjusting element in accordance with the invention, during which there is an additional, subsequent adjustment or resetting of the current flowing through the solenoid, it is possible to compensate in a simple manner the dependence of this current on the temperature of the solenoid and thus to shorten control delays when setting the pressure in the high pressure accumulator. Furthermore, the control according to the invention is defined by a high level of control stability, because sufficient control dynamics are achieved even at low adjustment speeds of the pressure adjusting element. Moreover, high current peaks in the solenoid, which could cause damage, are also avoided.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a device and a method for regulating pressure in an accumulator injection system having an electromagnetically actuated pressure adjusting element, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a fuel injection system;
FIG. 2 is a diagrammatic sectional view of a pressure regulating valve; and
FIG. 3 is a schematic block diagram illustrating the regulation of the pressure according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is shown a schematic diagram of a fuel injection system. The fuel injection system shown in FIG. 1 is called a common-rail system and may be used in diesel engines. In this injection system, fuel is drawn out of a fuel tank or fuel reservoir vessel 10 via a fuel line 11 through the use of a presupply pump 12 and is fed from the latter to a high pressure pump 15 via a fuel filter 13. The high pressure pump 15 then feeds the fuel under high pressure into a high pressure accumulator 17. The high pressure accumulator 17 is connected to injection valves 18, via which the fuel is injected into the cylinders of the internal combustion engine (not shown). The injection process is triggered by an electronic control unit 19, which is connected to the injection valves 18 via signaling lines 20. The leakage flow occurring in the injection valves 18 is fed back into the fuel vessel 10 via fuel lines 21.
In order to be able to set the volume flow of the high pressure pump 15 according to requirements in accordance with the respective operating conditions of the internal combustion engine, in the embodiment shown in FIG. 1 an additional suction throttle valve 14 is provided. The suction throttle valve 14 is controlled by the electronic control unit 19 via a control line 22 and regulates the delivery flow of the high pressure pump 15. The suction throttle valve 14 is provided along the fuel line 11 between the presupply pump 12 and the high pressure pump 15.
In addition, a pressure regulating valve 16 is connected into the fuel line 11 between the high pressure pump 15 and the pressure accumulator 17 in order to regulate pressure in the high pressure accumulator 17 in accordance with the desired operating conditions of the internal combustion engine. This pressure regulating valve 16 controls the discharge of excess fuel into the fuel reservoir vessel 10 via a fuel line 25. The excess fuel is not required to maintain the pressure prevailing in the high pressure accumulator 17. The pressure regulating valve 16 is set here by the electronic control unit 19 through the use of an integrated regulating unit via a control line 24 in accordance with a pressure which is measured by a pressure sensor 23 which is mounted on the pressure accumulator 17. FIG. 2 shows a schematic sectional view of the construction of the pressure regulating valve 16. This pressure regulating valve 16 has a valve housing 161 with an inlet opening 162 which is connected to the high pressure accumulator 17 via a fuel line 111. In addition, an outlet opening 168 is provided in the valve housing 161, the opening being connected to the fuel line 25 which leads back into the fuel reservoir vessel 10. The inlet opening 162 has a seal seat which opens inward in a conical shape and into which a shut-off element 163, which is also of a conical construction, engages. This shut-off element 163 is seated with its base surface on one end of a closing rod 164 which projects with its other end through a hole out of the valve housing 161. In addition, a valve spring 166, which applies a spring prestress to the shut-off element, is provided around the closing rod 164 between the valve housing 161 and the base surface of the shut-off element 163. At the end of the closing rod 164 which projects out of the valve housing 161 there is a magnet armature 165, a current-conducting solenoid 167 being provided around the closing rod 164 between the magnet armature 165 and the valve housing 161.
The pressure regulating valve 16 which is shown schematically in FIG. 2 operates as follows: In the closing direction, a holding force, which is composed of the spring force provided by the spring 166 and of the armature force generated by the current-conducting solenoid 167, acts on the shut-off element 163. In contrast, in the opening direction the fuel pressure which prevails in the high pressure accumulator 17 acts on the shut-off element 167 via the fuel line 111. If the pressure force which is exerted on the shut-off element 163 and which results from the fuel pressure exceeds the counteracting holding force of the spring 166 and magnet armature 165, the shut-off element 163 lifts off from the seal seat in the inlet opening 162 and causes the excess fuel to discharge out of the high pressure accumulator 17 back into the fuel reservoir vessel 10 via the fuel line 25. By changing the current applied to the solenoid 167 it is possible to set the armature force and thus the holding force which acts on the shut-off element 163 and which counteracts the fuel pressure.
The solenoid 167 of the pressure regulating valve 16 generally has a pulse-width-modulated drive signal applied to it by the regulating unit of the electronic control unit 19. By changing the pulse duty ratio of this pulse-width-modulated drive signal, and thus the current pulse length for the solenoid 167, the regulating unit of the electronic control unit 19 adapts the armature force, and thus the holding force of the pressure regulating valve 19, to the desired pressure in the high pressure accumulator 17.
As is shown by the block circuit diagram in FIG. 3, the regulating unit of the electronic control unit 19 is composed of a cascade circuit of a regulator 191 and a downstream- connected current regulator 192. The following regulating process is carried out: The pressure prevailing in the high pressure accumulator 17 is determined by the fuel quantity contained in the high pressure accumulator. This fuel quantity is composed of the flow of fuel which is fed in by the high pressure pump 15, of the injection quantity which is discharged during the injection, the leakage flow which flows off via the injection valve and the fuel which is discharged via the pressure regulating valve 16. Both the leakage current of the injection valves and the fuel quantity discharged via the pressure regulating valve 16 depend on the fuel pressure prevailing in the high pressure accumulator 17.
As shown in more detail by the block circuit diagram in FIG. 3, in order to regulate the pressure regulating valve 16, the pressure value determined in the high pressure accumulator 17 using the pressure sensor 23 is compared with a setpoint pressure value in the regulator 191 of the electronic control unit 19. The electronic control unit 19 obtains the setpoint pressure value from a memory device, constructed as a unidimensional or multidimensional data field, in accordance with the operating conditions of the internal combustion engine, in particular its load or rotational speed. The regulator 191, which is preferably constructed as a PI controller, determines, from the difference pressure value, which is obtained by subtracting the setpoint pressure value from the fuel pressure measured in the high pressure accumulator 17, a regulator value TV according to the following equation: ##EQU1## P dif =differential pressure value; K p =a predefined amplification factor;
T n =a predefined reset time (subsequent adjustment time).
The amplification factor and the reset time (subsequent adjustment time) are predefined in accordance with the desired control response of the pressure regulating valve 16. The calculated regulating value TV constitutes a pulse duty ratio of the pulse-width-modulated drive signal for the current-conducting solenoid 167 of the pressure regulating valve 16, the pulse duty ratio representing the ratio of pulse length, i.e. the time during which the solenoid 167 is supplied with current, to the period length, that is to say the distance between two current pulses. Here, the regulating value which is output to the current-conducting solenoid 167 continues to have a fixed current value. By applying current to the solenoid 167, an armature force is exerted on the shut-off element 163 in the pressure regulating valve 16 via the magnet armature 165. This force, together with the spring force 166, determines the holding force of the shut-off element 163 counteracting the fuel pressure. The free flow passage (flow cross section), which results from the equilibrium of forces acting on the shut-off element 163, through the inlet opening 162 of the pressure regulating valve determines the fuel flow which is discharged via the pressure regulating valve 16, and thus determines the pressure prevailing in the high pressure accumulator 17.
However, the current flowing through the solenoid 167 causes heat to be generated in the solenoid 16 due to the resistance heating that occurs in the current-conducting coil elements. This generation of heat also influences the temperature-dependent, specific resistance of the current-conducting elements in the solenoid 16, in which case, with conventionally used current-conducting elements, the resistance rises with the temperature. This rise in the resistance in the current-conducting coil elements which is caused by the generation of heat leads in turn to a decrease in the current value flowing through the solenoid 167. However, as a consequence of this decrease in the current value, the armature force acting on the shut-off element 163 is reduced, which leads to an increase in pressure in the high pressure accumulator 17.
In order to compensate the control error (control deviation) caused by the temperature-dependence of the current flowing through the solenoid 167, the current value flowing through the coil is determined with a current meter 193 and is compared with the setpoint current value in a current regulator 192. This current regulator 192 then compensates a difference between the measured current value and the setpoint current value by additionally supplying current to the solenoid 167, so that the desired holding force is again set at the pressure regulating valve 16.
According to the invention, the additional measured variable of the magnet current value, and its resetting, i.e. subsequent adjustment, in a secondary regulating circuit compensates the interfering factors influencing the regulation of the pressure regulating valve 16 which are caused by the temperature-dependence of current flowing through the solenoid, so that a very fast regulating circuit with a high level of control dynamics is obtained. The PI controller 191, the current meter 193 and the current regulator 192 can also be integrated directly into the pressure regulating valve 16, instead of into the electronic control unit 19. In addition, the regulation of the pressure according to the invention can be carried out in internal combustion engines with all types of pressure regulating elements having an electromagnetic drive.
|
A device for regulating a pressure in a high pressure accumulator of a fuel injection system includes a pressure adjusting element which has a shut-off element and an electromagnetic drive actuating the shut-off element. A first regulating device is connected to the pressure adjusting element and compares a pressure value obtained in the high pressure accumulator with a given setpoint pressure value. A drive signal with a setpoint current value for the electromagnetic drive is determined as a function of the comparison. A second regulating device is connected downstream of the first regulating device for comparing a current value of a current flowing through the electromagnetic drive with the setpoint current value and readjusting the current value in response to a deviation between the current value and the setpoint current value. A method for regulating a pressure in a high pressure accumulator is also provided.
| 5
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention pertains to the art of appliances and, more particularly, to a molded plastic door assembly for a dishwasher.
[0003] 2. Discussion of the Prior Art
[0004] When purchasing a dishwasher, a consumer would typically have to select a particular model, followed by a particular style. For instance, it is common to provide three or more styles for any particular dishwasher model, with the styles generally only differing by the color of the outer surface of a door of the dishwasher. Commonly, dishwasher doors are available in white, almond and black colors. Given that the doors between these various style dishwasher door assemblies only differ in visible appearance, it has been heretofore proposed to construct a dishwasher door with interchangeable front door panels of varying colors. Therefore, it is known to provide dishwashers with interchangeable front panels which advantageously allows a consumer to simply select between various decorative outer door panels when purchasing a particular dishwasher model.
[0005] Interchangeable dishwasher panels as proposed in the prior art are typically rectangular in shape and designed to only cover the front side of the dishwasher door. Such door assemblies typically utilize grooves or bracing members along a frame of the dishwasher door for receiving the decorative panel. Often the decorative panels are held in place with retainer strips positioned along an edge of the door frame. This overall arrangement requires the assembly of a fair number of components which must be maintained in respective positions in order to accommodate the retainer strips. The use of these multiple assembly components and the requirement for maintaining a certain alignment during the overall assembly is considered to lead to disadvantageous assembly costs.
[0006] In today's marketplace, dishwasher door assemblies, with or without decorative front panels, almost invariably have metal frames. The use of metal in forming door frames is considered to disadvantageously add weight to the overall structure. Most typical assemblies utilize metal screws and the like which require alignment between holes formed in the various components and, inherently, longer assembly times. In any event, for at least these reasons, there exists a need in the art for a dishwasher door assembly that is preferably formed of plastic so as to be lightweight, while being structurally sound. More particularly, there exists a need in the art for a dishwasher door assembly which is simple in construction, incorporates at least a frame and a decorative front panel which can be easily interconnected to the frame in a time efficient and effective manner, with the front panel being of a selected color and/or style.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a dishwasher door assembly including a door frame, an inner door panel and a decorative outer door panel. In accordance with the most preferred embodiment of the invention, the door frame is sandwiched between the inner and outer door panels, with each of the inner and outer door panels being snap-fittingly connected to the door frame. The decorative door panel preferably fits over at least side portions of the door frame. The door frame actually defines a housing for a control panel, as well as constituting a support for the overall door assembly. In accordance with the invention, each of the door frame, inner door panel and decorative outer door panel are formed is of plastic.
[0008] In the most preferred form of the invention, side portions of the door frame are formed with slots for receiving tabs provided on each of the outer door panel and inner door panel. That is, the inner door panel includes tabs that extend outward from a body portion thereof. As the inner door panel is joined to the door frame, the tabs register with structure provided on the door frame such that a snap-fit connection is affected. In a similar manner, the decorative outer panel is formed with tabs which are snap-fitted to the door frame. More particularly, the outer door panel is formed with various projections which are slidably received within slots provided in the door frame, whereupon the outer door panel is pivoted and snap-fittingly attached to the door frame about side portions thereof. As the outer door panel and the door frame are joined, the outer door panel covers at least front and side portions of the door frame to establish an overall aesthetic arrangement. Additional mechanical fasteners can be utilized to finalize the overall assembly.
[0009] With this construction, the dishwasher door assembly of the present invention presents a lightweight and structurally sound door assembly that can be easily assembled with substantially self-aligning parts being connected in a snap-fit manner. In accordance with the invention, an overall dishwasher model can be selected by a consumer, followed by a particular decorative outer door panel having a desired color and/or style, with the outer door panel being easily attached to the remainder of the door assembly to establish the final product.
[0010] Additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of a preferred embodiment thereof when taken in conjunction with the drawing wherein like reference numerals refer to corresponding parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a front perspective view of a dishwasher incorporating a door assembly constructed in accordance with the present invention;
[0012] [0012]FIG. 2 is a partial exploded view of the door assembly of the present invention, with a decorative outer door panel thereof being shown spaced apart from a remainder of the assembly;
[0013] [0013]FIG. 3 is an exploded, rear perspective view of the dishwasher door assembly of the invention;
[0014] [0014]FIG. 4 is an enlarged perspective view of tab structure provided on an inner door panel of the door assembly; and
[0015] [0015]FIG. 5 is an enlarged perspective view of tab structure provided on an outer door panel of the door assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] With initial reference to FIG. 1, a dishwasher 2 is generally indicated to be positioned below a kitchen countertop 5 . Also below countertop 5 is shown cabinetry 8 including two columns of drawers 10 . Dishwasher 2 includes a door assembly 17 which is constructed in accordance with the present invention and pivotally mounted for movement relative to a tub 22 (see FIG. 2) of dishwasher 2 . Although not shown, dishwasher 2 preferably includes a support frame for tub 22 , with dishwasher door assembly 17 being pivotally connected to the support frame. As the pivotable mounting of dishwasher doors are widely known in the art and not considered part of the present invention, this pivotable mounting arrangement will not be discussed further here. As shown, dishwasher 2 includes a control panel 24 . In accordance with the preferred embodiment, control panel 24 includes a display 27 , as well as a set of buttons, generally indicated at 29 , for establishing a desired washing operation. In general, the overall control and operation of dishwasher 2 is also known in the art and will not be discussed in further detail. As further well known in the art, control panel 24 is preferably undercut, such as that indicated at 34 , so as to define a handle for use in opening and closing of door assembly 17 . Instead, the present invention is particularly directed to the construction of dishwasher door assembly 17 as will be detailed below.
[0017] As best shown in FIGS. 2 and 3, dishwasher door assembly 17 has three main components, i.e., a door frame 40 , an inner door panel 45 and an outer door panel 48 . In accordance with the most preferred form of the invention, door frame 40 is molded of plastic and includes a main body portion 52 provided with various cut-out sections 55 - 58 . Arranged above cut-out portions 55 - 58 is a cross ledge 60 that is formed with various spaced, laterally extending slots 61 - 63 . Door frame 40 also includes a top wall 65 , a bottom wall 66 and lateral side walls 67 and 68 . As indicated above, outer door panel 48 is preferably molded of plastic such that main body portion 52 , cross ledge 60 and walls 65 - 68 are integrated to define a unitary piece.
[0018] Each of side walls 67 and 68 are undercut, such as that indicated at 71 . With this arrangement, the lowermost portions (not separately labeled) of side walls 67 and 68 are recessed relative to the upper portions (also not separately labeled) of control panel 24 for the reasons which will be clearly identified below. Side walls 67 and 68 also include respective side edges 76 and 77 , each of which is formed with vertically spaced grooved portions 80 - 82 . Each grooved portion 80 - 82 preferably leads into a respective grooved zone 85 - 87 provided in a respective side wall 67 , 68 . At the forwardmost portion of grooved zones 85 - 87 , side walls 67 and 68 are formed with elongated openings 88 - 90 . Between elongated opening 89 and grooved portion 81 on each side wall 67 , 68 , a respective bore or opening 92 is provided as clearly shown in FIG. 3. As also shown in these Figures, door frame 40 is preferably molded with respective corner bosses 94 - 97 , each of which has an associated bore 100 .
[0019] Inner door panel 45 is preferably defined by a main panel portion 104 having opposing faces 105 and 106 , as well as a body portion 108 . In a manner generally analogous to door frame 40 , inner door panel 45 is also preferably molded of plastic. As shown, body portion 108 includes a cut-out section 110 . In general, cut-out section 110 is provided to enable a portion of a door liner (not shown) to extend therein. As shown, main panel portion 104 includes various corner apertures 114 and, extending from face 105 , a plurality of vertically spaced side tabs 117 - 119 . As clearly shown in FIGS. 3 and 4, each side tab 117 - 119 includes a planar portion 122 which projects from face 105 and which terminates in an enlarged bead portion 124 . Each bead portion 124 is preferably rounded to enhance assembly of inner door panel 45 to door frame 40 as will be more fully discussed below. In accordance with the most preferred form of the invention, at least tab 118 is provided with a through opening 125 . Of course, although not shown based on the view taken, it should be readily apparent that a corresponding set of tabs 117 - 119 are provided on an opposing side edge of inner door panel 45 .
[0020] In accordance with the invention, outer door panel 48 can vary in color and style and represents a component of door assembly 17 which can be separately selected by a consumer upon purchasing of a dishwasher 2 . In the embodiment shown, outer door panel 48 includes a main panel portion 129 having in-turned side walls 132 - 134 . In a manner analogous to door frame 40 and inner door panel 45 , outer door panel 48 is also preferably molded of plastic. As shown, main panel portion 129 includes an upper edge 137 formed with various laterally spaced and tapering projections 138 - 140 . In addition, as clearly shown in each of FIGS. 2, 3 and 5 , each of side walls 132 and 134 are provided with vertically spaced sets of cut-outs, such as that indicated at 143 and 144 . Each set of cut-outs 143 and 144 defines a respective cantilevered tab 146 which, in a manner analogous to tabs 117 - 119 , preferably terminates in an elongated bead portion 147 . However, while tabs 117 - 119 have bead is portions 124 which project outwardly therefrom, bead portions 147 provided on cantilevered tabs 146 project inward. Furthermore, in a manner directly analogous to the incorporation of opening 125 and tab 118 , at least one cantilevered tab 146 provided on each side wall 132 and 134 is preferably provided with an opening 149 .
[0021] With this construction, dishwasher door assembly 17 can be readily assembled in an easy and convenient manner. More particularly, door 17 is assembled by connecting inner door panel 45 to door frame 40 after the positioning of control components behind panel 24 and thermal and/or sound insulation between main body portion 52 of door frame 40 and main panel portion 104 of inner door panel 45 . During assembly, each set of tabs 117 - 119 provided along a respective edge of main panel portion 104 is slidably received within a respective grooved zone 85 - 87 . The lateral space between the sets of tabs 117 - 119 provided on each side of main panel portion 104 causes tabs 117 - 119 to slightly deflect inward during assembly of inner door panel 45 to door frame 40 until the enlarged bead portion 124 of a respective tab 117 - 119 is received within a corresponding slot 88 - 90 . At this point, tabs 117 - 119 are deflected laterally outwardly to retain inner door panel 45 to door frame 40 . Therefore, with this arrangement, inner door panel 45 is snap-fittingly connected to door frame 40 , with the interaction between tabs 117 - 119 and grooved zones 85 - 87 aiding in assuring a proper alignment for ease of assembly. Once this attachment is made, apertures 114 provided on main panel portion 104 are automatically aligned with bores 100 . This alignment can be advantageously utilized in connecting an inner door liner (not shown), to the overall door assembly 17 , while also permitting a further mechanical attachment between inner door panel 45 and door frame 40 . In the most preferred form of the invention, threaded screws are utilized for this purpose.
[0022] As indicated above, a consumer purchasing dishwasher 2 would be able to select a particular outer door panel 48 from various designs which differ in color and/or style. Once a particular outer door panel 48 is selected, the outer door panel 48 would be interconnected to door frame 40 . In accordance with the most preferred form of the invention described above, this interconnection would be performed by initially sliding projections 138 - 140 into respective slots 61 - 63 . Thereafter, outer door panel 48 is pivoted to position in-turned side walls 132 - 134 about side wall 67 , bottom wall 66 and side walls 68 respectively. During this movement of outer door panel 48 , cantilevered tabs 146 are forced to project laterally outwardly until elongated bead portion 147 of each cantilevered tab 146 reaches a respective grooved portion 80 - 82 . At this point, the cantilevered tabs 146 will shift laterally inwardly to securely attach outer door panel 48 to door frame 40 . Therefore, with this arrangement, it should be readily apparent that outer door panel 48 is also snap-fittingly connected to door frame 40 , with the cooperation between elongated bead portion 147 and grooved portions 80 - 82 assuring a proper alignment and fit. Due to the presence of undercut 71 , a smooth transition is defined between control panel 24 and outer door panel 48 . Once assembled in this manner, openings 92 , 125 and 149 will be aligned. A mechanical fastener 150 , which can constitute a threaded fastener or a serrated plastic insert, is placed within aligned openings 92 , 125 and 149 .
[0023] Based on the above, it should be readily apparent that the dishwasher door assembly of the present invention is lightweight, can be easily assembled, requires an efficient number of parts and advantageously enables the use of a selectable, decorative outer door panel which can vary in color, shape and the like. In any event, although described with respect to a preferred embodiment of the invention, it should be readily understood that various changes and/or modifications can be made to the invention without departing from the spirit thereof. In general, the invention is only intended to be limited by the scope of the following claims.
|
A dishwasher door assembly includes a frame, an inner door panel and a decorative outer door panel. The door is assembled by snap-fitting the inner door panel to the frame and then further snap-fitting the decorative outer panel over the frame. Thereafter, mechanical fasteners are inserted in aligned openings formed in the outer door panel, frame and inner door panel. This overall arrangement enables a consumer to select between various decorative outer door panels available to a retailer such that an outer door panel of a desired color and/or style can be sold with the overall dishwasher. The overall door assembly is preferably formed from plastic so as to be lightweight, yet structurally sound.
| 0
|
RELATED APPLICATION
[0001] The present application claims priority to U.S. provisional patent application ser. No. 61/529,774 filed 31 Aug. 2011, which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention is generally related to protective devices and is more particularly related to a configurable cushion device that provides protection from injury or discomfort caused by items in contact with a person.
[0004] 2. Related Art
[0005] There are many items that come in contact with people during the normal course of everyday living. A large number of these items cause discomfort, physical pain or even injury. If a person happens to already be injured, physical contact by such items can cause severe discomfort and pain and can even cause further injury. Therefore, what is needed is a device that overcomes these significant problems.
SUMMARY
[0006] A configurable cushion device is described herein that provides protection from injury or discomfort caused by items in contact with a person. In one embodiment, the device includes a cushioned pillow wrapped in a protective case that includes a plurality of fastener straps for attaching the device to an object such as a seat belt. The protective case may include an internal or external pocket and may have include portions that provide additional friction against the object to keep the device in a desired location with respect to the object or the person. The device may also include a strap with a connector to allow the device to be secured around a larger object such as the waist of a person. The device may also include a drape cloth that is secured to the interior of the protective case and can be taken out and draped around an object or a person.
[0007] In an alternative embodiment, the device includes one or more fasteners to allow a plurality of devices to be connected to each other to adapt the configurable device for a particular use. An angled fastener allows two devices to be connected in an L shape to enable the combined device to attach to the lap portion as well as the torso portion of a seatbelt. Orthogonal fasteners allow three devices to form an H shape to enable the combined device to attach to a seat belt integrated with a child's car seat. Fasteners on the ends of the device allow connection of external pockets or other devices such as stuffed animals or other comfort devices.
[0008] In an alternative embodiment, the exterior of the protective case includes a custom fastener that is adapted to fit a particular object such as a hand, a foot or a wheel chair arm or leg. The interior of the protective case may also include a lined pocket that houses a compress that can be heated or cooled prior to placing the device in contact with a person.
[0009] In yet another embodiment, the device includes a zipper along the length of the casing that is configured to engage the zipper of a companion device and two companion devices are zippered together to create a large seat cushion device. In additional, the length and width of the device can be configured for specific uses such as protection for c-section injuries, pregnancy, hysterectomy, lap-band surgery, gastric bypass, hernia, appendix, gall bladder, abdominal surgery, chest/heart surgery, other surgery, tummy-tuck, liposuction, car travel, bus travel, train travel, airplane travel, cruise travel, sporting event seating, lumbar support, and the like.
[0010] Fasteners used throughout the device may include snaps, hook-and-loop, zippers, and the like as necessary or desirable for the particular use. Other features and advantages of the present invention will become more readily apparent to those of ordinary skill in the art after reviewing the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The structure and operation of the present invention will be understood from a review of the following detailed description and the accompanying drawings in which like reference numerals refer to like parts and in which:
[0012] FIG. 1 is a block diagram illustrating an example configurable cushion device according to an embodiment of the invention;
[0013] FIG. 2 is a block diagram illustrating an example configurable cushion device for use with a lap and shoulder seat belt according to an embodiment of the invention;
[0014] FIG. 3 is a block diagram illustrating an example configurable cushion device for use with a lap and shoulder seat belt according to an embodiment of the invention;
[0015] FIG. 4 is a block diagram illustrating an example configurable cushion device according to an embodiment of the invention;
[0016] FIG. 5 is a block diagram illustrating an example configurable cushion device for use as a seat cushion according to an embodiment of the invention;
[0017] FIG. 6 is a block diagram illustrating an example configurable cushion device for use with an H belt according to an embodiment of the invention;
[0018] FIG. 7 is a block diagram illustrating an example configurable cushion device with a hot or cold compress pocket according to an embodiment of the invention; and
[0019] FIG. 8 is a block diagram illustrating an example configurable cushion device with a nursing drape according to an embodiment of the invention.
DETAILED DESCRIPTION
[0020] Certain embodiments disclosed herein provide for a configurable cushion device that protects a person from discomfort or injury caused by items that come into contact with the person. For example, one device disclosed herein provides for a configurable cushion device that attaches to a seat belt to protect a person's abdomen from contact by the seatbelt. After reading this description it will become apparent to one skilled in the art how to implement the invention in various alternative embodiments and alternative applications. However, although various embodiments of the present invention will be described herein, it is understood that these embodiments are presented by way of example only, and not limitation. As such, this detailed description of various alternative embodiments should not be construed to limit the scope or breadth of the present invention as set forth in the appended claims.
[0021] FIG. 1 is a block diagram illustrating an example configurable cushion device 10 according to an embodiment of the invention. In the illustrated embodiment, the device 10 comprises a case 100 having a zipper 110 that when unzipped defines an opening in the case 100 into which pillow 120 can be inserted into the case 100 .
[0022] The case 100 may be made of any of a variety of materials. In one embodiment, the case 100 is made of a stretchable fabric that functions to grip the pillow 120 when the pillow is inserted into the case 100 and also functions to grip the item to which the device 10 is attached.
[0023] The function of the zipper 110 is to open and close the case 100 to allow the user to access the internal cavity of the case 100 . Accordingly, the zipper 100 may be implemented using a zipper, a hook and loop fastener, one or more buttons or snaps or the like, as will be understood by those skilled in the art.
[0024] The pillow 120 can be any of a variety of cushion devices. In one embodiment, the pillow is made of a solid foam material.
[0025] The fastener straps 130 are affixed to the case 100 at a first end and include a fastener 140 at a second end. The fastener 140 is releasably attached to the case 100 . For example, the fastener 140 may be a zipper, a hook and loop, a snap, a button or the like that comprises two portions where one portion is attached to the fastener strap 130 and the other portion is attached to the case 100 .
[0026] The internal pocket is located on the inside surface of the case 100 . In one embodiment, the internal pocket 150 is located on the inside surface of the portion of the case 100 that is furthest away from the person who is using the device 10 . This is referred to as the distal side of the device 10 and advantageously allows the person using the device 10 to be able to conveniently access the pocket 150 . In an alternative embodiment, the picket 150 can be located on the inside surface of the portion of the case 100 that is nearest to the person who is using the device 10 . This is referred to as the proximal side of the device 10 .
[0027] In one embodiment, the pocket 150 is configured to be closed using the fastener 160 . Advantageously, the fastener 160 may comprise any of a variety of fasteners including a zipper, a hook and loop, a snap, a button and the like.
[0028] In one embodiment, one or more grippers 170 are located on the same side of the case 100 as the fastener straps 140 . The one or more grippers 170 are configured to grip the item to which the device 10 is attached. One example of a gripper 170 is a strip of rubberized material that frictionally engages the item to which the device 10 is attached. Other materials that serve to grip the item to which the device 10 is attached may also be used for the one or more grippers 170 as will be understood by those skilled in the art.
[0029] The connector straps 180 and 190 are each affixed to a separate end of the case 100 and are configured to interconnect in order to allow the device 10 to be strapped around an object. In one embodiment, the connector straps 180 and 190 function to strap the device 10 around the waist or other body part of a person.
[0030] FIG. 2 is a block diagram illustrating an example configurable cushion device 20 for use with a lap and shoulder seat belt according to an embodiment of the invention. In the illustrated embodiment, the device 20 comprises a first case 100 and a second case 102 . The first case 100 and the second case 102 are attached to each other by way of angled zipper 200 .
[0031] The first and second cases 100 and 102 may include any or all of the additional elements previously described with respect to FIG. 1 . As shown, the first case 100 includes a zipper 100 that defines an opening into which a pillow 120 can be inserted. The case 100 additionally includes at least one fastener strap 130 that is attached to the case 100 at a first end of the fastener strap 130 and comprises a fastener 140 at a second end of the fastener strap 130 . As previously described, the fastener 140 may comprise a zipper, a hook and loop, a button, a snap or any of a variety of other fasteners as will be understood by those skilled in the art.
[0032] Similarly, the second case 102 comprises a zipper 230 that defines an opening into which a pillow 122 can be inserted. The second case 102 additionally includes at least one fastener strap 210 that is attached to the second case 102 at a first end of the fastener strap 210 and comprises a fastener 220 at a second end of the fastener strap 210 . As previously described, the fastener 220 may comprise a zipper, a hook and loop, a button, a snap or any of a variety of other fasteners as will be understood by those skilled in the art.
[0033] As shown in the illustrated embodiment, the angled zipper 200 is advantageously positioned to orient the second case 102 at a particular angle with respect to the case 100 . This angle advantageously approximates the angle at which the shoulder belt is positioned with respect to the lap belt in a lap and shoulder seat belt. This angle allows the device 20 to attach to both the lap belt and the shoulder belt of a lap and shoulder seat belt such that person wearing the seat belt is protected from each of the belts in the lap and shoulder seat belt.
[0034] FIG. 3 is a block diagram illustrating an example configurable cushion device 30 for use with a lap and shoulder seat belt according to an embodiment of the invention. In the illustrated embodiment, the device 30 comprises many of the same elements as previously described with respect to FIG. 2 . Accordingly, only the additional elements will be described with respect to FIG. 3 . In the illustrated embodiment, the device 30 includes an extension zipper 310 that is located on a first end of the case 100 that is closest to where the angled zipper 200 is positioned on the case 100 . The extension zipper 310 secures an attachment 320 to the device 30 . In the illustrated embodiment, the attachment 320 comprises a buckle opening 300 and a fastener strap 330 that includes a fastener 340 . Advantageously, in operation the device 30 can be attached to a seat belt with the fastener straps 130 and 220 and the buckle on the seat belt can pass through the buckle opening 300 to further secure the device 30 to the seat belt in combination with the fastener strap 330 .
[0035] FIG. 4 is a block diagram illustrating an example configurable cushion device 40 according to an embodiment of the invention. In the illustrated embodiment, the device 40 comprises a case 100 that includes a zipper 110 that defines an opening in which a pillow 120 can be inserted. The device 40 additionally includes one or more fastener straps 130 that each include a fastener 140 as previously described. In the illustrated embodiment, the device 40 includes at least one attachment zipper 410 that is locate on an end of the device 40 . The attachment zipper 410 allows an attachment 420 to be connected to the device 40 . For example, the attachment 420 can be any of a variety of attachments such as an external pocket 430 , a toy (not shown), a stuffed animal, and the like.
[0036] In addition, the device 40 may also include an adaptor 400 that is attached to the case 100 . The adaptor 400 is advantageously sized and shaped to receive a particular body part or component of the item to which the device 40 is attached. For example, the adaptor 400 may be in the shape of a glove or a sock in order to snugly receive a hand or foot of a person that is wearing the device 40 . In one embodiment a sock shaped adaptor 400 is open on both ends.
[0037] FIG. 5 is a block diagram illustrating an example configurable cushion device 50 for use as a seat cushion according to an embodiment of the invention. In the illustrated embodiment, the device 50 comprises a first case 100 and a second case 102 . Each case defines an opening into which a pillow 120 or 122 can be inserted. Advantageously, a zipper on each case may define the respective openings, whereby the zipper on the first case and the zipper on the second case are each configured to mate with a portion of the zipper on the opposing case in order form a dual zipper 500 that secures the first and second cases together into a single larger case. In alternative embodiments, the zipper 500 can be an actual zipper, a hook and loop, a snap or a button, just to name a few. In one embodiment, a first portion 520 of a logo 510 is presented on the first case 100 while a second portion 530 of the logo 510 is presented on the second case 102 . When the first and second cases are secured together into a single larger case, the two portions align to create the complete logo 510 . In one embodiment, the first and second cases 100 and 102 can be independent and complete devices that when secured together create the device 50 that can be used as a seat cushion.
[0038] FIG. 6 is a block diagram illustrating an example configurable cushion device 60 for use with an H belt according to an embodiment of the invention. The H belt can be part of an amusement park ride or a child's car seat or any other apparatus that employs a similar style of safety system. In the illustrated embodiment, the device 60 comprises a plurality of cases 100 , 102 and 104 that each include a pillow 120 , 122 and 124 , respectively. The pillows 120 , 122 and 124 are positioned in an internal cavity of their respective cases 100 , 102 and 104 .
[0039] The first case 100 and a first end of the third case 104 each include a portion of a zipper 600 that functions to secure the first end of the third case 104 to the first case 100 . Similarly, the second case 102 and a second end of the third case 104 each include a portion of a zipper 602 that functions to secure the second end of the third case 104 to the second case 102 . Advantageously, when the third case 104 is secured to the first case 100 and the second case 102 , the device 60 can be secured to an H belt using a plurality of fastener straps with fasteners as previously described above.
[0040] As will be understood by those skilled in the art, certain modifications to the zippers 600 and 602 will allow the device 60 to be configured in a plurality of shapes. Furthermore, the addition or subtraction of case and pillow units will also allow the device 60 be adapted to a variety of items that may come into contact with a person. Each of these alternative shapes and sizes are contemplated by the broadest scope of the present invention.
[0041] FIG. 7 is a block diagram illustrating an example configurable cushion device 70 with a hot or cold compress pocket according to an embodiment of the invention. In the illustrated embodiment, the device 70 comprises a case 100 that includes a zipper 110 that defines an opening into which a pillow 120 can be inserted. The case 100 has a proximal side that is positioned closer to a person that is using the device 70 and a distal side that is positioned further away from a person that is using the device 70 .
[0042] On the inside portion of the proximal side of the case 100 , the device 70 includes an internal pocket 700 . The internal pocket 700 may extend along substantially the entire length of the proximal side of the inside portion of the case 100 or it may only extend along a portion of the inside portion of the proximal side of the case 100 . The internal pocket 700 may also include one or more fasteners 710 that function to close the internal pocket 700 . The one or more fasteners 710 may include a zipper, a hook and loop, a button or a snap, just to name a few.
[0043] In one embodiment, the proximal side internal pocket 700 is configured to receive a hot or cold compress (not shown) and secure the hot or cold compress against the body of a person that is using the device 70 .
[0044] FIG. 8 is a block diagram illustrating an example configurable cushion device 80 with a drape 800 according to an embodiment of the invention. In the illustrated embodiment, the device 80 includes a case 100 that comprises a zipper 110 that defines an opening into which a pillow 120 can be inserted into an internal cavity defined by the case 100 . The drape 800 is releasably secured to the inside portion of the device 80 using one or more fasteners 810 . The one or more fasteners 810 may include a zipper, a hook and loop, a button or a snap, just to name a few. In one embodiment, the device 80 can be used as a nursing pillow for support and the drape 800 can be used as a screen for privacy. Alternative uses for the device 80 that combines the pillow 120 and drape 180 will be readily apparent to those skilled in the art.
[0045] The above description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles described herein can be applied to other embodiments without departing from the spirit or scope of the invention. Thus, it is to be understood that the description and drawings presented herein represent a presently preferred embodiment of the invention and are therefore representative of the subject matter which is broadly contemplated by the present invention. It is further understood that the scope of the present invention fully encompasses other embodiments that may become obvious to those skilled in the art and that the scope of the present invention is accordingly not limited.
|
A configurable cushion device is provided that protects from injury or discomfort caused by items in contact with a person. In one embodiment, the device includes a cushioned pillow wrapped in a protective case that includes a plurality of fastener straps for attaching the device to an object such as a seat belt. The protective case may include an internal or external pocket and may be made of a frictional material or include one or more grippers that provide additional friction against the object to keep the cushion device in a desired location with respect to the object or the person. The cushion device may also include a strap with a connector to allow the device to be secured around a larger object such as the waist of a person. The device may also include a drape cloth that is secured to the interior of the protective case and can be taken out and draped around an object or a person.
| 1
|
BACKGROUND OF THE INVENTION
In public and private restrooms, it is common to see rolls of toilet paper and paper towels mounted securely on brackets which are attached to the wall. Because of the shortage of maintenance personnel, it is highly likely that by the end of a given working day, the roll of toilet paper or roll of paper towels is used up.
Consequently, users of the restroom are unable to use all or part of the facility until an attendant has replaced the rolls of toilet paper or rolls of paper towels.
Accordingly, it is an object of this invention to provide a tissue dispenser which eliminates or reduces the requirement of daily maintenance.
It is a further object to provide such a dispenser that is aesthetically attractive.
It is still a further object to provide such a dispenser that is of simple construction and, consequently, relatively inexpensive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a dispensing device constructed in accordance with and embodying the present invention.
FIG. 2 is a front elevational view of the device with the cover removed.
FIG. 3 is a side elevational view of the device showing the cover in its open position.
FIG. 4 is a sectional view taken along line 4--4 of FIG. 2.
FIG. 5 is an exploded perspective view of the belt and spring-loaded retention core which forms part of the device.
SUMMARY OF THE INVENTION
This invention relates to improvements in dispensers for tissues, towels and other paper and plastic products that are commonly provided in the form of rolls. More specifically, the invention relates to dispensers that are capable of storing several rolls of tissues, towels, etc.
The preferred embodiment comprises a frame made of a back plate and two side plates, a left side plate and a right side plate. Through apertures in the left side plate and in the right side plate is disposed a rotatable shaft which can be turned from outside of the frame. Attached to the shaft are a pair of drive wheels which rotate along with rotation of the shaft. In the same planes as the drive wheels are sets of rollers, which are mounted on the left side plate and right side plate. Belts made of flexible material are wrapped over each set of rollers. These belts have both an interior and an exterior surface. On the exterior surface are mounted means for retaining the rolls which hold the tissues, towels, etc.; on the interior surface are holes which engage the teeth on the drive wheel. When the rotatable shaft is turned, the drive wheels also turn and move the belts over the surface defined by the rollers. In this manner, the unused rolls of tissue will reach a position where the user has access to them.
DETAILED DESCRIPTION
The dispenser assembly A, has as its base, a back plate 10, which may be made of metal, plastic, wood, or any other suitable substitute. The back plate 10 is preferably of rectangular cross section and has a top 10a, bottom 10b, and two sides, a left side 10c, and a right side 10d. The dispenser assembly "A" is joined to a wall surface (not shown) by means of the back plate 10. The preferred embodiment has a series of key shaped mounting holes 10e, by means of which the assembly can be hung on a wall [See FIG. 2].
Projecting at a 90° angle from side 10c of the back plate 10 is the left side plate 11. Likewise, the right side plate 12 projects at a 90° angle from side 10d of the back plate 10. The side plates 11, 12 are made of the same material as the back plate 10. The side plates 11, 12 may be separable from the back plate 10 or they may be of unitary construction with the back plate.
In the preferred embodiment, the side plates 11, 12 have essentially trapezoidal cross-sections [See FIG. 3]. However, the cross-section may be rectangular, triangular, or other shape if so desired. Irrespective of their configuration, the side plates 11, 12 must project far enough from the back plate 10 to completely enclose the inner workings of the dispenser, including the rolls to be stored and dispensed.
Each of the side plates 11, 12 has an aperture 13 formed therein. A rod 14 extends through the apertures 13 in the side plates 11, 12 and is fitted at its ends with hand wheels 15. Each hand wheel 15 includes a knurled gripping portion 16 that is located outermost, a drive wheel 17 that is located innermost and a hub 18 that is between the gripping portion 16 of the hand wheel 15 and drive wheel 17. The rod 14 is secured by means of the hub 18. The hub 18 has a groove formed in its surface which engages the edges of the aperture 13 to secure rod 14 in a stable position but still permitting rotation when a torque is applied to the rod 14. The torque can be applied through the hub 18 by turning the hand wheel 15.
Mounted on the rod 14 within the frame formed by the back plate 10 and side plates 11, 12 are a pair of drive wheels 17. In the preferred embodiment, the drive wheels 17 are sprocket wheels [See FIG. 4]. The wheels 17 should be separated by a distance substantially equivalent to the length of the roll to be used. The drive wheels 17 should each be sent in from their respective side plates 11 or 12 an equal distance in order to insure that the dispenser will be balanced when mounted properly on a wall. The wheels may be made of metal, plastic, or any other suitable material.
Mounted on the interior surface of the side plates 11, 12 are a plurality of pairs of rollers (19a, 19b, 20a, 20b, 21a, 21b, 22a, 22b). The rollers 19a, 20a, 21a, 22a mounted on the right side plate 12 are in the same plane as the drive wheel 17 that is adjacent to the right side plate 12. Each roller on the right side plate 12 has a corresponding roller on the left side plate 11--i.e. roller 19a corresponds in position to roller 19b, and is the mirror image thereof; this same relationship holds for rollers 20a, 20b, rollers 21a, 21b, and rollers 22a, 22b. The rollers 19a, 19b, 20a, 20b, 21a, 21b, 22a, 22b are mounted to the side plates 11, 12 by means of axles 23a, 23b, 24a, 24b, 25a, 25b, 26a, 26b, respectively. The axles project inwardly from the side plates 11, 12 to such a distance that the rollers, when mounted on the axles, lie in the same plane as the related drive wheels 17.
It should be understood that the device is not to be limited to employing eight and only eight rollers. The dispenser may operate with fewer rollers or with more rollers; moreover, it is not necessary that the number of rollers joined to each side plate be equal.
The rolls of tissue, towels, etc., are retained on and are moved by endless belts 27 which pass over and are supported on the rollers 19a, 19b, 20a, 20b, 21a, 21b, 22a, 22b and are engaged by the drive wheels 17. Each belt 27 is constructed of a flexible material, preferably plastic. However, it can be made of other flexible materials or metal. In the preferred embodiment, the belt 27 consists of two plies 27a, 27b of flexible material. The belt formed from the plies is formed into a loop, as shown in FIG. 5. The loop is placed over the rollers and the drive wheel 17 so that the inner ply 27b engages the drive wheel 17 and the rollers. The inner ply 27b has evenly spaced holes 28 set therein which will allow the loop to engage the teeth 29 of the drive wheel 17. As the drive wheel 17 is revolved, the belt 27 will move by virtue of the action of the teeth. The outer ply 27a forms the base for the core holders 30. The core holders 30 are made of the same material as the belt itself 27. In the preferred embodiment of the invention, the core holders 30 are molded to the outer ply 27a of the belt 27, and thus form an integral part of the belt 27. The preferred embodiment of the core holder 30 is a tab 31 projecting from the belt 27, and having a hole 32 established therein to receive a spindle 33 on one end 34 of a spring-loaded retention core 35 upon which the roll of tissue is retained. The other belt 27 has an identical tab 31 projecting therefrom, also having a hole 32 to receive a second spindle 36 on the other end 37 of the spring-loaded retention core 35. Each tab 31 on one of the belts 27 should have an equivalent counterpart tab on the other belt 27.
The retention core 35 is a conventional cylindrical unit which is commonly employed to retain tissue rolls B. In the preferred embodiment of the invention, the retention core 35 is of the spring-loaded variety. The spring-loaded retention core 35 comprises a first hollow cylindrical element 35a, a second hollow cylindrical element 35b having a diameter only slightly smaller than the diameter of the first element, and a coiled spring 35c (see FIGS. 2, 5). The second cylindrical element 35b is capable of fitting into the first cylindrical element 35a. The coiled spring 35c is located in the hollow area formed by the cylindrical elements 35a, 35b when the second cylindrical element 35b is fitted into the first cylindrical element 35a. The diameter of the coiled spring 35c is slightly smaller than the diameter of the second cylindrical element 35b.
Attached to each end 34, 37 of the retention core 35 is a spindle 33, 36. The spindles are inserted into the holes 32 in the tabs 31 of the core holders 30 in order to attach the retention core 35 to the movable belts 27.
In order to remove the retention core 35 from the core holders 30 for the purpose of putting a roll of tissues on the core, one pushes the second cylindrical element 35b into the hollow portion of the first cylindrical element 35a. This action compresses the spring 35c and allows the length of the core 35 to decrease sufficiently to allow it to be removed from the holes 32 in the tabs 31 of the core holders 30.
After the roll of tissues is placed on the retention core 35, the spindles 33, 36 on the cylindrical elements 35a, 35b are aligned with the holes 32 in the tabs 31 of the core holders 30, and the cylindrical elements are released. The spring 35c expands and forces the cylindrical elements to move in opposite directions, thus causing the spindles 33, 36 to enter the holes 32, thereby allowing the core holders 30 to retain the retention core 35.
It should be noted that the core holders 30 and the retention core 35 need not be limited to the embodiment shown.
The foregoing assembly has a cover 38 to render the dispenser aesthetically pleasing to the user. The inside surface of the cover 38 faces the back plate 10. The cover 38 is pivotally attached by hinge pins 39 to the side plates 11, 12 as shown in FIG. 3. To open the cover 38 to replace the paper rolls, one merely releases latch 40 and allows the cover 38 to pivot about the pins 39. The cover 38 has an opening in its bottom portion so that the user has access to the paper rolls when the cover 38 is closed.
OPERATION
To load the dispenser, the cover 38 of the dispenser is unlatched and dropped to its open position (see FIG. 3). A spring-loaded core 35 is inserted through each paper roll. The spindles 33, 36 of the spring-loaded core 35 are inserted into the holes 32 of the tabs 31 of the core holders 30, and the action of the spring 35c serves to keep the core 35 in proper position. The cover 38 of the dispenser is then pivoted to the closed position, and the latch 40 operates to retain the cover 38 in this position.
To place a paper roll in such a position so that a user has access to it, one turns the hand wheel 15 in such a way that the rod 14 is caused to rotate. The rotation of the rod 14 brings about rotation of the drive wheels 17. The teeth 29 on the drive wheels 17 engage the holes 28 of the belts 27, thus causing the belts 27 to move over the paths defined by the rollers 19a, 19b, 20a, 20b, 21a, 21b, 22a, 22b. The user has access to a paper roll when the roll is adjacent to the opening in the cover 38. After a roll is consumed, the user merely repeats the foregoing operation to obtain access to a fresh roll of paper.
The clearance between the belts 27 and the back plate 10 should be of sufficient magnitude that the device can be operated without fear of the tissue rolls B contacting the back plate 10.
This invention is intended to cover all changes and modifications of the example of the invention herein chosen for purposes of the disclosure which do not constitute departures from the spirit and scope of the invention.
|
A device for storing and dispensing tissues, towels, and the like, that are provided in the form of a roll. The device comprises a pair of belts which can be caused to move over a surface of rollers by the action of drive wheels. To the belts are joined a plurality of pairs of holding units which retain the tissue rolls. The foregoing assembly is provided with a base to facilitate attachment to a wall, and a decorative cover for aesthetic purposes.
| 0
|
FIELD OF THE INVENTION
[0001] The invention concerns assemblies for assembling saggars for use in high temperature treatment, for example, the firing of ceramics, metal, powder calcinations or isolation foam manufacturing.
BACKGROUND OF THE INVENTION
[0002] Saggars are ceramic, box-like containers used in the firing of pottery to enclose or protect ware in kilns, or in powder calcinations for holding a powder to be calcined, or in isolation foam manufacturing for carrying the load, or in metal heat treatment. Traditionally, saggars were made primarily from fireclay. Saggars are used to protect or safeguard their load from open flame, smoke, gases and kiln debris. Modern saggars are made of various types of tailored ceramics such as for example alumina ceramics, cordierite ceramics, mullite ceramics, zirconia ceramics, magnesia ceramics, alumina-magnesia spinel ceramics, fused silica ceramics, aluminatitanate ceramics and silicon carbide ceramics.
[0003] Traditionally, saggars in commercial use used to comprise rigid rectangular boxes of unitary construction with an open top for receiving green ceramic articles placed therein for subsequent firing. Such saggars were adapted for storing vertically in the kiln for firing. Conventional saggars have a tendency to expand and contract as they are subjected to extreme temperature variations, and they often change shape, making them difficult to stack, or they may even break. It is not economically feasible to repair such saggars.
[0004] In many cases, saggars are used in heat treatments involving very rapid heating and cooling, such that high temperature gradients may appear within the saggars, leading to cracking. In the case of box-shaped solids in general, this implies a practicable upper size limit, while larger saggar sizes would be required. Furthermore, corrosion resistance in extreme temperatures is a general problem with saggars.
[0005] U.S. Pat. No. 4,008,997 discloses ceramic saggars composed of a square floor section and four identical wall sections, wherein the wall sections each comprise a flange at one end and a flange-receiving socket at an opposite end, as well as a floor supporting flange. The wall sections are assembled in positive locking engagement such that they form a square based volume and the floor section is lowered into the base of the said square. Since the base plate merely rests on the said floor supporting flanges, the assembled saggar is unstable. Furthermore, the appearance of gaps between the base and wall sections is inevitable, making this unsuitable for particulate loads, for example in powder calcinations. Despite the optional presence of gaps between the said flanges and flange-receiving sockets, which are intended to avoid the formation of thermal stresses, this does not solve the problem of upper size limits for the saggars.
[0006] The state of the art therefore constitutes a problem.
SHORT DESCRIPTION OF THE INVENTION
[0007] The above mentioned drawbacks are overcome by the invention according to the appended claims.
[0008] In one embodiment, the invention provides an assembly for providing a saggar, for use in high temperature applications, comprising a first essentially rectangular base element, two sets of two essentially rectangular side elements, the elements of each set having one dimension corresponding to the dimensions of first and second opposite edges of the said base element, four corner elements, and fasteners. According to the said embodiment, the said base element and the said side elements may be assembled into a box-shaped saggar and secured using the said corner elements and the said fasteners. The first base element is made of a corrosion resistant material.
[0009] In one embodiment, the assembly further comprises a second base element which is physically strong, such as resistant against thermal shock, physical impact and bending. In an assembled state, the first and second base elements are superimposed such that the fist base element faces the load bearing side of the box shaped saggar. The second base element preferably has substantially identical edge dimensions than the first base element. Optionally, the first base element may be thinner than the second base element.
[0010] In one embodiment, the side elements and/or the corner elements are also made of a corrosion resistant material.
[0011] In one embodiment, the fasteners may be selected from the group ceramic pins, ceramic screws, ceramic glue, or a mixture or a combination thereof.
[0012] In one embodiment, the side elements each comprise a rectangular extension at each of the two opposite ends that do not come into contact with the said base elements in an assembled state. In this embodiment, the corner elements each have two recesses facing in directions at a 90 degrees angle to each other for accepting the said rectangular extension of a side element such that they form a positive engagement in an assembled state, and they further each comprise a hole extending in a direction rectangular to the plane of the said base elements in an assembled state. In this embodiment, the first and optional second base elements each comprise four holes arranged in the vicinity of each one of the corners of the essentially rectangular base portions, such that the corner elements and the base elements may be secured to each other using the fasteners of the assembly.
[0013] In one embodiment, the assembly is such that in an assembled state, each fastener may be arranged in a hole of each of the first and optional second base elements as well as a whole of each corner element in order to secure the first and optional second base elements and corner elements together.
[0014] In one embodiment, the fasteners are ceramic screws and the corner elements further comprise a nut arranged within the hole for threadably securing the ceramic screws within the hole.
[0015] In one embodiment, the fasteners are ceramic pins and the corner elements may further comprise means for fixing the said ceramic pins.
[0016] In one embodiment, the fasteners comprise a head and the holes in the second base element are chamfered in order to allow space for the head to be embedded in an assembled state.
[0017] In one embodiment, the corner elements have extensions at one or both their ends not facing the said side elements in an assembled state, such that he saggars formed in the assembled state become stackable.
[0018] In one embodiment, each of the base and side elements may or may not be constituted of separate element portions which in an assembled status may be secured together to form the respective element.
[0019] In one embodiment, the holes intended to comprise the fasteners n an assembled state may be filled with a sealant, such as for example a ceramic glue.
[0020] In one embodiment, the corrosion resistant material is based on a material selected from Al 2 O 3 , MgO, Al 2 O 3 —MgO-spinel, ZrO 2 , SiC and combinations of the aforementioned. In a further embodiment, the physically resistant material is based on a material selected from Al 2 O 3 , MgO, Al 2 O 3 —MgO-spinel, ZrO 2 , SiC, aluminasilicate, cordierite, fused silica and combinations thereof.
[0021] In a further embodiment of the present invention, the assembly is for forming a box-shaped saggar suitable for being loaded with goods consisting of corrosive components, such as for example metal oxides or alkali used as base materials in batteries, pigments, or electronic components.
[0022] Also part of the present invention is a saggar assembled from the assembly according to the present invention. The saggars according to the invention may be stackable and any intersections between the elements of the assembly may be filled with a sealant, such as for example a ceramic glue.
SHORT DESCRIPTION OF THE FIGURES
[0023] The invention is now being described in detail by illustration of embodiments thereof and with reference to the appended figures.
[0024] FIG. 1 shows a schematic representation of an assembled box-saggar constituted of the parts of an assembly according to the present invention;
[0025] FIG. 2 shows a schematic representation of the separate parts of an assembly according to the present invention;
[0026] FIG. 3 shows a schematic representation of a side element, which is a part of the assembly according to the present invention;
[0027] FIG. 4 shows a schematic representation of a corner element, which is a part of the assembly according to the present invention;
[0028] FIG. 5 shows a schematic representation of a second base element, which is a part of the assembly according to the present invention;
[0029] FIG. 6 shows a schematic representation of a screw, which is a part of the assembly according to the present invention;
[0030] FIG. 7 shows a schematic representation of a cut through a corner element and screw in an assembled state, which is a part of the assembly according to the present invention;
[0031] FIG. 8 shows a schematic representation of cut through an assembled box-saggar, showing base elements combined of separate element portions;
[0032] FIG. 9 shows a schematic representation of a fastener in the shape of a ceramic pin;
[0033] FIG. 10 shows a schematic representation of a cut through a corner element and secured pin in an assembled state, which is a part of the assembly according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] FIG. 1 shows a saggar 1 in an assembled state, as obtained from an assembly according to the present invention. There is a first base element 2 facing the inside of the box-shaped saggar 1 . Four side elements 3 , 3 ′, 3 ″, 3 ′″ are secured to the first base element 2 using four corner elements 4 , 4 ′, 4 ″, 4 ′″. An optional second base element and screws cannot be seen in this perspective in the assembled state.
[0035] FIG. 2 shows all the elements of an assembly according to the present invention in a view intended to show one way of assembling the elements of the assembly in order to form a box-shaped saggar 1 . Fasteners 5 , 5 ′, 5 ″, 5 ′″ have been inserted into holes 6 , 6 ′, 6 ′″ located in the vicinity of the corners of the optional second base element 7 . The first base element 2 , side elements 3 , 3 ′, 3 ″, 3 ′″ and corner elements 4 , 4 ′, 4 ″, 4 ′″ are also shown. The side elements 3 , 3 ′, 3 ″, 3 ′″ each comprise rectangular extensions 3 - 1 , 3 - 2 , 3 ′- 1 , 3 ′- 2 , 3 ″- 1 , 3 ″- 2 , 3 ′″- 1 , 3 ′″- 2 , at each of their two opposite ends that do not come into contact with the said first base element in an assembled state. These are shown more clearly in FIG. 3 .
[0036] Furthermore in FIG. 2 recesses 4 - 1 , 4 ′- 1 can be seen in the corner elements 4 , 4 ′. All the corner elements shown comprise two recesses oriented facing in directions at a 90 degrees angle to each other, albeit that other recesses cannot be seen due to the perspective chosen. Holes 8 , 8 ′, 8 ″, 8 ′″ in the corner elements 4 , 4 ′, 4 ″, 4 ′″ are also represented. The first base element 2 comprises four holes 9 , 9 ′, 9 ″, 9 ′″ in the vicinity of each of the corners of the first base element 2 .
[0037] FIG. 4 shows a more detailed representation of a corner element 4 , with one recess 4 - 1 , and a second recess oriented at 90 degrees to the first recess, pointing into the plane of the paper and therefore not visible. Also visible is hole 8 for accommodating a ceramic screw, as well as an extension 10 , which serves as a spacer in the assembled state, such that several assembled box-like saggars may be stacked in use.
[0038] FIG. 5 shows a detailed view of a second base element 7 , clearly showing that holes 6 , 6 ′, 6 ″, 6 ′″ are chamfered in order to accommodate heads of fasteners 5 , 5 ′, 5 ″, 5 ′″. This can also relate to a first base element having chamfered holes in the absence of a second base element.
[0039] FIG. 6 shows a detailed view of a fastener in the example of a ceramic screw 5 with a head 5 - 1 . FIG. 7 shows a cut through a corner of a box-like saggar assembled form an assembly according to the present invention, wherein there is visible a cut through a corner element 4 with ceramic screw 5 , secured using a nut 11 within the hole 8 in the corner element 4 . Also shown is a section of a second base element 7 with chamfered hole 6 for accommodating the head 5 - 1 of ceramic screw 5 .
[0040] FIG. 8 shows a schematic representation of an assembled box-saggar, showing base elements combined of separate element portions 2 - 1 , 2 - 2 , 7 - 1 , 7 - 2 . The base element portions are connected at a connector 12 , consisting of cooperating ends of the respective element portions which may form a locking engagement in an assembled state. This arrangement element allows further improved thermal shock resistance of the whole assembly even in case of large overall sizes of a saggar in an assembled state.
[0041] According to the present invention, it is possible to provide box-like saggars, wherein the normally competing challenges of obtaining good corrosion resistance and good physical strength, such as impact resistance, thermal shock resistance and bending resistance are simultaneously met. According to the present invention the first base element 2 is an element made of a corrosion resistant material, and which in the assembled state is intended to face towards the interior of the box-like saggar and therefore to come into contact with potentially corrosive loadings. Such corrosive loadings may for example be metal oxides or alkali components used as base materials in batteries, pigments, or electronic components, to mention just a few. Possible corrosion resistant materials for use as or in the material of the first base material are selected from Al 2 O 3 , MgO, Al 2 O 3 —MgO-spinel, ZrO 2 , SiC and combinations thereof. The drawback of such corrosion resistant materials is that they may have poor performance when it comes to the physical resistance against the adverse conditions experienced by saggars in use. Some important factors are thermal shock resistance, bending resistance and impact resistance.
[0042] This is why the assembly according to the present invention may optionally comprise a second base element 7 , which has identical or very similar edge dimensions to the first base element 2 , such that the first and second base elements 2 , 7 may be placed on top of each other and together to form the base of an assembled box-like saggar 1 . In order to provide the assembled box-like saggar 1 with the required physical resistance, the said second base element 7 may be relatively thick, which provides added stability to the finished assembled saggar 1 . Furthermore, the said second base element 7 may be made of a material that has good physical resistance, such as good thermal shock resistance, good bending resistance and/or good impact resistance. Therefore the second base element 7 may be made of or comprise a material with improved physical properties, such as for example Al 2 O 3 , MgO, Al 2 O 3 —MgO-spinel, ZrO 2 , SiC, aluminasilicate, cordierite, fused silica or combinations thereof. The second base element 7 may be thicker than the said first base element 2 .
[0043] The said corner elements ( 4 , 4 ′, 4 ″, 4 ′″) may also be made of or comprise a material with improved physical properties, such as for example Al 2 O 3 , MgO, Al 2 O 3 —MgO-spinel, ZrO 2 , SiC, aluminasilicate, cordierite, fused silica or combinations thereof.
[0044] When assembling a box-like saggar 1 from an assembly according to the present invention, and if a second base element 7 is employed, first and second base elements 2 , 7 are placed on top of each other and four fasteners 5 , 5 ′, 5 ″, 5 ′″ are inserted through holes 6 , 6 ′, 6 ″, 6 ′″, 8 , 8 ′, 8 ″, 8 ′″ arranged in the vicinity of the corners of the now superimposed base elements 2 , 7 . The holes 6 , 6 ′, 6 ″, 6 ′″, 8 , 8 ′, 8 ″, 8 ′″ are arranged such that when the base elements 2 , 7 are placed on top of each other, the holes of each element are also superimposed and it remains possible to insert fasteners 5 , 5 ′, 5 ″, 5 ′″ through the said holes. Then, four corner elements 4 , 4 ′, 4 ″, 4 ′″ as described above are assembled with four side elements 3 , 3 ′, 3 ″, 3 ′″ as described above. These corner and side elements may preferably also be formed of a corrosion resistant material, such as for example the same corrosion resistant material as the said first base element 2 . The corner elements 4 , 4 ′, 4 ″, 4 ′″ and the side elements 3 , 3 ′, 3 ″, 3 ′″ may be assembled by inserting the said extensions 3 - 1 , 3 - 2 , 3 ′- 1 , 3 ′- 2 , 3 ″- 1 , 3 ″- 2 , 3 ″'- 1 , 3 ′″- 2 of the side elements into the recesses 4 - 1 , 4 ′- 1 of the respective corner elements 4 , 4 ′, 4 ″, 4 ′″.
[0045] At this stage, the fasteners 5 , 5 ′, 5 ″, 5 ′″ can be inserted into the holes 8 , 8 ′, 8 ″, 8 ′″ of the corner elements 4 , 4 ′, 4 ″, 4 ′″, therefore connecting the super-imposed first and second base elements 2 , 7 with the assembled corner elements 4 , 4 ′, 4 ″, 4 ′″ and the side elements 3 , 3 ′, 3 ″, 3 ′″. The fasteners 5 , 5 ′, 5 ″, 5 ′″ may be ceramic screws, secured to the corner elements 4 , 4 ′, 4 ″, 4 ′″ by threadable connection to nuts 11 placed within the holes 8 , 8 ′, 8 ″, 8 ′″ in the corner elements 4 , 4 ′, 4 ″, 4 ′″. At this stage, the screws and the corner elements 4 , 4 ′, 4 ″, 4 ′″ securely hold together the first and second base elements 2 , 7 and the side elements 3 , 3 ′, 3 ″, 3 ′″ in order to form a box-like saggar 1 for use for example in kiln firing operations.
[0046] In the general case of a box-like saggar 1 without a second base element 7 , the assembly is performed in an equivalent way to the above, without the said second base element 7 .
[0047] The fasteners may also be present in the shape of ceramic pins 13 , held in place within the holes 8 , 8 ′, 8 ″, 8 ′″ in the corner elements 4 , 4 ′, 4 ″, 4 ′″ with ceramic glue or cross pin or other securing means. An exemplary ceramic pin 13 and securing means therefore within corner element 4 is shown in FIGS. 9 and 10 . Other fasteners known to the skilled person are also possible. It is also conceivable to fasten the parts together using only ceramic glue as a fastener.
[0048] The box-like saggar 1 thus obtained has corrosion resistant internal surfaces, since the first base element 2 is made of a corrosion resistant material as described above. This property is even more pronounced in the case in which also the corner elements 4 , 4 ′, 4 ″, 4 ′″ and the side elements 3 , 3 ′, 3 ″, 3 ′″ are made of a corrosion resistant material. The secure connection of all the structural elements is obtained through the fasteners 5 , 5 ′, 5 ″, 5 ′″ and the corner elements 4 , 4 ′, 4 ″, 4 ′″ The connection can be made even more secure by filling any gaps, in particular gap between the fasteners 5 , 5 ′, 5 ″, 5 ′″ and the corner elements 4 , 4 ′, 4 ″, 4 ′″ within the holes 8 , 8 ′, 8 ″, 8 ′″ in the corner elements with a sealant, such as for example a ceramic glue. Also gaps between the side elements 3 , 3 ′, 3 ″, 3 ′″ and the first base element 2 or between the side elements 3 , 3 ′, 3 ″, 3 ′″ and the corner elements 4 , 4 ′, 4 ″, 4 ′″ may be sealed using a sealant such as ceramic glue.
[0049] The box-like saggar 1 thus obtained may have improved physical properties due to the optional presence of the said second base element 7 , which may be relatively thick, providing added stability to the box-like saggar 1 . Furthermore, the optional second base element 7 has improved thermal shock resistance, improved bending resistance and improved impact resistance. Due to the close connection between the first and second base elements 2 , 7 , the good physical resistance properties of the second base element 7 also protect the said first base element 2 and the box-like saggar 1 as a whole in its assembled state.
[0050] With the presence of the extensions 10 at the corner elements 4 , 4 ′, 4 ″, 4 ′″, it is rendered possible to stack assembled saggars 1 whilst they are in use, for example in a firing operation in a kiln. This allows to effectively drive multiple assembled saggars 1 through a firing kiln and protects the structural parts of the box-like saggars 1 from damage. In the case of abrasion at the contact points between separate stacked saggars 1 , such abrasion occurs at the said extensions of the corner elements 4 , 4 ′, 4 ″, 4 ′″ and the base elements 2 , 7 and side elements 3 , 3 ′, 3 ″, 3 ′″ of the box-like saggars 1 are protected.
[0051] In the case of failure of a box-like saggar 1 due to structural damage, the saggar 1 may be disassembled and the undamaged elements may be recycled by reusing them in a separate assembly for forming a box-like saggar 1 . Furthermore, the use of assemblies according to the present invention allows the use of larger box-like saggars 1 , since the above-described problems regarding thermal shock are alleviated.
[0052] It should be noted that the present disclosure includes any combination of the features and/or limitations referred to herein, except for combinations of such features which are mutually exclusive. The foregoing description is directed to particular embodiments of the present invention for the purpose of illustrating it. It will be apparent, however, to one skilled in the art, that many modifications and variations to the embodiments described herein are possible. All such modifications and variations are intended to be within the scope of the present invention, as defined in the appended claims.
REFERENCE SIGNS
[0053] 1 saggar;
[0054] 2 first base element;
[0055] 2 - 1 , 2 - 2 first base element portions;
[0056] 3 , 3 ′, 3 ″, 3 ′″ side elements;
[0057] 3 - 1 , 3 - 2 , 3 ′- 1 , 3 ′- 2 , 3 ″- 1 , 3 ″- 2 , 3 ′″- 1 , 3 ′″- 2 rectangular extensions on side elements;
[0058] 4 , 4 ′, 4 ″, 4 ′″ corner elements;
[0059] 4 - 1 , 4 ′- 1 recesses in corner elements;
[0060] 5 , 5 ′, 5 ″, 5 ′″ fasteners;
[0061] 6 , 6 ′, 6 ″, 6 ′″ holes in the second base element;
[0062] 7 second base element;
[0063] 7 - 1 , 7 - 2 second base element portions;
[0064] 8 , 8 ′, 8 ″, 8 ′″ holes in the corner elements;
[0065] 9 , 9 ′, 9 ″, 9 ′″ holes in the first base element;
[0066] 10 extension;
[0067] 11 nut;
[0068] 12 connector
[0069] 13 ceramic pin
[0070] 13 - 1 ceramic pin head.
|
An assembly for providing a saggar for use in high temperature applications, may include a first substantially rectangular base element and two sets of two substantially rectangular side elements, wherein the side elements of each set of side elements have at least one dimension corresponding to dimensions of first and second opposite edges of the base element. The assembly may also include four corner elements and fasteners, wherein the base element and the side elements are configured to be assembled into a box-shaped saggar and secured to one another using the corner elements and the fasteners, and wherein the first base element is made of a corrosion resistant material.
| 5
|
BOTANICAL/COMMERCIAL CLASSIFICATION
Prunus persica /Clingstone Peach Tree.
VARIETAL DENOMINATION
cv. ‘Goodwin’.
BACKGROUND OF THE INVENTION
The new clingstone peach cultivar was created at Davis, Calif., U.S.A., in 1983 as part of a breeding program of the University of California for the development of improved processing peaches. During the course of the breeding program that yielded the new cultivar of the present invention, many seedlings were developed and evaluated. An objective of the program was to develop a superior replacement cultivar for the early-maturity ‘Dixon’ and ‘Andross’ cultivars (both non-patented in the United States). The ‘Dixon’ cultivar originated at Linden, Calif., U.S.A., and was introduced during 1956. Trees of this cultivar are recognized to be highly productive and yield yellow-gold fruit that commonly displays a pink to red coloration at the pit area that is attributable to the formation of anthocyanins. The red coloration often oxidizes to brown when canned and thereby provides less than optimum fruit color as well as an undesirable brown staining of the canned syrup. Additionally, the red-stained stone or endocarp of the ‘Dixon’ cultivar tends to be prone to breakage during processing and sometimes imparts unwanted pit fragments to the fruit flesh that are difficult to remove.
The ‘Andross’ cultivar originated at the University of California at Davis, Calif., U.S.A., and was introduced in 1964. Trees of the ‘Andross’ cultivar consistently set heavy crops, have leaves with globose glands, and flowers of the large non-showy type. The ‘Andross’ cultivar also produces fruit having red-staining of the pit area and unwanted higher frequencies of stone or endocarp fragments in the processed fruit flesh.
The female parent (i.e., seed parent) of the new cultivar was a University of California processing peach breeding line named ‘11, 11-37’ (non-patented in the United States). The male parent (i.e., pollen parent) of the new cultivar was the ‘Dr. Davis’ cultivar (non-patented in the United States). The parentage of the new cultivar of the present invention can be summarized as follows:
‘11, 11-37’בDr. Davis’.
Four seedlings from this cross were recovered in 1984, and have been carefully studied and evaluated thereafter. The new cultivar was selected from among these and was designated ‘R, 7-5’ and ‘Early #3’.
It was found that the new clingstone peach cultivar of the present invention:
(a) Exhibits an upright-spreading growth habit,
(b) Forms medium-sized non-showy pink flowers,
(c) Forms attractive fruit having uniform yellow flesh that is free from red staining at the pit cavity,
(d) Ripens approximately four days earlier than the ‘Andross’ cultivar (non-patented in the United States), and
(e) Is particularly well suited for processing.
The new cultivar of the present invention can be readily distinguished from its ‘11, 11-37’ and ‘Dr. Davis’ parental cultivars. More specifically, the ‘11, 11-37’ and ‘Dr. Davis’ cultivars commonly ripen at approximately the same time and approximately 10 to 14 days after the new cultivar of the present invention. Also, the fruit of the new cultivar commonly displays a slightly asymmetrical shape with a noticeable bulging at the suture area. In contrast, the fruit of the ‘11, 11-37’ and ‘Dr. Davis’ cultivars is characteristically symmetrical in shape.
The new cultivar has been asexually propagated at Davis, Calif.; Winters, Calif.; and Parlier, Calif. U.S.A., by grafting on ‘Nemared’ peach rootstock (non-patented in the United States). Such propagation has confirmed that the characteristics of the new cultivar are stable and are reliably transmitted to subsequent generations.
The new cultivar of the present invention is considered to offer superior characteristics when compared to the previously-available early-maturity processing peach cultivars ‘Dixon’ and ‘Andross’. Unlike these cultivars, the new cultivar is free from red staining at the pit cavity. The fruit flesh is bright yellow to yellow-gold and the fruit color, flavor and texture have been rated superior to the ‘Dixon’ and ‘Andross’ cultivars. The fruit skin is slightly less pubescent than that of the ‘Andross’ cultivar with a more uniform golden-yellow color. The pit size is medium to slightly below average. Some split pits occur during high crop years however at a lower rate than the ‘Dixon’ and ‘Andross’ cultivars. The crop yield for the new cultivar appears to average and somewhat lower than that of the ‘Andross’ cultivar thus commonly requiring less thinning following a high-chill winter. The fruit hangers are similar to those of the ‘Andross’ cultivar and a bit denser. The leaves are medium to dark green and similar in size to those of the ‘Andross’ cultivar. Unlike the ‘Andross’ cultivar, reniform leaf glands are present. The flowers of new cultivar are pink and non-showy.
The new cultivar of the present invention has been tested in plantings at Davis, Calif.; Winters, Calif.; and Parlier, Calif., U.S.A.
Wood of the new cultivar has been subjected to the virus indexing program of Foundation Plant Materials Service, University of California at Davis, Calif., U.S.A. All indices have proven to be negative for viruses for foundation trees of this genotype being maintained by such Foundation Plant Materials Service.
The new cultivar of the present invention has been named ‘Goodwin’.
DETAILED DESCRIPTION OF THE PHOTOGRAPHS
The accompanying photographs show typical specimens of trees, foliage, fruit, and stone of the new cultivar of the present invention in color as true as it is reasonably possible to make the same in color illustrations of this character. Trees of the new cultivar were being grown on ‘Nemared’ peach rootstock at Davis, Calif., U.S.A.
FIG. 1 illustrates trees having an age of approximately six years on Mar. 10, 2000. The non-showy flowers are shown as well as the upright-spreading growth habit.
FIG. 2 illustrates on Aug. 3, 1999 external and internal views of the fruit, stone, and of a leaflet of the new cultivar.
DETAILED DESCRIPTION
The following is a detailed description of the new cultivar obtained from the observation of vegetatively propagated progeny of the new cultivar during the 1999 and 2000 growing seasons. The trees were grown on ‘Nemared’ peach rootstock at the Wolfskill Experimental Orchards of the University of California located at Winters, Calif., U.S.A., and at the University of California Pomology Research Plots located at Davis, Calif., U.S.A. Color designations are presented with reference to the “Dictionary of Color” by Maerz and Paul, First Edition (1930). More common color terms are to be accorded their customary dictionary significance.
Tree:
Size.— Medium. The trees resulting from the asexual propagation of 1998 during the fall of 2000 had a height of approximately 3.3 meters, a breadth of approximately 3.4 meters across the crown, and commonly possessed approximately four scaffolds.
Vigor.— Medium. Produced approximately 0.61 to 0.92 meter of new growth during the 2000 growing season.
Growth.— Upright-spreading.
Hardiness.— Hardy under typical Sacramento Valley climatic conditions.
Production.— Productive.
Bearing.— Regular bearer.
Trunk:
Size.— Medium to large. The trunk diameter at 10 cm above the ground is approximately 21 cm. The scaffold diameters at the base of the scaffolds are approximately 10 cm.
Texture.— Relatively coarse with substantial scarfskin.
Color.— The bark color ranges from brown-grey (15-H-7 Olive Brown) to more medium brown (8-H-10 Chocolate Brown).
Lenticels.— Numerous, medium in size, flattened and generally oval-shaped. Typically the lenticels range from approximately 2 to 6 mm in width at a right angle to the trunk and are approximately 1 to 2 mm in height. The lenticel surface is light brown in coloration (13-J-9 Hazel Brown).
Branches:
Size.— Medium.
Texture.— Medium.
Color.— Mature shoots are light brown (14-J-9 Mummy Brown) to darker brown (7-H-12 Mohawk Brown). The current season's shoots are pale light green (18-K-5). The exposed surfaces are commonly tinged rose-red (5-K-10 Ember). The coloration of the new expanding shoot tips is bright yellow green (17-L-4).
Lenticels.— At a right angle to the shoots, and light in coloration.
Internode length.— On current season's hanger shoots the length between nodes commonly is approximately 10 to 25 mm.
Leaves:
Size.— Medium to large. Typical length from vigorous current season's growth is approximately 16.1 to 19.6 cm including the petiole, and typical width is approximately 3.7 to 4.6 cm. The leaf thickness is average.
Form.— Lanceolate.
Apex.— Acuminate and often with a slight curve downward.
Aspect.— The blade commonly ranges from substantially flat to somewhat folded upwards.
Color.— The upper surface is dark green (23-J-5 Elm Green) and the lower surface is a much lighter grey-green (21-1-6). The primary and mid-vein on the under surface is pale yellow-green (17-H-1).
Margin.— Crenate and occasionally double crenate. The crenations are relatively large and uniform. The leaf margins commonly range from straight to moderately undulate.
Petiole.— Generally medium in size, commonly approximately 8 to 12 mm in length, approximately 2 mm in thickness, and pale yellow-green in coloration (17-K-3).
Glands.— Small to medium in size, almost always reniform, alternate, commonly 1 to 3 on the petiole, and frequently 0 to 3 additional glands can be observed at the base of the leaf blade. The coloration is shiny light green-yellow (17-K-6) and often with a reddish center.
Stipules.— Linear lanceolate in configuration, most are early deciduous, margins are serrate, commonly approximately 6 to 9 mm in length, and the coloration of young stipules commonly is light green-yellow (17-K-5) with darkening to brownish upon aging.
Fruit:
Maturity when described.— Full commercial maturity.
Picking.— First pick was Jul. 24, 2000 and last pick was Jul. 29, 2000.
Season of maturity.— Approximately four days earlier than the ‘Andross’ cultivar.
Size .—Uniform, large. Average axial diameter is approximately 60 to 65 mm, the average suture diameter is approximately 65 to 71 mm, and the average cheek diameter is approximately 64 to 70 mm.
Form .—In lateral aspect the fruit is slightly oblate, and in the apical aspect is nearly globose with slight variability. Most frequently the fruit is slightly asymmetrical.
Suture .—As an inconspicuous line. Is slightly deeper at the base and with a slight depression at the apex.
Ventral surface .—Relatively smooth and only occasionally lipped.
Base .—Rounded to slightly truncate in form. The base angle is slightly variable and most often is at a right angle to the fruit axes.
Stem cavity .—Broad and moderately deep, commonly approximately 3.3 cm in length on average, approximately 2.2 cm in width on average, and approximately 1.6 cm in depth on average.
Apex .—Commonly rounded with a low to medium tip. The pistil point commonly is apical.
Pistil point .—Most frequently is oblique.
Stem length .—Medium, and commonly averages 1.0 cm.
Stem thickness .—Commonly averages approximately 3 to 3.3 mm and usually is more thickened at the distal end.
Skin pubescence .—Fine, short, and matted. Commonly with slightly less pubescence than the ‘Andross’ cultivar.
Skin tendency to split .—None observed.
Skin color .—The primary ground color is uniform orange-yellow (10-J-6). The fruit surface has a moderate amount of blush coloration that commonly covers approximately 20 to 60 percent of the total surface. Fruit exposed to direct sunlight commonly possesses more blush. The blush pattern is primarily washed with a moderate amount of dark mottling.
The blush color ranges from dark garnet red (7-E-5) to a lighter shade of red (6-K-7) with a range of variation in between.
Flesh color .—A uniform yellow coloration from the skin to the stone cavity (10-K-5).
Flesh texture .—Firm, and non-melting.
Flesh fibers .—Few in number, short and fine.
Ripening .—Ripens evenly.
Flavor .—Excellent quality, rich and well-balanced. Rated superior to that of the ‘Andross’ cultivar in taste trials.
Aroma .—Pleasant and moderate.
Eating quality .—Good.
Canning quality .—Very good.
Stone type .—Clingstone with flesh connected over the entire stone surface.
Stone size .—Medium to slightly below average, and commonly averages approximately 28.6 mm in length, approximately 22.2 mm in width, and approximately 17.3 mm in thickness.
Stone fibers .—Numerous very short and fine fibers attached laterally to the stone.
Stone form .—Variable, but most often slightly obovate.
Stone base .—Typically positioned at right angles to slightly oblique to the stone axis.
Stone hilum .—Medium to small in size, well defined, and surrounded by a raised collar.
Stone apex .—Generally rounded with a broad rather blunt tip.
Stone sides .—Variable and most often nearly equal.
Stone surface .—Moderately coarse with the heaviest grooving being present apically over the lateral apical shoulders. Several deep grooves are present near the dorsal and ventral edges and meet the edges at an oblique angle.
Ventral edge .—Medium in width with several low wings.
Dorsal edge .—Somewhat variable in form, and most commonly the dorsal suture is moderately narrow with a deep groove extending from the base to the apical shoulder. The apical shoulder area is somewhat eroded and somewhat concave in configuration.
Stone color .—When dry, light clay-brown (13-B-8).
Tendency to split .—Low to moderate, and similar to that of the ‘Andross’ cultivar.
Flowers:
Chilling season .—Low to medium for the growing location. There were approximately 1,200 chilling hours below 45° F. for the 1999 winter season, and approximately 770 hours below 45° F. for the 2000 winter season.
Buds .—Medium in size, conic in form, plump, free of the stem with pubescent surfaces of light grey coloration. The exterior bud scale ranges from grey (15-A-6 Beaver Grey) to grey-brown (15-A-8 Winter Leaf Brown) in coloration. The buds are hardy under typical climatic conditions of the Sacramento Valley. There commonly are one to two floral buds per node and most frequently two floral buds per node.
Bloom timing .—Mid-season in relation to other commercial cling peach cultivars. During 1999 and 2000 the bloom periods were substantially the same as the ‘Andross’ cultivar.
Size .—The flower size is medium and non-showy. The fully expanded flower diameter commonly is approximately 26 to 32 mm.
Bloom quality .—Commonly abundant throughout the tree. There commonly are two flowers per node.
Petals .—The petal size is medium to large and commonly ranges from approximately 12 to 14 mm in length and from approximately 8 to 10 mm in width. The petal number is five. The petal form varies from broadly ovate to at times nearly oval. The petal color is very light pink (1-B-1) at the central area and dark pink (1-E-2) along the margin. The petal claw is relatively narrow and truncate in form. The claw color is dark pink (1-G-2). The petal margins are moderately undulate and the petals are substantially cupped inward. The petal apices are commonly rounded with no tip.
Pedicel .—Relatively short and commonly exhibits a length of approximately 1 to 1.5 mm and an average thickness of approximately 1 mm. The coloration is light green (18-I-7) and the surface is glabrous.
Nectaries .—Moderately bright orange (11-J-11) and become slightly darker at maturity.
Calyx .—Glabrous and quite rugose, and the coloration is light maroon (5-J-4) with areas of green (19-L-2 Jewel Green) especially basally, and darkening to intense maroon (6-J-5 Rubaiyat).
Sepals .—With greyish pubescence, average in size, conic in form, and dark maroon (6-J-4 to 6-J-5) in coloration.
Anthers .—Average in size, red dorsally (5-L-11 Brickdust) and tan ventrally (Chamois 11-I-5).
Stamens .—Medium in length and commonly slightly longer than the pistil at full maturity. The filament color is nearly white when the bloom first opens, and darkens to dull light violet (4-H-3) with senescence.
Pollen .—Abundant, bright yellow (Empire Yellow 9-K-3) in coloration.
Pistil .—Pubescent basally over the ovary, and less so near the stigma and over the upper style area. The length commonly is approximately 12 to 15 mm including the ovary. The coloration basally is pale green (17-J-3) and a paler green (17-J-1) over the upper style area.
Major use: Canning.
Keeping quality: Good. In cold storage tests where fruit was stored at 4° C. under ambient conditions with no controlled atmosphere for 10 days, fruit processing was carried out with no detectable loss in eating quality (i.e., flavor, color and firmness). Longer tests were not performed since 10 days is the maximum expected storage time for peach fruit of this maturity period. Previous tests had shown that the ‘Dr. Davis’ parental cultivar displays exceptional cold storage quality with no detectable loss of quality following in excess of 15 days in cold storage.
Resistance to diseases: Average. Diseases evaluated included brown rot disease ( Monilinia fructicola ) of the fruit, and powdery mildew ( Sphaerotheca pannosa ) and peach leaf-curl ( Taphrina deformans ) of the foliage. The brown-rot resistance was determined through controlled laboratory screenings. Conidal suspensions of Monilinia fructicola were produced by washing 5 to 7 day-old PDA cultures with 20 ml sterile distilled water containing 0.01% TWEEN 20 wetting agent. The inoculum was filtered through four layers of sterile cheesecloth to minimize the presence of mycelial fragments and was adjusted to a concentration of 2×104 conidia per ml. Ten microliters of conidial suspension were deposited on the fruit surface which was previously determined to be free of visible injury by examination with a stereo microscope. Inoculated fruit was incubated for 72 hours at 22 to 25° C. in the dark at approximately 95% relative humidity. Lesion diameters were recorded 72 hours after inoculation. Diameters on the ‘Goodwin’ fruit averaged 19 mm which was generally comparable to that formed on the ‘Dr. Davis’ fruit which averaged 22 mm. The ‘Dr. Davis’ parent is widely considered to have only average resistance to brown rot. The powdery mildew resistance was evaluated through the observation of natural field infections. It was rated during 1995 at Winters, Calif., in a field epiphytotic evaluation block. Numerical rating were based on leaf symptoms where “1”=no disease, and “6”=several disease. ‘Goodwin’ received a “1” rating as did the ‘Dr. Davis’ parent. For comparative purposes the ‘Dixon’ and ‘Andross’ cultivars were rated “ 3”. The peach leaf-curl resistance also was evaluated through the observation of natural field infections. It was rated during 1995 at Winters, Calif., in a field epiphytotic evaluation block that experienced heavy rains and poor fungicide spray control. ‘Goodwin’ received a “4” rating, ‘Dr. Davis’ a “3” rating, and ‘Dixon’ and ‘Andross’ each received a “4” rating on the same scale identified above.
Resistance to insects: Average. The major insect pest to Peach trees is the twig-borer ( Anarsia lineatella ) which feeds on young peach tree shoots possibly causing their eventual collapse and on the ripening fruit resulting in worm feeding damage and greater susceptibility to fruit molding. The incidence of damage for ‘Goodwin’ from this insect was observed to be comparable to that of the ‘Dr. Davis’, ‘Dixon’ and ‘Andross’ cultivars.
|
A new and distinct cultivar of early-season clingstone peach tree (i.e., Prunus persica ) is provided. Attractive fruit is formed that is well suited for processing having uniform yellow flesh that is free from red staining at the pit cavity. The fruit color, flavor, and texture are believed to be superior to the ‘Dixon’ and ‘Andross’ cultivars (both non-patented in the United States). The fruit ripens at approximately four days earlier than the ‘Andross’ cultivar. The pink flowers are medium-sized and non-showy and the growth habit is upright-spreading.
| 0
|
FIELD OF THE INVENTION
The present invention relates generally to vehicular component storage, and more particularly to storage of motor vehicle components under at least one seat in the passenger compartment.
BACKGROUND
Modern motor vehicles have a multitude of components that must be assembled and stored in the vehicle. A problem that has arisen in many modern vehicles is that to minimize overall body size and to increase vehicle features the space in the engine compartment has become premium. This being the case, there has been a movement to place some components that had been previously mounted in the engine compartment in the passenger compartment. The areas most conducive to such storage within the passenger compartment are the areas below the passenger seats. If components are not mounted here then the area below the seats often goes unutilized or under utilized.
There have been a few designs for under seat compartments, but they have often required the removal of the seats to service the stored components. The removal of the seats has become disadvantageous as more features are added to vehicle seats. Seats with more features generally have more electronics routed through them so that owner removal of the seats is unwanted. Therefore, the old storage compartments that require the removal of the seats to service the stored components are no longer advantageous.
Consequently, storage compartments under the seats must allow access through side doors so that the stored component may be slid out from under the seat. Thus a solid, or unmovable, storage area must contain a door that is secured to contain the vehicle component. Therefore, it is desirable to provide the storage compartment with a passive restraining device that will ensure the component is properly secured in the storage compartment even without a standard securing device.
SUMMARY OF THE INVENTION
According to the invention, a storage compartment is mounted to the vehicle floor under at least one seat in the vehicle. The compartment further comprises an opening that is secured by a strap that is hingedly attached to the remainder of the compartment so that the strap may be moved to allow access to the component stored within the storage compartment. The strap is secured by a removable fastener that is generally installed to secure the opening to the storage compartment. However, a passive restraint is also present to supplement the removable fastener and to secure the strap when the removable fastener is not properly installed or not present. The passive restraint is secured to the vehicle floor and is not removed once installed in the vehicle.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood however that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for purposes of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a transparent side view of a motor vehicle with a car battery having been placed under a front seat;
FIG. 2 is a schematic view of a seat bottom having a component storage unit having a car battery placed within it;
FIG. 3 is a schematic view of the component storage unit;
FIG. 4 is a schematic view of the component storage unit in its open position and the direction of the car battery's movement to be serviced;
FIG. 5 shows the seat bottom and the installed and uninstalled position of the car battery;
FIG. 6 shows a car battery installed in the component storage unit and the passive restraint;
FIG. 7 shows the strap engaging the passive restraint to the component storage unit if the fastener were not present or broken when the battery moves forward;
FIG. 7 a is an enlarged view of the passive restraint engaging the component storage unit strap;
FIG. 8 shows one embodiment of the passive restraint being disengaged from the locked position so as to allow the component storage unit strap to be opened;
FIG. 9A shows the main body strap being deformed so as to gain access to the storage area without engaging the passive restraint; and
FIG. 9B shows the component storage unit strap being deformed so as to gain access to the storage area without engaging the passive restraint.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the possible placement of a vehicle component, here a battery 1 . The battery 1 is placed below a vehicle seat 3 and resting on the vehicle floor 17 . The battery 1 may be loaded vertically into place before the seat 3 is installed into the vehicle 7 . The battery 1 or other component can be stored within the plurality of supports 21 of the vehicle seat. This space would otherwise be unutilized within the vehicle 7 . However, the battery 1 must be secured to ensure retention of the battery 1 . Also this system for securing the battery will also allow for ease of service access.
FIG. 2 shows a component retention system 15 for securing the battery 1 in place so that it can not move once properly installed. The component retention system 15 includes a main body strap 5 , a strap 16 for opening the component retention system 15 and a hinge 4 which hingedly attaches the strap 16 and allows for ease of entry into the component retention system 15 .
FIG. 3 shows only the component retention system 15 in which the component may be placed. It can be seen that the strap 16 has a first part 22 which is the main body of the strap 16 and a second part, a flange 13 that extends essentially perpendicular to the main body 22 of the strap 16 . A removable fastener 6 fits through an opening in the flange 13 which secures the strap 16 in its closed position. The fastener 6 is secured to the floor 17 of the vehicle.
FIG. 4 shows the component retention system 15 with the strap 16 moved in the direction of Arrow A to the opened position. When the strap 16 is in this position the battery 1 may be slid laterally to remove it from the component retention system 15 . The strap 16 may be oriented in a fore-aft direction under the seat 3 as long as there is adequate room to remove the battery 1 . This allows the battery 1 to be easily serviced after it has been installed under the seat 3 . FIG. 5 illustrates how the battery 1 may be moved from its first installed position to a second uninstalled/service position. This entire process is completed without disturbing the seat 3 and any electronics that may be attached to such seat.
FIG. 6 shows the passive restraint device in the form of a tab 12 mounted in front of the strap 16 . The passive restraint 12 is fixedly attached to the vehicle floor 17 so that it can not be removed even if the captured fastener 6 is lost or not properly replaced. Preferably, the captured fastener 6 is provided with a push nut to prevent the fastener 6 from being removed. The passive restraint 12 is engaged, as shown in FIGS. 7 and 7 a when the battery 1 moves towards the strap 16 when the removable fastener 6 has not been properly replaced. FIG. 6 further shows how the passive restraint 12 is truly passive in that when the strap 16 is released the force of gravity pushes the strap away from the passive restraint 12 . Therefore, when the battery 1 shifts within the storage compartment 5 the flange 13 on the strap 16 will engage the passive restraint 12 .
FIG. 7 shows the flange 13 on the strap 16 engaging the passive restraint 12 . FIG. 7A shows an enlargement of this action. The battery 1 is shown moving in the direction ‘A’ so as to come into contact with the strap 16 . In these Figures the removable fastener 6 is not in place so that the passive restraint 12 may be engaged. If the passive restraint 12 were not present then the battery 1 would be able to move out of the component retention system 15 and enter the area of the passenger compartment of the automobile 7 . The advantage of this system is that even when the removable fastener 6 is not properly replaced the battery 1 will still remain in the component retention system 15 .
FIG. 8 shows a first embodiment for disengaging the passive restraint 12 to service the battery 1 stored in the component retention system 15 . In this embodiment the passive restraint 12 is pressed towards the vehicle floor 17 , thereby moving the passive restraint 12 from a first generally vertical locked position to a second generally horizontal unlocked position, so that the strap 16 may move over the passive restraint 12 . In this manner, the flange 13 may not engage the passive restraint 12 . In this embodiment a spring device 30 ensures that the passive restraint 12 will move back to its generally vertical locked position so that the passive restraint 12 may engage the flange 13 once the battery 1 is reinstalled.
FIG. 9A shows a second embodiment for disengaging the passive restraint 12 to service the battery 1 stored in the component retention system 15 . In this embodiment the main body strap 5 is constructed of a material that may be deformed from a first generally straight form to a second bent form so that the strap 16 can be lifted upward so the flange 13 may clear the passive restraint 12 . In this embodiment the passive restraint 12 is fixedly attached to the vehicle floor 17 and does not move. As an alternative, as shown in FIG. 9B, the strap 16 is constructed of a material that may be deformed from a first generally straight form to a second bent form so that the flange may clear the passive restraint 12 .
The battery 1 is installed below the seat 3 by fixing the battery 1 within the retention system 15 . The strap 16 is then positioned so that the flange 13 is disposed behind the passive restraint 12 . This is performed by bending the main body strap 5 upward and/or bending the strap 16 depending on which embodiment is utilized (FIG. 9A, 9 B). the captured fastener 6 is then inserted in the threaded hole provided in the floor 17 .
During removal, the fastener 6 is released and the flange 13 is lifted upward as shown in either FIGS. 9A or 9 B or alternatively, the passive restraint 12 is rotated downward and rearward (as illustrated in FIG. 8) so that the strap 16 can be lifted out of the way. The battery 1 can then be removed.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
|
A storage compartment mounted to the floor of a motor vehicle under a seat. The compartment is for storing vehicle components such as car batteries. The compartment includes an opening secured by a strap and the strap is held in place by a removable fastener and a passive restraint. The passive restraint is meant to secure the strap when the removable fastener is not in place so that the contents of the compartment may not exit the compartment.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATONS
[0001] This application is based on and claims priority from provisional patent application Ser. No. 60/208,199 filed on May 31, 2000.
BACKGROUND OF THE INVETION
[0002] This invention relates to vitamin D compounds, and more particularly to vitamin D derivatives substituted at the carbon 2 position.
[0003] The natural hormone, 1α,25-dihydroxyvitamin D 3 and its analog in ergosterol series, i.e. 1α,25-dihydroxyvitamin D 2 are known to be highly potent regulators of calcium homeostasis in animals and humans, and more recently their activity in cellular differentiation has been established, Ostrem et al., Proc. Natl. Acad. Sci. USA, 84, 2610 (1987). Many structural analogs of these metabolites have been prepared and tested, including 1α-hydroxyvitamin D 3 , 1α-hydroxyvitamin D 2 , vaious side chain homologated vitamins and fluorinated analogs. Some of these compounds exhibit an interesting separation of activities in cell differentiation and calcium regulation. This difference in activity may be useful in the treatment of a variety of diseases.
[0004] Recently, a new class of vitamin D analogs has been discovered, i.e. the so called 19-nor-vitamin D compounds, which are characterized by the replacement of the A-ring exocyclic methylene group (carbon 19), typical of the vitamin D system, by two hydrogen atoms. Biological testing of such 19-nor-analogs (e.g., 1α,25-dihydroxy-19-nor-vitamin D 3 ) revealed a selective activity profile with high potency in inducing cellular differentiation, and very low calcium mobilizing activity. Thus, these compounds are potentially useful as therapeutic agents for the treatment of malignancies, or the treatment of various skin disorders. Two different methods of synthesis of such 19-nor-vitamin D analogs have been described (Perlman et al., Tetrahedron Lett. 31, 1823 (1990); Perlman et al., Tetrahedron Lett. 32, 7663 (1991), and DeLuca et al., U.S. Pat. No. 5,086,191).
[0005] In U.S. Pat. No. 4,666,634, 2β-hydroxy and alkoxy (e.g., ED-71) analogs of 1α,25-dihydroxyvitamin D 3 have been described and examined by Chugai group as potential drugs for osteoporosis and as antitumor agents. See also Okano et al., Biochem. Biophys. Res. Commun. 163, 1444 (1989). Other 2-substituted (with hydroxyalkyl, e.g., ED-120, and fluoroalkyl groups) A-ring analogs of 1α,25-dihydroxyvitamin D 3 have also been prepared and tested (Miyamoto et al., Chem. Pharm. Bull. 41, 1111 (1993); Nishii et al., Osteoporosis Int. Suppl. 1, 190 (1993); Posner et al., J. Org. Chem. 59, 7855 (1994), and J. Org. Chem. 60, 4617 (1995)).
[0006] Recently, 2-substituted analogs of 1α,25-dihydroxy-19-norvitamin D 3 have also been synthesized, i.e. compounds substituted at 2-position with hydroxy or alkoxy groups (DeLuca et al., U.S. Pat. No. 5,536,713), which exhibit interesting and selective activity profiles. All these studies indicate that binding sites in vitamin D receptors can accommodate different substituents at C-2 in the synthesized vitamin D analogs.
SUMMARY OF THE INVENTION
[0007] The discovery of the hormonally active form of vitamin D 3 , 1α,25-dihydroxyvitamin D 3 (1α,25-(OH) 2 D 3 , calcitriol, 1; FIG. 1 ), has greatly stimulated research into its physiology and chemistry. As previously noted, it has been established that 1 not only regulates the mineral metabolism in aninals and humans, but also exerts potent effects upon cell proliferation and cellular differentiation. Therefore, the chemistry of vitamin D has been recently focused on the design and synthesis of analogs that can exert selective biological actions.
[0008] In a previous investigation of the structure-activity relationship of the vitamin D molecule, an analog of the natural hormone 1, 1α,25-dihydroxy-2-methylene-19-norvitamin D 3 (2), was prepared in which the exocyclic methylene group is transposed, in comparison with 1, from C-10 to C-2. Also, 2α-methyl analog 3 was obtained by selective hydrogenation of 2. Both analogs were characterized by significant biological potency, enhanced especially in their isomers in the 20S-series.
[0009] In a continuing search for biologically active vitamin D compounds novel 19-nor analogs of 1, substituted at C-2 with ethylidene (4a,b and 5a,b) and ethyl (6a,b and 7a,b) groups, have now been synthesized and tested. Structurally the novel 2-ethylidene analogs belong to a class of 19-nor vitamin D compounds characterized by the general formula I shown below:
where Y 1 , and Y 2 , which may be the same or different, are each selected from the group consisting of hydrogen and a hydroxy-protecting group, and where the group R represents any of the typical side chains known for vitamin D type compounds.
[0010] Structurally the novel 2-ethyl analogs belong to a class of 19-nor vitamin D compounds characterized by the general formula II shown below:
where Y 1 and Y 2 , which may be the same or different, are each selected from the group consisting of hydrogen and a hydroxy-protecting group, and where the group R represents any of the typical side chains known for vitamin D type compounds.
[0011] More specifically R can represent a saturated or unsaturated hydrocarbon radical of 1 to 35 carbons, that may be straight-chain, branched or cyclic and that may contain one or more additional substituents, such as hydroxy- or protected-hydroxy groups, fluoro, carbonyl, ester, epoxy, amino or other heteroatomic groups. Preferred side chains of this type are represented by the structure below:
where the stereochemical center (corresponding to C-20 in steroid numbering) may have the R or S configuration, (i.e. either the natural configuration about carbon 20 or the 20-epi configuration), and where Z is selected from Y, —OY, —CH 2 OY, —C≡CY, —CH═CHY, and —CH 2 CH 2 CH═CR 3 R 4 , where the double bond may have the cis or trans geometry, and where Y is selected from hydrogen, methyl, —COR 5 and a radical of the structure:
where m and n, independently, represent the integers from 0 to 5, where R 1 is selected from hydrogen, deuterium, hydroxy, protected hydroxy, fluoro, tifluoromethyl, and C 1-5 -alkyl, which may be straight chain or branched and, optionally, bear a hydroxy or protected-hydroxy substituent, and where each of R 2 , R 3 , and R 4 , independently, is selected from deuterium, deuteroalkyl, hydrogen, fluoro, trifluoromethyl and C 1-5 alkyl, which may be straight-chain or branched, and optionally, bear a hydrox or protected-hydroxy substituent, and where R 1 and R 2 , taken together, represent an oxo group, or an alkylidene group, ═CR 2 R 3 , or the group —(CH 2 ) p —, where p is an integer from 2 to 5, and where R 3 and R 4 , taken together, represent an oxo group, or the group —(CH 2 ) q —, where q is an integer from 2 to 5, and where R 5 represents hydrogen, hydroxy, protected hydroxy, C 1-5 alkyl or —OR 7 where R 7 represents C 1-5 alkyl, and wherein any of the CH-groups at positions 20, 22, or 23 in the side chain may be replaced by a nitrogen atom, or where any of the groups —CH(CH 3 )—, —CH(R 3 )—, or —CH(R 2 )— at positions 20, 22, and 23, respectively, may be replaced by an oxygen or sulfur atom.
[0012] The wavy lines, e.g. to the substituents at C-2 and at C-20 indicate that those substituents may have either the R or S configuration.
[0013] Specific important examples of side chains with natural 20R-configuration are the structures represented by formulas (a), b), (c), (d) and (e) below. i.e. the side chain as it occurs in 25-hydroxyvitamin D 3 (a); vitamin D 3 (b); 25-hydroxyvitamin D 2 (c); vitamin D 2 (d); and the C-24 epimer of 25-hydroxyvitamin D 2 (e):
[0014] Specific important examples of side chains with the unnatural 20S (also referred to as the 20-epi) configuration are the structures presented by formulas (f), (g), (h), (i) and (j) below:
[0015] The above novel compounds exhibit a desired, and highly advantageous, pattern of biological activity. The synthesized vitamins were tested for their ability to bind the porcine intestinal vitamin D receptor. The presented results ( FIG. 5 ) indicate that 2-ethylidene-19-norvitamins, possessing methyl group from ethylidene moiety directed toward C-3, i.e., trans in relation to C(6)-C(7) bond (isomers E), are more active than 1α,25-(OH) 2 D 3 in binding to VDR, whereas their counterparts with cis relationship between ethylidene methyl substituent and C(7)-H group (isomers Z) exhibit significantly reduced affinity for the receptor. The competitive binding analysis showed also that 2α-ethyl-19-norvitamins bind to the receptor better than their isomers with 2β-ethyl substituents ( FIG. 6 ). In the next assay, the cellular activity of the synthesized compounds was established by studying their ability to induce differentiation of human promyelocyte HL-60 cells into monocytes. E isomer of (20S)-2-ethylidene-19-norvitamin D 3 ( FIG. 7 ) and both 2α-ethyl-19-norvitamins ( FIG. 8 ) are more potent than 1α,25-(OH) 2 D 3 in this assay, whereas the remaining tested compounds are almost equivalent to the hormone 1. Both E isomers of 2-ethylidene-19-norvitamins, when tested in vivo in rats (Table 1) exhibited very high calcemic activity, the (20S)-compound being especially potent. On the contrary, isomeric Z compounds are significantly-less active. 2-Ethyl-19-norvitamins have some ability to mobilize calcium from bone but not to the extent of the hormone 1, while being inactive in intestine. The only exception is the 2α-ethyl isomer from the 20S-series which shows strong calcium mobilization response and marked intestinal activity.
[0016] These compounds are thus highly specific in their calcemic activity. Their preferential activity on mobilizing calcium from bone and either high or normal intestinal calcium transport activity allows the in vivo administration of these compounds for the treatment of metabolic bone diseases where bone loss is a major concern. Because of their preferential calcemic activity on bone, these compounds would be preferred therapeutic agents for the treatment of diseases where bone formation is desired, such as osteoporosis, especially low bone turnover osteoporosis, steroid induced osteoporosis, senile osteoporosis or postmenopausal osteoporosis, as well as osteomalacia and renal osteodystrophy. The treatment may be transdermal, oral or parenteral. The compounds may be present in a composition in an amount from about 0.1 μg/gm to about 50 μg/gm of the composition, and may be administered in dosages of from about 0.0 1 μg/day to about 50 μg/day.
[0017] The compounds of the invention are also especially suited for treatment and prophylaxis of human disorders which are characterized by an imbalance in the immune system, e.g. in autoinmunue diseases, including multiple sclerosis, diabetes mellitus, host versus graft reaction, lupus, atherosclerosis, and rejection of transplants; and additionally for the treatment of inflammatory diseases, such as inflammatory bowel disease, rheumatoid arthritis and asthma, as well as the improvement of bone fracture healing and improved bone grafts. Acne, alopecia especially chemically induced alopecia (e.g. resulting from chemotherapy), skin conditions such as dermatitis, eczema, keratosis, dry skin (lack of dermal hydration), undue skin slackness (insufficient skin firmness), insufficient sebum secretion and wrinkles, as well as hypocalcemia, hypoparathyroidism and hypertension are other conditions which may be treated with the compounds of the invention.
[0018] The above compounds are also characterized by high cell differentiation activity. Thus, these compounds also provide therapeutic agents for the treatment of psoriasis, or as an anti-cancer agent, especially against leukemia, colon cancer, breast cancer and prostate cancer. The compounds may be present in a composition to treat psoriasis, cancer, and/or the above list of diseases in an amount from about 0.01 μg/gm to about 100 μg/gm of the composition, and may be administered topically, transdermally, orally or parenterally in dosages of from about 0.01 μg/day to about 100 μg/day.
[0019] This invention also provides novel intermediate compounds formed during the synthesis of the end products.
[0020] This invention also provides a novel synthesis for the production of the end products of structures I and II. Two different synthetic paths were devised, both based on Lythgoe type Wittig-Horner coupling of the A-ring fragments, the corresponding phosphine oxides prepared from quinic acid, with the protected 25-hydroxy Grundmann's ketone. In the first method, the allylic phosphine oxides were substituted at C-4′ with the ethylidene group whereas in the alternative approach the introduction of ethylidene moiety was performed in the final step of the synthesis, by Wittig reaction of the intermediate 2-oxo-vitamin D analog. The selective catalytic hydrogenation of 2-ethylidene analogs of 1α,25-dihydroxy-19-norvitamin D 3 provided the corresponding 2α- and 2β-ethyl compounds.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 illustrates the general structural formulae for 1α,25-dihydroxyvitamin D 3 , 1α,25-dihydroxy-2-methylene-19-norvitamin D 3 , and 1α,25-dihydroxy-2α-methyl-19-norvitamin D 3 , and further illustrates the general structural formulae for the four 2-ethylidene-19-nor-vitamins and the four 2-ethyl-19-nor-vitamins of the present invention synthesized and tested herein;
[0022] FIG. 2 illustrates the configurations and preferred conformations of the 4′-ethylidene intermediates 16 and 17 used in the synthesis disclosed herein;
[0023] FIG. 3 a illustrates the α- and β- forms of the A-ring chair conformers for vitamin D compounds in solutions;
[0024] FIG. 3 b illustrates that the presence of bulky 2-alkyl substituents, characterized by large conformational free energy A values, shifts the A-ring conformational equilibrium of the synthesized 2-ethyl-19-nor-vitamins toward the conformers with the equatorial C(2)-substituents;
[0025] FIG. 3 c illustrates that a strong interaction (designated as A (1,3) -strain) exists between the methyl group from the ethylidene moiety and equatorial hydroxyls at C-1 or C-3, and results in a strong bias toward conformers with an axial orientation of this hydroxy group to which the methyl from ethylidene fragment is directed; and
[0026] FIG. 4 illustrates the conformational equilibrium in ring A of 2-methylene-19-norvitamin 2 (a) and the preferred, energy minimized (PC MODEL 6.0, Serena Software) A-ring conformations of the synthesized analogs: 4a,b (b), 5a,b (c), 6a,b (d) and 7a,b (e).
[0027] FIG. 5 a is a graph illustrating the relative activity of a 2-ethylidene-19-nor-vitamins (isomers E and Z) and 1α,25-dihydroxyvitamin D 3 to compete for binding of [ 3 H]-1,25-(OH) 2 -D 3 to the pig intestinal nuclear vitamin D receptor;
[0028] FIG. 5 b is a graph similar to FIG. 5 a except illustrating the relative activity of individual compounds 2α and 2β-ethyl- 19-nor-vitamins and 1α,25-dihydroxyvitamin D 3 to compete for binding of [ 3 H]-1,25-(OH) 2 -D 3 to the vitamin D pig intestinal nuclear receptor;
[0029] FIG. 6 a is a graph illustrating the percent HL-60 cell differentiation as a function of the concentration of the 2-ethylidene-19-nor-vitamins as compared to 1α,25-dihydroxyvitamin D 3 ; and
[0030] FIG. 6 b is a graph illustrating the percent HL-60 cell differentiation as a function of the concentration of the 2α and 2β-ethyl-19-nor-vitamins as compared to 1α,25-dihydroxyvitamin D 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0031] As used in the description and in the claims, the term “hydroxy-protecting group” signifies any group commonly used for the temporary protection of hydroxy functions, such as for example, alkoxycarbonyl, acyl, alkylsilyl or alkylarylsilyl groups (hereinafter referred to simply as “silyl” groups), and alkoxyalkyl groups. Alkoxycarbonyl protecting groups are alkyl-O—CO— groupings such as methoxycarbonyl, ethoxycarbonyl, propoxycarbonyl, isopropoxycarbonyl, butoxycarbonyl, isobutoxycarbonyl, tert-butoxycarbonyl, benzyloxycarbonyl or allyloxycarbonyl. The term “acyl” signifies an alkanoyl group of 1 to 6 carbons, in all of its isomeric forms, or a carboxyalkanoyl group of 1 to 6 carbons, such as an oxalyl, malonyl, succinyl, glutaryl group, or an aromatic acyl group such as benzoyl, or a halo, nitro or alkyl substituted benzoyl group. The word “alkyl” as used in the description or the claims, denotes a straight-chain or branched alkyl radical of 1 to 10 carbons, in all its isomeric forms. Alkoxyalkyl protecting groups are groupings such as methoxymethyl, ethoxymethyl, methoxyethoxymethyl, or tetrahydrofuranyl and tetrahydropyranyl. Preferred silyl-protecting groups are trimethylsilyl, triethylsilyl, t-butyldimethylsilyl, dibutylmethylsilyl, diphenylmethylsilyl, phenyldimethylsilyl, diphenyl-t-butylsilyl and analogous alkylated silyl radicals. The term “aryl” specifies a phenyl-, or an alkyl-, nitro- or halo-substituted phenyl group.
[0032] A “protected hydroxy” group is a hydroxy group derivatised or protected by any of the above groups commonly used for the temporary or permanent protection of hydroxy functions, e.g. the silyl, alkoxyalkyl, acyl or alkoxycarbonyl groups, as previously defined. The terms “hydroxyalkyl”, “deuteroalkyl” and “fluoroalkyl” refer to an alkyl radical substituted by one or more hydroxy, deuterium or fluoro groups respectively.
[0033] It should be noted in this description that the term “24-homo” refers to the addition of one methylene group and the term “24-dihomo” refers to the addition of two methylene groups at the carbon 24 position in the side chain. Likewise, the term “trihomo” refers to the addition of three methylene groups. Also, the term “26,27-dimethyl” refers to the addition of a methyl group at the carbon 26 and 27 positions so that for example R 3 and R 4 are ethyl groups. Likewise, the term “26,27-diethyl” refers to the addition of an ethyl group at the 26 and 27 positions so that R 3 and R 4 are propyl groups.
[0034] In the following lists of compounds, the particular isometric form of the ethylidene substituent attached at the carbon 2 position should be added to the nomenclature. For example, if the methyl group of the ethylidene substituent is in its (E) configuration, then the term “2(E)” should be included in each of the named compounds. If the methyl group of the ethylidene substituent is in its (Z) configuration, then the term “2(Z)” should be included in each of the named compounds. In addition, if the methyl group attached at the carbon 20 position is in its epi or unnatural configuration, the term “20(S)” or “20-epi” should be included in each of the following named compounds. Also, if the side chain contains an oxygen atom substituted at any of positions 20, 22 or 23, the term “20-oxa”, “22-oxa” or “23-oxa”, respectively, should be added to the named compound. The named compounds could also be of the vitamin D 2 or D 4 type if desired.
[0035] Specific and preferred examples of the 2-ethylidene-compounds of structure I when the side chain is unsaturated are:
2-ethylidene-19-nor-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethylidene-19-nor-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethylidene-19-nor-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamn D 3 ; 2-ethylidene-19-nor-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethylidene-19-nor-26,27-dimethyl-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethylidene-19-nor-26,27-dimethyl-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethylidene-19-nor-26,27-dimethyl-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethylidene-19-nor-26,27-diethyl-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethylidene-19-nor-26,27-diethyl-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethylidene-19-nor-26,27-diethyl-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethylidene-19-nor-26,27-dipropoyl-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethylidene-19-nor-26,27-dipropyl-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; and 2-ethylidene-19-nor-26,27-dipropyl-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3.
[0049] With respect to the above unsaturated compounds, it should be noted that the double bond located between the 22 and 23 carbon atoms in the side chain may be in either the (E) or (Z) configuration. Accordingly, depending upon the configuration, the term “22,23(E)” or “22,23(Z)” should be included in each of the above named compounds. Also, it is common to designate the double bond located between the 22 and 23 carbon atoms with the designation “Δ 22 ”. Thus, for example, the first named compound above could also be written as 2-ethylidene-19-nor-22,23(E)-Δ 22 -1,25-(OH) 2 D 3 where the double bond is in the (E) configuration. Similarly, if the methyl group attached at carbon 20 is in the unnatural configuration, this compound could be written as 2-ethylidene-19-nor-20(S)-22,23(E)-Δ 22 -1,25-(OH) 2 D 3 .
[0050] Specific and preferred examples of the 2-ethylidene-compounds of structure I when the side chain is saturated are:
2-ethylidene-19-nor-1,25-dihydroxyvitamin D 3 ; 2-ethylidene-19-nor-24-homo-1,25-dihydroxyvitamin D 3 ; 2-ethylidene-19-nor-24-dihomo-1,25-dihydroxyvitamin D 3 ; 2-ethylidene-19-nor-24-trihomo-1,25-dihydroxyvitamin D 3 ; 2-ethylidene-19-nor-26,27-dimethyl-24-homo-1,25-dihydroxyvitamin D 3 ; 2-ethylidene-19-nor-26,27-dimethyl-24-dihomo-1,25-dihydroxyvitamin D 3 ; 2-ethylidene-19-nor-26,27-dimethyl-24-trihomo-1,25-dihydroxyvitamin D 3 ; 2-ethylidene-19-nor-26,27-diethyl-24-homo-1,25-dihydroxyvitamin D 3 ; 2-ethylidene-19-nor-26,27-diethyl-24-dihomo-1,25-dihydroxyvitamin D 3 ; 2-ethylidene-19-nor-26,27-diethyl-24-trihomo-1,25-dihydroxyvitamin D 3 ; 2-ethylidene-19-nor-26,27-dipropyl-24-homo-1,25-dihydroxyvitamin D 3 ; 2-ethylidene-19-nor-26,27-dipropyl-24-dihomo-1,25-dihydroxyvitamin D 3 ; and 2-ethylidene-19-nor-26,27-dipropyl-24-trihomo-1,25-dihydroxyvitamin D 3 .
[0064] As noted previously, the above saturated side chain compounds should have the appropriate 2(E) or 2(Z) configuration and/or carbon 20 configuration added to the nomenclature. For example, particularly preferred compounds are:
19-nor-2(E)-ethylidene-1α,25-dihydroxyvitamin D 3 ; 19-nor-2(Z)-ethylidene-1α,25-dihydroxyvitamin D 3 ; 19-nor-2(E)-ethylidene-20(S)-1α,25-dihydroxyvitamin D 3 ; and 19-nor-2(Z)-ethylidene-20(S)-1α,25 -dihydroxyvitamin D 3 .
[0069] In the following lists of compounds, the particular isometric form of the ethyl substituent attached at the carbon 2 position should be added to the nomenclature. For example, if the ethyl group is in the alpha configuration, the term “2α-methyl” should be included in each of the named compounds. If the ethyl group is in the beta configuration, the term “2β-ethyl” should be included in each of the named compounds. In addition, if the methyl group attached at the carbon 20 position is in its epi or unnatural configuration, the term “20(S)” or “20-epi” should be included in each of the following named compounds. Also, if the side chain contains an oxygen atom substituted at any of positions 20, 22 or 23, the term “20-oxa,” “22-oxa” or “23-oxa,” respectively, should be added to the named compound. The named compounds could also be of the vitamin D 2 or D 4 type if desired.
[0070] Specific and preferred examples of the 2-ethyl-compounds of structure II when the side chain is unsaturated are:
2-ethyl-19-nor-1,25-dihydroxy-22,23 -dehydrovitamin D 3 ; 2-ethyl-19-nor-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethyl-19-nor-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethyl-19-nor-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethyl-19-nor-26,27-dimethyl-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethyl-19-nor-26,27-dimethyl-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethyl-19-nor-26,27-dimethyl-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethyl-19-nor-26,27-diethyl-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethyl-19-nor-26,27-diethyl-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethyl-19-nor-26,27-diethyl-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethyl-19-nor-26,27-dipropoyl-24-homo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; 2-ethyl-19-nor-26,27-dipropyl-24-dihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3 ; and 2-ethyl-19-nor-26,27-dipropyl-24-trihomo-1,25-dihydroxy-22,23-dehydrovitamin D 3.
[0084] With respect to the above unsaturated compounds, it should be noted that the double bond located between the 22 and 23 carbon atoms in the side chain may be in either the (E) or (Z) configuration. Accordingly, depending upon the configuration, the term “22,23(E)” or “22,23(Z)” should be included in each of the above named compounds. Also, it is common to designate the double bond located between the 22 and 23 carbon atoms with the designation “Δ 22 ”. Thus, for example, the first named compound above could also be written as 2-ethyl-19-nor-22,23(E)-Δ 22 -1,25-(OH) 2 D 3 where the double bond is in the (E) configuration. Similarly, if the methyl group attached at carbon 20 is in the unnatural configuration, this compound could be written as 2-ethyl-19-nor-20(S)-22,23(E)- Δ 22 -1,25-(OH) 2 D 3 .
[0085] Specific and preferred examples of the 2-ethyl-compounds of structure II when the side chain is saturated are:
2-ethyl-19-nor-1,25-dihydroxyvitamin D 3 ; 2-ethyl-19-nor-24-homo-1,25-dihydroxyvitamin D 3 ; 2-ethyl-19-nor-24-dihomo-1,25-dihydroxyvitamin D 3 ; 2-ethyl-19-nor-24-trihomo-1,25-dihydroxyvitamin D 3 ; 2-ethyl-19-nor-26,27-dimethyl-24-homo-1,25-dihydroxyvitamin D 3 ; 2-ethyl-19-nor-26,27-dimethyl-24-dihomo-1,25-dihydroxyvitamin D 3 ; 2-ethyl-19-nor-26,27-dimethyl-24-tihomo-1,25-dihydroxyvitamin D 3 ; 2-ethyl-19-nor-26,27-diethyl-24-homo-1,25-dihydroxyvitamin D 3 ; 2-ethyl-19-nor-26,27-diethyl-24-dihomo-1,25-dihydroxyvitamin D 3 ; 2-ethyl-19-nor-26,27-diethyl-24-trihomo-1,25-dihydroxyvitamin D 3 ; 2-ethyl-19-nor-26,27-dipropyl-24-homo-1,25-dihydroxyvitamin D 3 ; 2-ethyl-19-nor-26,27-dipropyl-24-dihomo-1,25-dihydroxyvitamin D 3 ; and 2-ethyl-19-nor-26,27-dipropyl-24-trihomo-1,25-dihydroxyvitamin D 3 .
[0099] As noted previously, the above saturated side chain compounds should have the appropriate 2α- or 2β- configuration and/or carbon 20 configuration added to the nomenclature. For example, particularly preferred compounds are:
19-nor-2α-ethyl-1α,25-dihydroxyvitamin D 3 ; 19-nor-2β-ethyl-1α,25-dihydroxyvitamin D 3 ; 19-nor-20(S)-2α-ethyl-1α,25-dihydroxyvitamin D 3 ; and 19-nor-20(S)-2β-ethyl-1α,25-dihydroxyvitamin D 3 .
[0104] The preparation of 2-ethylidene-19-nor-vitamin D compounds, and the 2-ethyl-19-nor-vitamin D compounds, having the basic structure I and II can be accomplished by a common general method, i.e. the condensation of a bicyclic Windaus-Grundmann type ketone III with the allylic phosphine oxide IVa or IVb to the corresponding 2-ethylidene-19-nor-vitamin D analogs Va or Vb, respectively followed by a selective reduction of the ethylidene group at C-2 to the corresponding 2-ethyl compounds.
In the structures III, IV, and V groups Y 1 and Y 2 and R represent groups defined above; Y 1 and Y 2 are preferably hydroxy-protecting groups, it being also understood that any functionalities in R that might be sensitive, or that interfere with the condensation reaction, be suitable protected as is well-known in the art. The process shown above represents an application of the convergent synthesis concept, which has been applied effectively for the preparation of vitamin D compounds [e.g. Lythgoe et al., J. Chem. Soc. Perkin Trans. I, 590 (1978); Lythgoe, Chem. Soc. Rev. 9, 449 (1983); Toh et al., J. Org. Chem. 48, 1414 (1983); Baggiolini et al., J. Org. Chem. 51, 3098 (1986); Sardina et al., J. Org. Chem. 51, 1264 (1986); J. Org. Chem. 51, 1269 (1986); DeLuca et al., U.S. Pat. No. 5,086,191; DeLuca et al., U.S. Pat. No. 5,536,713].
[0105] Hydrindanones of the general structure III are known, or can be prepared by known methods. Specific important examples of such known bicyclic ketones are the structures with the side chains (a), (b), (c) and (d) described above, i.e. 25-hydroxy Grundmann's ketone (f) [Baggiolini et al., J. Org. Chem, 51, 3098 (1986)]; Grundmann's ketone (g) [Inhoffen et al., Chem. Ber. 90, 664 (1957)]; 25-hydroxy Windaus ketone (h) [Baggiolini et al., J. Org. Chem., 51, 3098 (1986)] and Windaus ketone (i) [Windaus et al., Ann., 524, 297 (1936)]:
[0106] For the preparation of the required phosphine oxides of general structure IV, a new synthetic route has been developed starting from methyl quinicate derivative 9, easily obtained from commercial (1R,3R,4S,5R)-(−)-quinic acid 8 as described by Perlman et al., Tetrahedron Lett. 32, 7663 (1991) and DeLuca et al., U.S. Pat. No. 5,086,191. The overall process of transformation of the starting methyl ester 9 into the desired A-ring synthons, is summarized by the Scheme I. Reduction of the ester 9 with diisobutylaluminum hydride (DIBALH) or other suitable reducing agent (e.g. lithiumn aluminum hydride) provided the diol 10 which was subsequently oxidized by sodium periodate to the cyclohexanone ketone derivative 11. Then, the secondary 4-hydroxyl group of 11 was oxidized with RuO 4 (a catalytic method with RuC1 3 and NaIO 4 as co-oxidant). Use of such a strong oxidant was necessary for an effective oxidation process of this very hindered hydroxyl. However, other more commonly used oxidants can also be applied (e.g. pyridinium dichromate), although the reactions usually require much longer time for completion. The next step of the process comprises the Peterson reaction of the ketone 12 with methyl(trimethylsilyl)acetate to form ester 13.
[0107] Referring now to Scheme 2, the next step of the synthesis comprises the Wittig reaction of the sterically hindered 4-keto compound 13 with ylide prepared from ethyltriphenylphosphonium bromide and n-butyllithium leading to ethylidene compounds 14 and 15. Ethylidene compounds 14 and 15 in turn were treated with diisobutylaluminum hydride and the formed alcohols 16 and 17 were in turn transformed to the desired A-ring phosphine oxides 18 and 19. Conversion of 16 and 17, to 18 and 19, respectively involved 3 steps, namely, in situ tosylation with n-butyllithium and p-toluenesulfonyl chloride, followed by reaction with diphenylphosphine lithium salt and oxidation with hydrogen peroxide.
[0108] Several 2-ethylidene-19-nor-vitamin D compounds of the general structure V may be synthesized using the A-ring synthons 18 and 19 and the appropriate Windaus-Grundmann ketone III having the desired side chain structure. Thus, for example, Scheme 3 illustrates that Wittig-Horner coupling of the phosphinoxy 18 with the protected 25-hydroxy Grundmann's ketone 20 prepared according to published procedure [Sicinski et al., J. Med. Chem. 37, 3730 (1994)] gave the expected protected vitamin compound 21. This, after deprotection afforded 1α,25-dihydroxy-2(E)-ethylidene-19-nor-vitamin D 3 (4a). Similarly, Scheme 3 illustrates the synthesis of 1α,25-dihydroxy-2(Z)-ethylidene-19-nor-vitamin D 3 (5a) from phosphinoxy 19 and Grundmann's ketone 20.
[0109] Referring now to Scheme 6, the final step of the process was the selective homogeneous catalytic hydrogenation of the ethylidene unit at carbon 2 in the vitamins 4a and 5a performed efficiently in the presence of tris(triphenylphosphine)rhodium(I) chloride [Wilkinson's catalyst, (Ph 3 P) 3 RhCl]. Such reduction conditions allowed to reduce only C(2)═CH 2 unit leaving C(5)-C(8) butadiene moiety unaffected. The isolated material is an epimeric mixture (ca. 1:1) of 2-ethyl-19-nor-vitamins 6a and 7a differing in configuration at C-2. The mixture can be used without separation or, if desired, the individual 2α- and 2β-isomers can be separated by an efficient HPLC system.
[0110] The C-20 epimerization may be accomplished by the analogous coupling of the phosphine oxides 18 and 19 with protected 20(S)-25-hydroxy Grundmann's ketone 26 (Scheme 5) which after hydrolysis of the hydroxy-protecting groups gave 20(S)-1α,25-dihydroxy-2-ethylidene-19-nor-vitamin D 3 compounds 4b and 5b. Hydrogenation of 4b and 5b provided the expected mixture of the 2-ethyl-19-nor-vitamin D analogs 6b and 7b.
[0111] As noted above, other 2-ethylidene and 2-ethyl-19-nor-vitamin D analogs may be synthesized by the method disclosed herein. For example, 1α-hydroxy-2-ethylidene-19-nor-vitamin D 3 can be obtained by providing the Grundmann's ketone (g). Subsequent reduction of the A-ring ethylidene group in the formed compound can also give the corresponding epimeric mixture of 1α-hydroxy-2-ethyl-19-nor-vitamin D 3 compounds.
[0112] A number of oxa-analogs of vitamin D 3 and their synthesis are also known. For example, 20-oxa analogs are described in N. Kubodera at al, Chem. Pharm. Bull., 34, 2286 (1986), and Abe et al, FEBS Lett. 222, 58, 1987. Several 22-oxa analogs are described in E. Murayama et al, Chem. Pharm. Bull., 34, 4410 (1986), Abe et al, FEBS Lett., 226, 58 (1987), PCT International Application No. WO 90/09991 and European Patent Application, publication number 184 112, and a 23-oxa analog is described in European Patent Application, publication number 78704, as well as U.S. Patent 4,772,433.
[0113] This invention is described by the following illustrative examples. In these examples specific products identified by Arabic numerals (e.g. 1, 2, 3, etc) refer to the specific structures so identified in the preceding description and in the Schemes.
EXAMPLE 1
Chemistry
[0114] The strategy of the synthesis of 2-substituted 19-norvitamins was based on Lythgoe-type Wittig-Horner coupling. Since the corresponding C,D-ring ketones were available, attention was focused on the synthesis of the phosphine oxide A-ring synthons (Scheme 1 and 2). Configurations of the ethylidene unit at C′-4 in the isomeric compounds 16, 17 ( FIG. 2 ) and 17, 18, as well as their preferred conformations, were determined by analysis of 1 H NMR spectra, NOE measurements and spin decoupling experiments.
[0115] The Wittig-Horner reaction of the conjugate base of 20 with the protected 25-hydroxy Grundmann's ketone 20 produced 19-norvitamin D compound 21 in a very high yield, i.e. 91% (Scheme 3), but the yield of an analogous coupling of the isomeric phosphine oxide 19 was very low, i.e. 13%. The obtained condensation products 21 and 22, following deprotection, gave 2-ethylidene-19-norvitamins 4a and 5a. Considering the low yield of the Wittig reaction of the cyclohexanone 13, leading to ethylidene compounds 14 and 15 (Scheme 2), an alternative synthetic approach was sought.
[0116] Thus, the carbonyl group in 13 was protected as O-trimethylsilyl hemimethylthioketal and the corresponding phosphine oxides 25 were efficiently synthesized (Scheme 4). Coupling of their anions with the hydrindanone 26 (Scheme 5) afforded the protected 19-norvitamin D compound 27 in a high yield. This, after deprotection of 2-oxo group, Wittig reaction and subsequent hydrolysis was converted to (20S)-2-ethylidene-19-norvitamins 4b and 5b. The selective catalytic hydrogenation of 2-ethylidene analogs 4a, b and 5a, b (Scheme 6) provided the corresponding 2-ethyl-19-norvitamins 6a, b and 7a, b, which were easily separated by HPLC.
[0117] Stereochemistry at C-2 in the synthesized vitamin D compounds was tentatively assigned on the basis of conformational analysis, molecular modeling studies, and 500 MHz 1 H NMR spectroscopy.
EXAMPLE 2
Conformational Analysis
[0118] It has been established that vitamin D compounds in solutions exist as a mixture of two rapidly equilibrating A-ring chair conformers abbreviated as α- and β-forms ( FIG. 3 a ). Presence of bulky 2-alkyl substituents, characterized by large conformational free energy A values ( FIG. 3 b ), shifts the A-ring conformational equilibrium of the synthesized 2-ethyl-19-norvitamins toward the conformers with the equatorial C(2)-substituents. In the obtained 2-ethylidene-19-norvitamin D compounds, an additional strong interaction (designated as A (1,3) -strain, FIG. 3 c ) is involved, existing between the methyl group from the ethylidene moiety and equatorial hydroxyls at C-1 or C-3. It results in the strong bias toward conformers with an axial orientation of this hydroxy group to which the methyl from ethylidene fragment is directed.
[0119] Conformational equilibrium in ring A of 2-methylene-19-norvitamin 2 (a) and the preferred, energy minimized (PC MODEL 6.0, Serena Software) A-ring conformations of the synthesized analogs: 4a, b (b), 5a, b (c), 6a, b (d) and 7a, b (e) are shown in FIG. 4 . The steric energy differences between the preferred conformers and their partners with the inverted chair forms (calculated for model compounds lacking side chain) are given. The corresponding percentage populations (in parentheses) of conformers are given for room temperature (25° C.).
EXAMPLE 3
Biological Evaluation
[0120] The synthesized vitamins were tested for their ability to bind the porcine intestinal vitamin D receptor. The presented results ( FIG. 5 a ) indicate that 2-ethylidene-19-norvitamins, possessing methyl group from ethylidene moiety directed toward C-3, i.e. trans in relation to C(6)-C(7) bond (isomers E), are more active than 1α,25-(OH) 2 D 3 in binding to VDR, whereas their counterparts with cis relationship between ethylidene methyl substituent and C(7)-H group (isomers Z) exhibit significantly reduced afnnity for the receptor. The competitive binding analysis showed also that 2α-ethyl-19-norvitamins bind the receptor better than their isomers with 2β-ethyl substituents ( FIG. 5 b ). In the next assay, the cellular activity of the synthesized compounds was established by studying their ability to induce differentiation of human promyelocyte HL-60 cells into monocytes. E isomer of (20S)-2-ethylidene-19-norvitamin D 3 ( FIG. 6 a ) and both-2α-ethyl-19-norvitamins ( FIG. 6 b ) are more potent than 1α,25-(OH) 2 D 3 in this assay, whereas the remaining tested compounds are almost equivalent to the hormone.
[0121] Both E isomers of 2-ethylidene-19-norvitamins, when tested in vivo in rats (Table 1) exhibited very high calcemic activity, the (20S)-compound being especially potent. On the contrary, isomeric Z compounds are significantly less active. 2-ethyl-19-norvitamins have some ability to mobilize calcium from bone but not to the extent of the hormone 1, while being inactive in intestine. The only exception is 2α-ethyl isomer from 20S-series that shows strong calcium mobilization response and marked intestinal activity.
TABLE 1 Support of Intestinal Calcium Transport and Bone Calcium Mobilization By 2-Substituted Analogs of 1α,25-Dihydroxy-19-norvitamin D 3 In Vitamin D-Deficient Rats on a Low-Calcium Diet a Ca transport Serum Ca compd. amount S/M (mean ± (mean ± compound no. (pmol) SEM) SEM) none (control) 0 3.0 ± 0.7 4.3 ± 0.1 1α,25-(OH) 2 D 3 1 130 5.5 ± 0.5 5.1 ± 0.3 260 5.9 ± 0.4 5.8 ± 0.3 2-ethylidene-19-nor- 4a 65 5.0 ± 0.4 4.5 ± 0.1 1α,25-(OH) 2 D 3 (E- 130 6.8 ± 0.4 5.2 ± 0.2 isomer) 2-ethylidene-19-nor- 5a 65 4.4 ± 0.4 4.4 ± 0.2 1α,25-(OH) 2 D 3 (Z- 130 5.7 ± 0.9 4.2 ± 0.0 isomer) none (control) 0 4.4 ± 0.2 4.1 ± 0.2 1α,25-(OH) 2 D 3 1 130 4.9 ± 0.7 5.2 ± 0.2 260 6.0 ± 0.9 6.4 ± 0.4 2-ethylidene-19-nor- 4b 65 9.0 ± 0.3 8.2 ± 0.3 (20S)-1α,25- 130 5.8 ± 0.8 12.1 ± 0.6 (OH) 2 D 3 (E-isomer) 2-ethylidene-19-nor- 5b 65 4.3 ± 0.7 4.0 ± 0.3 (20S)-1α,25- 130 3.8 ± 0.3 4.0 ± 0.1 (OH) 2 D 3 (Z-isomer) none (control) 0 3.8 ± 0.4 3.9 ± 0.1 1α,25-(OH) 2 D 3 1 260 6.5 ± 0.9 5.8 ± 0.1 2α-ethyl-19-nor- 6a 260 4.0 ± 0.4 5.1 ± 0.1 1α,25-(OH) 2 D 3 2β-ethyl-19-nor- 7a 260 3.7 ± 0.3 5.0 ± 0.1 1α,25-(OH) 2 D 3 2α-ethyl-19-nor- 6b 260 5.0 ± 0.4 7.0 ± 0.1 (20S)-1α,25-(OH) 2 D 3 2β-ethyl-19-nor- 7b 260 4.1 ± 0.3 5.6 ± 0.1 (20S)-1α,25-(OH) 2 D 3 a Weanling male rats were maintained on a 0.47% Ca diet for one week and then switched to a low-calcium diet containing 0.02% Ca for an additional three weeks. During the last week, they were dosed daily with the appropriate vitamin D compound for seven consecutive days. All doses were administered intraperitoneally in 0.1 mL propylene glycol/ethanol (95:5). Controls received the vehicle. Determinations were made 24 hours after the last dose. There were at least six rats per group.
[0122] For treatment purposes, the novel compounds of this invention defined by formula I and/or II may be formulated for pharmaceutical applications as a solution in innocuous solvents, or as an emulsion, suspension or dispersion in suitable solvents or carriers, or as pills, tablets or capsules, together with solid carriers, according to conventional methods known in the art. Any such formulations may also contain other pharmaceutically-acceptable and non-toxic excipients such as stabilizers, anti-oxidants, binders, coloring agents or emulsifying or taste-modifying agents.
[0123] The compounds may be administered orally, topically, parenterally, sublingually, intranasally, or transdermally. The compounds are advantageously administered by injection or by intravenous infusion or suitable sterile solutions, or in the form of liquid or solid doses via the alimentary canal, or in the form of creams, ointments, patches, or similar vehicles suitable for transdermal applications. Doses of from about 0.01 μg to about 100 μg per day, preferably from 0.1 μg to 50 μg per day of the compounds are appropriate for treatment purposes, such doses being adjusted according to the disease to be treated, its severity and the response of the subject as is well understood in the art. Since the new compounds exhibit specificity of action, each may be suitably administered alone, or together with graded doses of another active vitamin D compound—e.g. 1α-hydroxyvitamin D 2 or D 3 , or 1α,25-dihydroxyvitamin D 3 —in situations where different degrees of bone mineral mobilization and calcium transport stimulation is found to be advantageous.
[0124] Compositions for use in the above-mentioned treatment of psoriasis and other malignancies comprise an effective amount of one or more 2-substituted-19-nor-vitamin D compound as defined by the above formula I and/or II as the active ingredient, and a suitable carrier. An effective amount of such compounds for use in accordance with this invention is from about 0.0 μg to about 100 μg per gm of composition, and may be administered topically, transdermally, orally, sublingually, intranasally, or parenterally in dosages of from about 0.1 μg/day to about 100 μg/day.
[0125] The compounds may be formulated as creams, lotions, ointments, topical patches, pills, capsules or tablets, or in liquid form as solutions, emulsions, dispersions, or suspensions in pharmaceutically innocuous and acceptable solvent or oils, and such preparations may contain in addition other pharmaceutically innocuous or beneficial components, such as stabilizers, antioxidants, emulsifiers, coloring agents, binders or taste-modifying agents.
[0126] The compounds are advantageously administered in amounts sufficient to effect the differentiation of promyelocytes to normal macrophages. Dosages as described above are suitable, it being understood that the amounts given are to be adjusted in accordance with the severity of the disease, and the condition and response of the subject as is well understood in the art.
[0127] The formulations of the present invention comprise an active ingredient in association with a pharmaceutically acceptable carrier therefore and optionally other therapeutic ingredients. The carrier must be “acceptable” in the sense of being compatible with the other ingredients of the formulations and not deleterious to the recipient thereof.
[0128] Formulations of the present invention suitable for oral administration may be in the form of discrete units as capsules, sachets, tablets or lozenges, each containing a predetermined amount of the active ingredient; in the form of a powder or granules; in the form of a solution or a suspension in an aqueous liquid or non-aqueous liquid; or in the form of an oil-in-water emulsion or a water-in-oil emulsion.
[0129] Formulations for rectal administration may be in the form of a suppository incorporating the active ingredient and carrier such as cocoa butter, or in the form of an enema.
[0130] Formulations suitable for parenteral administration conveniently comprise a sterile oily or aqueous preparation of the active ingredient which is preferably isotonic with the blood of the recipient.
[0131] Formulations suitable for topical administration include liquid or semi-liquid preparations such as liniments, lotions, applicants, oil-in-water or water-in-oil emulsions such as creams, ointments or pastes; or solutions or suspensions such as drops; or as sprays.
[0132] For asthma treatment, inhalation of powder, self-propelling or spray formulations, dispensed with a spray can, a nebulizer or an atomizer can be used. The formulations, when dispensed, preferably have a particle size in the range of 10 to 100μ.
[0133] The formulations may conveniently be presented in dosage unit form and may be prepared by any of the methods well known in the art of pharmacy. By the term “dosage unit” is meant a unitary, i.e. a single dose which is capable of being administered to a patient as a physically and chemically stable unit dose comprising either the active ingredient as such or a mixture of it with solid or liquid pharmaceutical diluents or carriers.
[0134] In its broadest application, the present invention relates to any 19-nor-analog of vitamin D which have the vitamin D nucleus. By vitamin D nucleus, it is meant a central part consisting of a substituted chain of five carbon atoms which correspond to positions 8, 14, 13, 17 and 20 of vitamin D, and at the ends of which are connected at position 20 a structural moiety representing any of the typical side chains known for vitamin D type compounds (such as R as previously defined herein), and at position 8 the 5,7-diene moiety connected to the A-ring of an active 1α-hydroxy vitamin D analog (as illustrated by formula I herein). Thus, various known modifications to the six-membered C-ring and the five-membered D-ring typically present in vitamin D, such as the lack of one or the other or both, are also embraced by the present invention.
|
Biologically active 19-nor vitamin D analogs substituted at C-2 in the A-ring with an ethylidene or an ethyl group. These compounds have preferential activity on mobilizing calcium from bone and either high or normal intestinal calcium transport activity which allows their in vivo administration for the treatment of metabolic bone diseases where bone loss is a major concern. These compounds are also characterized by high cell differentiation activity.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to sewing apparatus, and more particularly, apparatus for delivering, folding, and stitching belt loops to a garment.
2. Description of the Prior Art
Heretofore, it was common for belt loops to be sewn directly to the outside of work clothes, such as jeans. The individual loops were taken by a sewing machine operator, folded at opposite longitudinal ends, and stitched on their outside to the jeans. The manual handling of the individual loops and positioning of the same on the jeans is a time-consuming, production reducing process.
The apparatus of the present invention delivers the belt loops, folds them at their opposite longitudinal ends, and stitches them to the outside of the garment at the opposite longitudinally folded ends, all automatically, thereby reducing valuable production time and operator tedium associated with sewing belt loops to a garment.
In my prior patent, U.S. Pat. No. 4,034,690 issued July 12, 1977 entitled "Apparatus and Method for Forming Belt Loops", I disclose an apparatus and method for making belt loops from discrete, pre-sized plies of fabric material. The loops are collated in a bundle or spool so that they can be removed and sewn to garment pieces cut from adjacent areas on a fabric lay to maintain the same shading characteristics of the component pieces of the garment throughout its construction. The apparatus and method for collating and bundling the belt loops is disclosed in my prior patents, U.S. Pat. No. 4,149,709 issued Apr. 17, 1979 entitled "Apparatus and Method for Collating and Bundling Belt Loops" and U.S. Pat. No. 4,135,707 issued Jan. 23, 1979, also entitled "Apparatus and Method for Collating and Bundling Belt Loops".
The present apparatus is specifically adapted to remove the individual belt loops from the collated spool bundle, deliver them to a folder which folds their opposite ends, and then sews them to the exterior of a garment. While the apparatus is specifically adapted to operate with such a spool bundle, it will be obvious from the following disclosure that the apparatus can be used to deliver, fold and stitch any discrete one or more belt loops to a garment such as a pair of jeans, regardless of their source and the manner in which they are formed.
SUMMARY OF THE INVENTION
The apparatus of the present invention includes a conveyor handling section for feeding individual loops to a folder and sewing head. The spool bundle of belt loops is loaded onto a reel positioned above the conveyor, which comprises an endless belt. The spool includes a thread which is used to unwind the spool and deposit the loops wound on the spool onto the conveyor belt at spaced locations. The thread on the spool is fed down the middle of the conveyor belt and underneath the conveyor, through a loop guide which turns it ninety degrees, and is then wound upon a motorized spindle. Turning of the spindle pulls the thread and unwinds the loops from the spool and causes them to seat upside down at spaced locations on the conveyor belt.
The conveyor feeds the loops past a guide member mounted on at the front of the conveyor which causes the individual loops on the conveyor to be serially turned rightside up and deposited on a reciprocable L-shaped slide mounted beneath the conveyor. The L-shaped slide is provided with channel-shaped transverse ends. As each loop is deposited on the slide, a microswitch is activated, stopping the motorized spindle. At the desired time, the slide moves forward into mating engagement with a plastic block having an open front and open transverse ends. The slide, upon mating with the block, closes the front of the block forming a housing for the loop deposited on the slide. A pulse of air is then transmitted transversely through the channel ends of the slide and housing enclosure formed by the block and slide, or ninety degrees to the direction of movement of the slide, to move the loop and complete its delivery to a folding mechanism.
The loop is blown through the channel formed in one transverse end of the housing onto a platform on one end of a slidable plate, reciprocably mounted in a support plate. A cam-actuated folding mechanism then folds each transverse end of the individual belt loop back upon itself.
The folding mechanism includes a cam plate reciprocably movable in a slot on the slidable plate by an air cylinder mounted beneath the plate. The cam plate has a pair of elongated spiral slots each of which receives a cam follower mounted on an elongated rod. The rods are parallel to each other and have a folder at one end. The opposite end of each rod is mounted on an upright block fixed to the slidable plate in the support plate. Movement of the cam plate forwardly by the piston of the air cylinder causes rotation of the relatively stationary rods via the camming action between the cam followers on each rod and the camming slots on the movable cam plate. This causes downwardly projecting fingers on the end of each folder to pivot inwardly about the belt loop to turn each end of the belt loop on the platform in front of the folding mechanism back upon itself.
Continued forwrd movement of the cam plate will cause it to contact a stop positioned in the slot in the slidable plate in front of the cam plate. This stop is connected to the slidable plate so that continued movement of the air cylinder piston will cause the entire folder mechanism supported on the slidable plate to move forwardly along with the cam plate. This causes the platform holding the folded belt loop forward and the loop is deposited beneath the foot of a sewing head or tacker. A clamp associated with the tacker is pivoted downwardly to clamp the folded belt loop beneath the foot of the tacker.
The motion of the air cylinder associated with the folding mechanism is then reversed. This causes the cam plate to reverse its direction of movement and retract. Retraction of the cam plate in the slot in the slidable plate first causes the rods holding the folder fingers to rotate back to their initial position, through the camming action between the followers on the relatively stationary rods and spiral slots on the relatively movable cam plate resulting in dropping of the loop. Continued rearward movement of the cam plate in the slot in the slidable plate causes the cam plate to strike a second stop in the rear of the slot in the slidable plate to then move the slidable plate and folder mechanism assembly back to its initial position to receive another belt loop.
One transverse end of the loop is then sewn or tacked to a garment positioned beneath the sewing head or tacker. After this sewing operation is completed, a second air cylinder associated with the tacker has its piston moved horizontally to move the loop and its entire support platform beneath the foot of the tacker forwardly, to reposition the opposite transverse end of the loop beneath the sewing head of the tacker. The opposite transverse end of the loop is then sewn to the garment.
The downwardly pivotable clamp is then released so that the garment can be removed from beneath the tacker with the sewn loop on it and repositioned to receive the next loop. The platform associated with the tacker is then retracted by the horizontal air cylinder associated with the tacker to be realigned with the folder so as to be in a position to receive a subsequent loop for tacking to the garment.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the invention will become apparent from the following description and claims, and from the accompanying drawings, wherein:
FIG. 1 is a perspective view of the automatic belt loop tacker apparatus of the present invention;
FIG. 2 is a schematic perspective view illustrating the folding and tacking of a belt loop utilizing the apparatus of FIG. 1;
FIG. 3 is a top plan view of the apparatus of FIG. 1;
FIG. 4 is a cross-sectional view of the apparatus taken substantially along the plane indicated by line 4--4 of FIG. 3;
FIG. 5 is a cross-sectional view of the apparatus of the present invention taken substantially along the plane indicated by line 5--5 of FIG. 3;
FIG. 6 is a view similar to FIG. 5, but in a different position of operation and use;
FIG. 7 is a cross-sectional view taken substantially along the plane indicated by line 7--7 of FIG. 5; and
FIG. 8 is a cross-sectional view of the apparatus taken substantially along the plane indicated by line 8--8 of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail, wherein like numerals indicate like elements throughout the several views, the automatic belt loop tacker apparatus of the present invention is indicated in FIG. 1 by the numeral 10.
Apparatus 10 includes an endless conveyor belt 12 supported in spaced relation above a main support plate 14 by a plurality of threaded posts 16 and 18. The posts 16 and 18 are received in ears 20 connected to a rectangular frame 22 for the conveyor belt 12. Endless conveyor belt 12 is entrained about rollers 24 and 26 connected to the opposite ends of the rectangular framework 22.
An arm 28 is pivotably mounted on framework 22 and carries a spool support at its opposite end consisting of a block 30 mounting a pair of spring fingers 32 and 34 which form a V-shaped configuration when viewed in side elevation. A spool of belt loops 36 wound on a core 38 is inserted over the V-shaped spring fingers 32 and 34 which retains them on arm 28 above the surface of conveyor belt 12.
The individual belt loops 40 on spool 36 are retained wound about core 38 between a tape 42 and a thread 44. When the spool 36 is placed upon the spring fingers 32 and 34, the thread 44 is unwound and run down the center of the conveyor. The thread 44 is positioned beneath the conveyor and enters a guide (not shown) which bends it at an angle. The end of the thread 44 is wound about a motorized spindle 46 which extends upwardly through support plate 14.
Rotation of the spindle in a clockwise direction as viewed in FIG. 1, will wind the thread 44 upon the spindle 46 at the same time unwinding the spool of belt loops 36 and depositing the individual loops in spaced relation along the top run of belt 12. The frictional contact between thread 44 and the top run of conveyor 12 causes the conveyor 12 to move about idler rollers 24 and 26 on frame 22.
The individual belt loops 40 are deposited on the top run of conveyor 12 upside down. The conveyor 12 feeds each individual belt loop 40 past an angular guide member 48 consisting of a pair of arcuate fingers 50 and 52 at the front of the conveyor 12. The arcuate fingers 50 and 52 are connected together by a rod 54 mounted on an upright post 56 carried by one side member of frame 22. The guide fingers 50 and 52 cause each individual belt loop 40 to be turned right-side up about the front of conveyor 12 and deposited on an L-shaped plate 58 reciprocably slidable on support plate 14 by means of an air cylinder 60 mounted beneath the plate 14.
Air cylinder 60 has a piston 62 connected to a slide rod 64 slidable within an elongated slot 66 formed in plate 14 beneath conveyor belt 12. Slide rod 64 is connected at its opposite end to L-shaped slide plate 58 onto which each individual belt loop 40 is deposited. L-shaped slide plate 58 includes a channel member 68 at each end for a purpose which will be described hereinafter.
The deposit of the belt loop 40 from conveyor 12 onto the L-shaped slide plate 58 actuates a microswitch (not shown). The switch stops rotation of the motorized spindle. Air cylinder 60 is then actuated to move piston 62 forward as indicated in phantom lines in FIG. 4, sliding plate 58 forwardly towards a plastic block 70 mounted on the front end of plate 14. Slide plate 58 encloses the space between block 70 and the top support plate 14 so as to form with the block and support plate an enclosure having open lateral ends defined by opposed transverse channels 68 on slide plate 58.
When belt loop 40 is placed within the enclosure formed by block 70 and slide plate 58, a pulse of air is transmitted through a conduit 72 into the enclosure through one channel 68 to push the belt loop 40 laterally through the opposite channel 68 onto a support platform 73 mounted on the front of a slidable support plate 80 in main support plate 14, which carries a folder mechanism 75. The belt loop 40 is now positioned ready to have its transverse ends folded prior to being tacked to a garment.
The folder mechanism 75 includes a pair of parallel, spaced rods 74 and 76 fixed to a pair of spaced plates 78 on slide plate 80 on the left-hand side of support plate 14. Mounted on the forward end of each of the rods 74, 76 is a folder 84. Folder 84 includes a downwardly projecting substantially C-shaped plate for contact with opposite transverse ends of belt loop 40 supported on platform 73 to bend the ends of the belt loop back upon itself as illustrated in phantom in FIG. 7. In order to bend the belt loop 40 positioned on platform 73 back upon itself, the downwardly projecting C-shaped plates 84 must be rotated in opposite directions about the axis of its respective mounting rod 74, 76.
In order to rotate the C-shaped plates 84 about the axis of each of the rods 74, 76, each of the rods carry a cam follower 86 adjacent its rear end. Cam followers 86 comprise stube shafts or pintles welded or otherwise fixed to each of the rods 74, 76 and are positioned in a spiral wound groove 88 cut in opposite flanges 90 and 92 of a substantially U-shaped cam plate 94 fixed to a slide rod assembly 96 slidable in a groove 98 formed in the slide plate 80 and support plate 14. Cam plate 94 and slide 96 are movable by an air cylinder 99 mounted beneath support plate 14 having a piston rod 100 connected to slide assembly 96. The cam plate 94, rods 74, 76 and support blocks 78 are housed within a shield 102.
Upon retraction of the piston rod 100 of air cylinder 99, cam plate 94 and slide rod assembly 96 is moved forwardly in slot 98. Movement of the cam plate 94 in a forward direction causes cam follower pintles 86 on relatively stationary rods 74, 76 to travel rearwardly along spiral slots 88 in the flanges 90 and 92, respectively, in cam plate 94, which will rotate rod 76 in a counter clockwise direction and rod 74 in a clockwise direction, as viewed in FIG. 7, causing the downwardly projecting C-shaped folding plates 84 to contact the opposite transverse ends of the belt loop 40 on platform 73 to turn the transverse ends back upon itself. Cam plate 94 continues its forward movement until slide rod assembly 96 contacts a stop 104 (FIG. 6) connected to the bottom of plate 80 in its path of movement adjacent one end of groove 98. Continued retraction of piston rod 100 causes slide rod assembly 96 to contact stop 104, wich arrests further rotation of the rods 74 and 76. However, the stop 104 is fixed by threaded fasteners 106 to slide plate 80. Upon continued retraction of piston rod 100 and contact of slide rod assembly 96 with stop 104, the slide plate 80 is thrust forward to deliver the folded belt loop 40 beneath the foot 105 of a sewing machine tacker 108 (see phantom lines in FIG. 5).
The motion of the folder mechanism 75 is then reversed. However, prior to the motion being reversed, a vertical air cylinder having a piston 107 connected to a plate 109 fixed to an L-shaped clamp 110 adjacent the foot 105 of the sewing machine tacker 108 is activated to pivot the L-shaped clamp 110 into clamping engagement with the belt loop 40 deposited on platform 118 adjacent sewing machine tacker 108. The L-shaped clamp 110 holds the upper end of the loop. The foot 105 of the tacker 108 descends (see FIG. 3) to hold the lower end of the loop before extension of rod 100.
Once the belt loop 40 is deposited on platform 118 of the sewing machine 108 and clamped by L-shaped plate 110 and the foot 105 of the tacker, piston 100 of air cylinder 98 is extended. Extension of piston 100 causes rods 74 and 76 to first rerotate in a counter clockwise and clockwise manner, respectively, as viewed in FIG. 7 to release the folded belt loop 40. This is accomplished by cam plate 94 and slide rod assembly 96 moving to the right as viewed in FIGS. 5 and 6, causing cam plate 94 to move to the right leaving stop 104, while slide plate 80 is stationary. Movement of cam plate 94 to the right will cause relatively stationary cam follower pintles 86 on rods 74, 76 to follow grooves 88 to rotate the downwardly extending folder plates 84 in an opposite manner dropping the folded belt loops on platform 118 of the sewing machine 108. Continued movement of cam plate 94 to the right relative to rods 74, 76 will cause the cam plate 94 to contact a second stop 112 connected to slide plate 80 beneath the opposite end of slot 98, as shown in FIG. 5. Contact of cam plate 94 with the second stop 112 will return slide plate 80 to its initial position upon continued extension of piston 100.
With the folded belt loop 40 positioned on platform 118 of the sewing machine 108, the sewing machine needle N is adapted to tack one end of the folded loop 40 to the waist of a garment G draped between platform 118 and loop 40, as indicated in phantom in FIGS. 2 and 5. After tacking the same, the foot 105 is raised and a horizontal air cylinder 114 is activated to extend its piston 116 connected to platform 118. This repositions the opposite transverse end of the loop 40 beneath the needle N of the sewing machine 108 so that it can be tacked to the garment G. Retraction of pistons 116 and 107 and thus, clamp plate 110, enables the garment G to be repositioned by the operator to receive the next loop 40 to be tacked to the garment.
FIG. 2 summarizes the operation and process of the apparatus 10. Belt loops 40 are transported by conveyor belt 12 to L-shaped slide plate 58. Slide plate 58 moves the loops 40 into the enclosure formed by block 70 and L-shaped plate 58 wherein they are blown transversely onto platform 73 adjacent the folder apparatus. The ends of the belt loop 40 are folded by retraction of piston 100 causing the downwardly extending folder fingers 84 to fold the transverse ends of the loop 40 back upon itself. Slide rod assembly 96 is then moved forwardly in groove 98 until it abuts stop 104 to move the plate 80 forwardly to deposit the folded loop 40 on the platform 118 of the sewing machine 108 on the waist portion of garment G. After retraction of plate 80 and counter rotation of fingers 84 to drop loop 40 on platform 118, needle N is activated to tack one end of the folded loop to the garment. The vertical clamp plate 110 holds the loop to the garment after it has been deposited on the platform 118. Horizontal piston 116 is then extended to move the other transverse end of the loop 40 beneath needle N and it is also tacked to the garment.
|
Sewing apparatus for automatically feeding individual belt loops to a folding mechanism where opposite transverse ends of each of the belt loops is folded back upon itself. The loops are then delivered in tandem to a tacker where the folded ends are automatically stitched to a garment.
| 3
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a short-range wireless communication device such as a wireless USB (Universal Serial Bus).
[0003] 2. Description of the Related Art
[0004] Along with progress in the wireless technology, cable connection in the related art is more and more replaced by radio connection. For example, in the related art, a LAN (Local Area Network) is primarily connected using an Ethernet, typically, the IEEE 802.3 (the Institute of Electrical and Electronic Engineers 802.3) system. However, recently, more and more information communication apparatuses are typically connected using the IEEE 802.11 wireless LAN standard.
[0005] This is true not only for LANs, but also for PANs (Personal Area Network) for close range communications. A USB is a typical example. At the present time, since the USB can be used to configure an inexpensive and stable PAN, usage of the USB is widely spread. In order to further improve convenience of usage of the USB, a wireless USB is more and more required. It is expected that because of its characteristics, the wireless USB will be more and more in demand in the audio and video fields in the future.
[0006] A TDMA (Time Division Multiple Access) scheme is used in communication through the wireless USB. It is well-known that the TDMA scheme is used in a PHS (Personal Handy phone System). In the TDMA used for the PHS, however, since the time slot is fixed, if the data rate decreases due to errors, it is difficult to maintain QoS (Quality of Service). Thus, if the TDMA scheme used in the PHS is applied to the communication through the wireless USB, the communication quality may degrade. This is because the communication through the wireless USB is different from the audio communication (phone call) in the PHS, and it is expected that a large variety of applications requiring a large capacity and real-time QoS will be involved in communications through the wireless USB.
[0007] In the above-mentioned wireless LAN system, the concept of QoS is introduced in the IEEE 802 .lle standard to ensure a transmission rate. This technique is disclosed, for example, in Japanese Laid-open Patent Application No. 2005-252897 (hereinafter, referred to as “reference 1”), and Japanese Laid-open Patent Application No. 2004-512705 (hereinafter, referred to as “reference 2”). In the communications through the wireless USB, however, the technique of ensuring the QoS is not yet established.
[0008] The communication through the wireless USB is performed in a super-frame.
[0009] FIG. 1 is a data diagram illustrating a configuration of a super-frame for the communication through the wireless USB.
[0010] As shown in FIG. 1 , a super-frame is a time interval of 65 ms, which includes 256 MASs (Media Access Slot), each MAS being an elementary unit of a beacon period and a communication time slot. During the communication through the wireless USB, an arbitrary number of the MASs are occupied by the communication to constitute a DRP (Distributed Reservation Protocol), and data transmission and reception are carried out within the “communication-occupied period”. For example, Japanese Laid-open Patent Application No. 2004-364257 (hereinafter, referred to as “reference 3”) discloses a technique for efficiently allocating the DRP. The technique in reference 3, however, is related to mediation between applications at an upper level, which applications use the wireless USB, and this technique cannot meet the requirements of the QoS.
[0011] Japanese Laid-open Patent Application No. 11-146454 (hereinafter, referred to as “reference 4”) discloses a digital wireless communication system able to prevent communication failure caused by a busy state of a connection between a main phone and a cordless phone.
[0012] As described above, in the communications through the wireless USB, the technique of ensuring the QoS is not yet established, and it is difficult to carry out stable communications. In addition, most devices used in the communications through the wireless USB are driven by batteries, and thus it is desirable to reduce power consumption of devices used in the wireless USB communication system.
SUMMARY OF THE INVENTION
[0013] An embodiment of the present invention may solve one or more problems of the related art.
[0014] A preferred embodiment of the present invention may provide a short-range wireless communication device, such as a wireless USB, which is able to ensure QoS of a communication and reduce power consumption by controlling allocation of a period occupied by the communication and by controlling a communication rate within the period occupied by the communication.
[0015] According to a first aspect of the present invention, there is provided a short-range wireless communication device that receives or transmits beacons in a beacon period, arbitrarily allocates a communication-occupied interval in a super-frame between two adjacent beacon periods, and carries out a communication in the communication-occupied interval in conformity with a predetermined protocol, said short-range wireless communication device comprising:
[0016] a control unit that dynamically sets and changes a communication rate in the communication-occupied interval and a number of slots constituting the communication-occupied interval.
[0017] As an embodiment, the control unit refers to a table prepared beforehand in the short-range wireless communication device, changes allocation of the slots constituting the communication-occupied interval in response to the communication rate in the communication-occupied interval, and maintains a communication band to be constant.
[0018] As an embodiment, the control unit sets the allocation of the slots constituting the communication-occupied interval to be a possible minimum in response to the amount of data to be transmitted.
[0019] As an embodiment, the control unit changes the communication rate in the communication-occupied interval or the allocation of the slots constituting the communication-occupied interval in response to the distance to a device coupled to the short-range wireless communication device through a radio connection.
[0020] As an embodiment, the control unit changes transmission power in response to the distance to a device coupled to the short-range wireless communication device through a radio connection.
[0021] According to a second aspect of the present invention, there is provided a short-range wireless communication method, comprising the steps of receiving or transmitting beacons in a beacon period; arbitrarily allocating a communication-occupied interval in a super-frame between two adjacent beacon periods; carrying out a communication in the communication-occupied interval in conformity with a predetermined protocol; and dynamically setting and changing a communication rate in the communication-occupied interval and the number of slots constituting the communication-occupied interval.
[0022] According to the above present invention, it is possible to provide a short-range wireless communication device, such as a wireless USB, which is able to ensure QoS of a communication and reduce power consumption by controlling allocation of a period occupied by the communication and by controlling a communication rate within the period occupied by the communication.
[0023] These and other objects, features, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments given with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a data diagram illustrating a configuration of a super-frame for the communication through the wireless USB;
[0025] FIG. 2 is a block diagram illustrating a configuration of a wireless USB device according to a first embodiment of the present invention.
[0026] FIG. 3A through FIG. 3D illustrate examples of the DRP-link rate correction tables;
[0027] FIG. 4 is a block diagram illustrating a configuration of a wireless USB device according to a second embodiment of the present invention;
[0028] FIG. 5 is a data diagram illustrating a configuration of a super-frame according to the second embodiment of the present invention;
[0029] FIG. 6 is a block diagram illustrating a configuration of a wireless USB device according to a third embodiment of the present invention;
[0030] FIG. 7 illustrates an example of the distance table;
[0031] FIG. 8 is a block diagram illustrating a configuration of a wireless USB device according to a fourth embodiment of the present invention; and
[0032] FIG. 9 illustrates an example of the distance table.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Below, preferred embodiments of the present invention are explained with reference to the accompanying drawings.
First Embodiment
[0034] FIG. 2 is a block diagram-illustrating a configuration of a wireless USB device according to a first embodiment of the present invention.
[0035] The wireless USB device shown in FIG. 2 includes an upper layer application 1 which holds transmission data, such as a MPEG (Moving Picture Coding Expert Group) stream, a transmission band controller 2 which receives data from the upper layer application 1 and calculates a transmission band required for transmitting the received data, a link rate controller 3 which determines a link rate in a physical layer, a DRP allocation controller 4 which controls allocation of DRPs, a USB protocol controller 5 which receives and transmits logic data in a wireless USB and controls re-sending and various procedures, a multi-band OFDM processor (MODEM) 6 which forms the physical layer of the wireless USB and includes RF. (Radio Frequency) blocks, and an antenna 7 which receives and transmits radio electrical waves.
[0036] Below, descriptions are made of operations of the wireless USB device shown in FIG. 2 .
[0037] First, the transmission band controller 2 receives data (below, referred to as “transmission data”) from the upper layer application 1 , and calculates the transmission band required for transmitting the transmission data. For example, when transmitting a MPEG stream, in order to secure a margin for the maximum MPEG data rate in advance, the transmission band controller 2 overestimates the transmission band by 30%.
[0038] Next, the transmission band controller 2 fixes a DRP (Distributed Reservation Protocol) interval beforehand, sets the value of the DRP interval into the DRP allocation controller 4 , and at the same time, determines a link rate at the physical layer required for exactly transmitting the transmission data in the fixed DRP interval, then sets the value of the link rate into the link rate controller 3 . In wireless signal transmission and reception, the value of the allocated DRP (namely, the number of MAS in the allocated DRP) and the value of the link rate at the physical layer are used to describe the status of the settings in the DRP allocation controller 4 and the link rate controller 3 . Here, the value of the allocated DRP equals A (namely, the number of MAS in the allocated DRP is A), and the value of the link rate at the physical layer equals X.
[0039] Under this condition, the transmission band controller 2 then transfers the transmission data, which are received from the upper layer application 1 , to the USB protocol controller 5 . The USB protocol controller 5 performs processing for data transmission at the specified DRP (A) and the specified link rate (X), and transmits data through the multi-band OFDM processor 6 and the antenna 7 . In this process, if communication errors occur between the wireless USB device shown in FIG. 2 and its counter part communication device, for example, due to packet loss, the USB protocol controller 5 performs processing for re-sending the data transmission and feeds back the number of times re-sending to the transmission band controller 2 .
[0040] In the wireless signal transmission, if there are few communication errors, and the number of times re-sending is less than a preset value, which is determined from a maximum data rate securing a margin of 30%, the transmission band controller 2 maintains the current link rate and DRP allocation. However, if the number of times re-sending is greater than the preset value, the transmission band controller 2 accesses a DRP-link rate correction table stored in the short-range wireless communication device beforehand, and changes the current link rate and DRP allocation pursuant to the DRP-link rate correction table.
[0041] FIG. 3A through FIG. 3D illustrate examples of the DRP-link rate correction tables.
[0042] As shown in FIG. 3A through FIG. 3D , corresponding to the required band, the link rates are associated with the required number of DRPs.
[0043] As an example of changes of the link rate and the DRP allocation, the transmission band controller 2 controls the link rate controller 3 to change the link rate from 480 Mbps to 200 Mbps. In addition, pursuant to the DRP-link rate correction table, the transmission band controller 2 controls the DRP allocation controller 4 to set the DRP allocation to be three, which is the required number of DRPs at the link rate of 200 Mbps.
[0044] Preferably, the DRP-link rate correction table satisfies the following relationship,
required band≦link rate≦required number of DRPs
[0046] Under this condition, even when the link rate decreases, it is possible to secure the required band.
[0047] As described above, when the link rate decreases, the transmission time (DRP) compensates for this; thereby, the transmission band for the total transmission data is secured, and thus it is possible to perform stable data transmission.
Second Embodiment
[0048] FIG. 4 is a block diagram illustrating a configuration of a wireless USB device according to a second embodiment of the present invention.
[0049] Note that in this embodiment, the same reference numbers are assigned to the same elements as described previously.
[0050] The wireless USB device shown in FIG. 4 includes an upper layer application 1 which holds transmission data, such as a MPEG stream, a transmission band controller 2 which receives data from the upper layer application 1 and calculates a transmission band required for transmitting the received data, a link rate controller 3 which determines a link rate in a physical layer, a DRP allocation controller 4 which controls allocation of DRPs, a USB protocol controller 5 which receives and transmits logic data in a wireless USB and controls re-sending and various procedures, a multi-band OFDM processor (MODEM) 6 which forms the physical layer of the wireless USB and includes RF (Radio Frequency) blocks, and an antenna 7 which receives and transmits radio electrical waves.
[0051] Below, descriptions are made of operations of the wireless USB device shown in FIG. 4 .
[0052] Assume that a MPEG stream to be transmitted is encoded at variable rates.
[0053] The transmission band controller 2 receives data (below, referred to as “transmission data”) from the upper layer application 1 , and reads out a coding rate (variable value) of the frame. This coding rate is set into the link rate controller 3 , and at the same time, the transmission band controller 2 calculates a minimum DRP required for transmission at this coding rate, and sets the minimum DRP into the DRP allocation controller 4 .
[0054] Under these conditions, the transmission band controller 2 transfers the transmission data, which are received from the upper layer application 1 , to the USB protocol controller 5 . The USB protocol controller 5 performs processing for data transmission at the specified DRP and the specified link rate, and transmits data through the multi-band OFDM processor 6 and the antenna 7 .
[0055] FIG. 5 is a data diagram illustrating a configuration of a super-frame according to the second embodiment of the present invention.
[0056] As shown in FIG. 5 , since DRP is set to be the minimum, regions other than transmission DRP intervals in the super-frame can sleep, thereby, it is possible to reduce power consumption.
Third Embodiment
[0057] FIG. 6 is a block diagram illustrating a configuration of a wireless USB device according to a third embodiment of the present invention.
[0058] In this embodiment, the same reference numbers are assigned to the same elements as described previously.
[0059] The wireless USB device shown in FIG. 6 includes an upper layer application 1 which holds transmission data, such as a MPEG stream, a transmission band controller 2 which receives data from the upper layer application 1 and calculates a transmission band required for transmitting the received data, a link rate controller 3 which determines a link rate in a physical layer, a DRP allocation controller 4 which controls allocation of DRPs, a USB protocol controller 5 which receives and transmits logic data in a wireless USB and controls re-sending and various procedures, a multi-band OFDM processor (MODEM) 6 which forms the physical layer of the wireless USB and includes RF (Radio Frequency) blocks, and an antenna 7 which receives and transmits radio electrical waves.
[0060] Below, descriptions are made of operations of the wireless USB device shown in FIG. 6 .
[0061] In order to obtain information of a counterpart communication device, the transmission band controller 2 sends a request to the USB protocol controller 5 for acquiring the information of the counterpart communication device. Receiving this request, the USB protocol controller 5 transmits packet signals used for measuring the distance to the counterpart communication device, and performs processing cooperatively with the counterpart communication device (for example, perform protocol processing for measuring the distance); thereby, the distance is obtained. The USB protocol controller 5 sends the thus measured distance to the transmission band controller 2 as the information of the counterpart communication device.
[0062] The transmission band controller 2 refers to the measured distance and a distance table stored in the wireless USB device in FIG. 6 beforehand, for example, the distance table is constructed so that the transmission reception error is optimized corresponding to the distance to the counterpart communication device, and appropriately determines the link rate and the DRP. The transmission band controller 2 sets the determined link rate into the link rate controller 3 and the determined DRP into the DRP allocation controller 4 , respectively.
[0063] FIG. 7 illustrates an example of the distance table.
[0064] As shown in FIG. 7 , corresponding to the required band (for example, 400 Mbps), the distance to the counterpart communication device, the link rate, and the required number of DRPs are associated with each other.
[0065] As described above, since the distance table is configured so that the transmission and reception error is optimized relative to the distance to the counterpart communication device, it is possible to optimize the rate of the communication error, and realize a communication environment having less packet loss.
Fourth Embodiment
[0066] FIG. 8 is a block diagram illustrating a configuration of a wireless USB device according to a fourth embodiment of the present invention.
[0067] In this embodiment, the same reference numbers are assigned to the same elements as described previously.
[0068] The wireless USB device shown in FIG. 8 includes an upper layer application 1 which holds transmission data, such as a MPEG stream, a transmission band controller 2 which receives data from the upper layer application 1 and calculates a transmission band required for transmitting the received data, a link rate controller 3 which determines a link rate in a physical layer, a DRP allocation controller 4 which controls allocation of DRPs, a USB protocol controller 5 which receives and transmits logic data in a wireless USB and controls re-sending and various procedures, a multi-band OFDM processor (MODEM) 6 which forms the physical layer of the wireless USB and includes RF (Radio Frequency) blocks, and an antenna 7 which receives and transmits radio electrical waves.
[0069] Below, descriptions are made of operations of the wireless USB device shown in FIG. 8 .
[0070] In order to obtain information of a counterpart communication device, the transmission band controller 2 sends a request to the USB protocol controller 5 for acquiring the information of the counterpart communication device. Receiving this request, the USB protocol controller 5 transmits packet signals used for measuring the distance to the counterpart communication device, and performs processing cooperatively with the counterpart communication device (for example, perform protocol processing for measuring the distance), thereby, the distance is measured. The USB protocol controller 5 sends the measured distance to the transmission band controller 2 as information of the counterpart communication device.
[0071] The transmission band controller 2 refers to the measured distance and a distance table stored in the wireless USB device in FIG. 8 beforehand. For example, the distance table is constructed so that the transmission reception error is optimized corresponding to the distance to the counterpart communication device. The transmission band controller 2 then appropriately determines the link rate and the DRP, and further, a transmission level. The transmission band controller 2 sets the determined link rate into the link rate controller 3 , the determined DRP into the DRP allocation controller 4 , and the determined transmission level into the multi-band OFDM processor 6 , respectively.
[0072] FIG. 9 illustrates an example of the distance table.
[0073] As shown in FIG. 9 , corresponding to the required band (for example, 400 Mbps), the distance to the counterpart communication device, the link rate, and the required number of DRPs are associated with each other.
[0074] As described above, since the distance table is configured so that the transmission and reception error is optimized relative to the distance to the counterpart communication device, it is possible to optimize the rate of the communication error, and realize a communication environment having less packet loss. Because the transmission level is set appropriately, it is possible to reduce RF current consumption. Namely, since the link rate and the DRP are optimized relative to the distance to the counterpart communication device, it is possible to obtain a communication environment having less packet loss, and since the transmission level can be reduced, it is possible to reduce power consumption.
[0075] While the present invention is described with reference to specific embodiments chosen for purpose of illustration, it should be apparent that the invention is not limited to these embodiments, but numerous modifications could be made thereto by those skilled in the art without departing from the basic concept and scope of the invention.
[0076] This patent application is based on Japanese Priority Patent Application No. 2006-027253 filed on Feb. 3, 2006, the entire contents of which are hereby incorporated by reference.
|
A short-range wireless communication device is disclosed that is able to ensure QoS of a communication and reduce power consumption by controlling allocation of a period occupied by the communication and by controlling a communication rate within the period occupied by the communication. The short-range wireless communication device receives or transmits beacons in a beacon period, allocates a communication-occupied interval in a super-frame between two adjacent beacon periods, and carries out a communication in the communication-occupied interval in conformity with a predetermined protocol. The short-range wireless communication device includes a control unit that dynamically sets and changes a communication rate in the communication-occupied interval and a number of slots constituting the communication-occupied interval.
| 8
|
BACKGROUND OF THE INVENTION
[0001] The invention relates to hydraulic processing grippers or hydraulic processing pincers.
[0002] “Processing gripper” according to the invention generally refers to a device with which workpieces can be gripped and/or machined and/or processed hydraulically and therefore with a high application of force and which for this machining and/or processing comprises at least two elements that can move in relation to each other and form a working gap between them, one of which is a hydraulically actuated press ram or is located on such a ram and the other of which forms a workpiece assembly or a further workpiece element.
[0003] A generic hydraulic processing gripper is known in the art from DE 103 59 879 and is used for example to provide functional elements or connecting elements, such as nuts, bolts etc. in workpieces made of sheet metal by means of joining and subsequent pressing.
[0004] Especially for pressing there is a press ram or plunger, which for closing of the processing gripper during feeding can be moved from a press ram or plunger starting position into a working position, in which the plunger is supported on the functional element to be inserted into the workpiece and the functional element is supported on the workpiece. A hydraulic pressure cylinder then fixes the functional element in the workpiece by means of pressing, i.e. by means of permanent material deformation for example of the functional element and/or of the workpiece.
[0005] The basic advantage of the known setting gripper is that the feed movement of the press ram or plunger can be executed with a large stroke, but with reduced force, while the increased force required for processing or pressing when the processing gripper is closed is generated by the pressure cylinder, but with an extremely short stroke. In order to achieve this, the processing gripper is designed so that the pressure piston of the pressure cylinder is arranged on the same axis with the press ram or plunger, however so that the plunger, when advanced, is at an axial distance from the pressure piston of the pressure cylinder. Via a pressure element, which can be moved radially to the axis of the press ram, the distance between the pressure piston of the pressure cylinder and the advanced press ram is bridged, so that the pressure piston acts on the press ram via this pressure element during pressing. When the press ram is retracted into starting position with the processing gripper open, the pressure element is located to the side of the press ram and therefore provides the free space necessary for the press ram to return to its starting position.
[0006] The disadvantage of the known processing gripper is its relatively large overall height, which is due in particular to the fact that the size of the pressure transfer element or pressure element in the axis direction of the workpiece is at least equal to the stroke of this press ram from its starting position to the working position.
[0007] It is an object of the invention is to present a processing gripper that enables a more compact design while retraining the basic advantages. This object is achieved by a processing gripper made up of a tool with a first tool part having an axially displaceable tool plunger, which, with a first end or with a tool provided there and an opposite work rest, forms a working region or a working gap and can be moved with the first end towards and away from the work rest, and having a hydraulic actuating device for applying a force to the tool plunger via a movable pressure-transmitting element, the force moving the tool plunger in the direction of the work rest.
SUMMARY OF THE INVENTION
[0008] The advantage of the invention is, in particular, that the press ram or plunger in its retracted position or starting position is accommodated at least partially in the pressure cylinder or in the piston there and/or in the piston rod, so that the dimensions of the pressure transfer element in the direction of the axis of the press ram can be much smaller than the stroke of the press ram.
[0009] To eliminate this disadvantage, it has already been suggested to provide the pressure cylinder so that it is radially movable to the axis of the press ram, which however entails a more complex design in particular due to the high pressure forces that have to be transferred from the pressure cylinder to the press ram.
[0010] The invention is characterized by a reduced overall height with a simplified design.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention is described below based on the drawings with sample embodiments, as follows:
[0012] FIG. 1 the elements of a work station for inserting components, for example connecting elements, in a workpiece;
[0013] FIGS. 2 and 3 a processing or setting gripper of the workstation in FIG. 1 in various operating states; and
[0014] FIG. 4 a schematic representation of the pressure cylinder of the processing gripper in a further possible embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The work station depicted in FIG. 1 is used for the insertion of components, e.g. for the insertion of nuts 1 , in workpieces 2 made of sheet metal.
[0016] The work station consists for this purpose essentially of a workplace comprising a C-shaped or setting gripper 3 and of a hydraulic working cylinder 4 that drives the setting gripper 3 and is spatially separate from this gripper. The working cylinder 4 or its working piston 4 . 1 is actuated in the depicted embodiment for example by a motor not depicted, via a threaded spindle 7 . The setting gripper 3 or a pressure cylinder 5 located there and the working cylinder 4 are connected with each other by means of a hydraulic pressure line 6 .
[0017] The setting gripper 3 , which is fastened to a machine frame or a mount not depicted, consists of a C-shaped gripper frame 8 comprising the gripper arms 8 . 1 and 8 . 2 and the yoke section 8 . 3 connecting the arms, by means of which (yoke section) the gripper 8 is also fastened to a machine frame not depicted. A tool head 9 , for example with a matrix-type tool element 10 , is provided on the arm 8 . 1 depicted as the lower arm in the drawings.
[0018] A punching head-shaped pressing tool 11 is fastened to the other gripper arm 8 . 2 , which is opposite the gripper arm 8 . 1 and depicted in the drawings as the upper arm. The pressing tool is depicted only very schematically in the drawings and consists essentially of a ram or plunger 12 , which is movably guided in a housing 13 fastened to the gripper arm 8 . 2 for an axial stroke in the plunger axis AP, extends with a partial length over the side of the housing 13 facing the gripper arm 8 . 1 and supports a tool element 14 on the end of said partial length, which (tool element) together with the tool element 10 joins and fixes (by pressing) the respective components 1 in the workpiece 2 .
[0019] A special characteristic of the setting gripper 3 or of the pressing tool 11 is that the closing of the setting gripper 3 , i.e. the moving of the plunger 12 with the tool element 14 and the components 1 to be inserted from the plunger starting position toward the workpiece 2 or into the plunger working position and the re-opening of the setting gripper 3 , i.e. the moving of the tool element 14 away from the workpiece 2 and the moving back of the plunger 12 into its plunger starting position takes place by axial movement of the plunger 12 with a large stroke A, namely by a drive 15 indicated schematically in FIG. 2 , for example a pneumatic, electric or hydraulic drive, which effects this axial movement of the plunger 12 with relatively little force. The pressing of the components 1 takes place with great force and a short stroke B by the pressure cylinder 5 , which is provided on the top of the housing 13 .
[0020] The pressure cylinder 5 , as schematically depicted in FIGS. 2 and 3 , consists of a cylinder housing 16 and a piston rod 17 that is axially movable in said cylinder housing with a piston 18 , which delimits two cylinder chambers 16 . 1 and 16 . 2 , of which the cylinder chamber 16 . 1 can be pressurized with the hydraulic pressure of the working cylinder 4 during pressing.
[0021] The axis of the piston rod 17 is the same as the axis AP of the plunger 12 , the piston rod 17 being designed as a hollow rod, namely with an inner diameter that is somewhat larger than the outer diameter of the plunger 12 , so that the plunger 12 in its raised, i.e. retracted plunger starting position, in which the tool element 14 is at the greater distance from the tool element 10 and therefore the setting gripper 3 is opened, is accommodated with a partial length in the piston rod 17 , therefore resulting in a low overall height for the setting gripper 3 .
[0022] To create the necessary driven connection between the piston rod 17 and the plunger 12 for pressing, a slide 19 is movably guided (double arrow C) on the top of the gripper arm 8 . 2 radially to the setting gripper axis AP, namely by a drive 20 , which is an electric motor, hydraulic or pneumatic drive. A pressure plate 21 is provided or guided in the slide 19 so that it can be moved in the slide with a short stroke in an axis direction parallel to the axis SA.
[0023] By means of the drive 20 the slide 19 can be moved from a starting position, in which the slide 19 including the pressure plate 21 is completely outside the sphere of movement of the plunger 12 ( FIG. 3 ) into a working position in which the slide 19 and its pressure plate 21 are located on the same axis as the axis SA.
[0024] The functional principle of the setting gripper 3 is shown in FIGS. 2 and 3 . It is assumed that the setting gripper 3 is opened. In this case the plunger, in the case of the slide 19 being retracted into the starting position, is moved upward by the drive 15 until the tool element 14 is at the greater distance from the tool element 10 and the upper partial length of the plunger 12 is accommodated in the piston rod 17 designed as a hollow rod. After insertion of the workpiece 2 the setting gripper 3 is closed, i.e. the plunger 12 is moved downward by the drive 15 into the plunger working position so that the tool element 14 bears with the functional element 1 already present on said tool element against the workpiece 2 . The upper end 12 . 1 of the plunger 12 is then in the plane of the bottom of the slide 19 and of the pressure plate 21 or somewhat lower, however in any case at a distance below the lower end 17 . 1 of the piston rod 17 , which is at the level or somewhat above the level of the top of the slide 19 and the top of the pressure plate 21 .
[0025] Afterwards, the drive 20 moves the slide 19 from its starting position into the working position (arrow C), in which the pressure plate 21 is then between the end 17 . 1 of the piston rod 17 and the top 12 . 1 of the plunger 12 , so that this pressure plate 21 creates a driven connection between the piston rod 17 and the plunger 12 . By pressurizing the cylinder chamber 16 . 1 with the hydraulic pressure supplied by the working cylinder 4 the functional element 1 (e.g. nut) can be pressed in the workpiece 2 (e.g. sheet metal part) with a short stroke B via the piston rod 18 , the pressure plate 21 , the plunger 12 and the tool element 14 .
[0026] After pressing, the slide 19 moves back to its starting position, so that the plunger 12 can be moved back up via the drive 15 to open the setting gripper 3 and the upper length of the plunger 12 is again accommodated in the piston rod 17 . The retraction of the piston 18 is achieved for example by pressurizing the cylinder chamber 16 . 2 with the hydraulic pressure.
[0027] It was assumed above that the piston rod 17 is designed as a hollow tube. Fundamentally, other designs are also possible. For example, as shown in FIG. 4 it is also possible to use instead of the piston 18 a piston 18 a, which is axially guided in the cylinder chamber of the cylinder housing 16 and has a suitable ratio of piston length to piston diameter for this purpose. The piston 18 a is provided with an opening 22 , which is open on the side facing the plunger 12 and in which the plunger 12 is accommodated with a partial length in the plunger starting position. For pressing, the opening 22 is then again closed by the pressure plate 21 , i.e. the latter is located between the piston 18 a and the upper plunger end 12 . 1 .
[0028] Further, it is possible to design in particular the tool element 14 so that it has a corresponding hold-down device, which for example presses the workpiece 2 against the tool element 10 prior to pressing and holds it in position there.
[0029] The invention was described above based on sample embodiments. It goes without saying that numerous modifications and variations are possible without abandoning the underlying inventive idea of the invention; all embodiments have in common that the piston or the piston rod of the pressure cylinder 5 is designed so that a partial length of the plunger 12 is accommodated in this pressure cylinder when the setting gripper is open.
REFERENCE LIST
[0030] 1 functional element, for example nut
2 workpiece
3 setting gripper
4 working cylinder
5 pressure cylinder
6 hydraulic pressure hose
7 threaded spindle
8 C-shaped gripper frame
8 . 1 , 8 . 2 gripper arm
8 . 3 section
9 tool head on gripper arm 8 . 1 10 tool element
11 pressing tool
12 plunger
12 . 1 top end of plunger 12 13 housing
14 tool element
15 drive
16 cylinder housing of pressure cylinder 5 16 . 1 , 16 . 2 cylinder chamber
17 piston rod
17 . 1 end of piston rod 17 18 , 18 a piston
19 slider
20 drive for slider 19 21 pressure plate
22 opening
A feed movement of plunger 12 or of tool element 14
B movement stroke of pressure cylinder 5
C movement of slide 19
|
The invention relates to a novel design of hydraulic processing pincers for processing workpieces, with a tool which, in a first tool part has an axially displaceable tool plunger which, with a first end or with a tool provided there and an opposite work rest, forms a working region or a working gap and can be moved with the first end towards and away from the work rest, and made up of a hydraulic actuating device for applying a force to the tool plunger via a movable pressure-transmitting element, said force moving said tool plunger in the direction of the work rest. The piston and/or the piston rod are/is designed with a cavity in which the tool plunger is accommodated in its initial position at least over part of its length.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Provisional Application No. 60/552,230 filed Mar. 11, 2004, the entire disclosure of which is hereby incorporated by reference herein for all purposes. Subject matter disclosed in this application might be considered to be related to subject matter disclosed in Patent Application Nos. (Attorney Docket ZUHL 2849) and (Attorney Docket ZUHL 2851), the entire disclosure of each of which is hereby incorporated by reference herein for all purposes.
BACKGROUND OF THE INVENTION
[0002] This invention relates to remote computer access.
[0003] The need to access computers from remote locations frequently arises. For example, a system administrator may desire to control a rack of systems from a location other than a noisy or inconveniently secure machine room, or even from home.
[0004] Early computer architectures made this fairly easy to do. All input and output from the computer could be directed over a single, low-bandwidth console serial interface. A remote display could easily be connected using a long cable or a modem.
[0005] Modern computer architectures, most notably the IBM PC architecture, utilize graphical consoles. The output from these computers is high bandwidth analog or digital video which is usually connected to a local video monitor. Serial PS/2 or USB interfaces are used for keyboard and mouse input. These interfaces are not suitable for long distance transmission.
[0006] The operation of PC architecture computers takes place in several stages. On power-up, the BIOS displays start-up messages on the console. A number of different configuration dialogs may be entered. A boot loader may be invoked through which the user may select an operating system. The operating system then starts up, generating various messages. A large variety of programs may then be run on top of the operating system. Upon exiting the operating system a number of shut-down messages are displayed on the console.
[0007] Several software packages exist that facilitate remote access. Some of these packages use standard networking protocols so that a remote display can be an almost unlimited distance from the computer. However, these packages run on top of the operating system and therefore cannot handle the start-up, configuration, boot loader, operating system start-up, and shut-down messages. Therefore, software packages don't work, for example, in an application where a remote access is desired for system configuration.
[0008] Hardware support for remote access exists in the form of keyboard, mouse, and video extension cables and repeaters. KVM (Keyboard, Video, Mouse) switches that allow a single keyboard, mouse, and monitor to be shared by multiple computers are in this category. Some products digitize the signals for transmission over moderately longer but still limited distances. Such hardware does not have the software limitation of requiring the operating system to be running. However, while they allow remote access further from the computer, the distance is effectively limited to hundreds of feet.
[0009] Some computers include internal serial-over-LAN capability that allows some control over a network. These solutions do not provide full functionality, and only provide access during system start-up and shut-down.
SUMMARY OF THE INVENTION
[0010] In accordance with a first aspect of the invention there is provided a remote access device for use with a local computer to allow a remote computer to interact with the local computer, said remote access device comprising a communication interface for receiving encoded human input device data from the remote computer over a communication medium, a decoder for receiving the encoded data from the communication interface and generating human input device signals, a human input device signal interface for receiving human input device signals from the decoder, and a computer interface for receiving the human input device signals from the human input device signal interface and supplying the human input device signals to the local computer.
[0011] In accordance with a second aspect of the invention there is provided a computer system comprising a local computer having a bus and a communication interface, a remote computer having a processor, a human input device for generating human input device signals, an encoder for receiving the human input device signals and generating encoded human input device data, and a communication interface, a communication medium for communicating messages from the communication interface of the remote computer to the communication interface of the local computer, and a remote access device comprising a communication interface for receiving encoded human input device data from the remote computer over the communication medium, a decoder for receiving the encoded human input device data from the communication interface and generating human input device signals, a human input device interface for receiving human input device signals from the decoder, and a computer interface for receiving the human input device signals from the human input device interface and supplying the human input device signals to the local computer, whereby the local computer responds to the human input device signals generated by the human input device of the remote computer.
[0012] In accordance with a third aspect of the invention there is provided a computer system comprising a local computer, a remote computer having a processor, a human input device for generating human input device signals, an encoder for receiving the human input device signals and generating encoded human input device data, and a communication interface, a remote access device comprising a communication interface for receiving encoded human input device data, a decoder for receiving the encoded human input device data from the communication interface and generating human input device signals, a human input device interface for receiving human input device signals from the decoder, and a computer interface for receiving the human input device signals from the human input device interface and supplying the human input device signals to the local computer, and a communication medium for communicating encoded human input device data from the communication interface of the remote computer to the communication interface of the remote access device, whereby the local computer responds to the human input device signals generated by the human input device of the remote computer.
[0013] An embodiment of this invention is a remote access device that attaches to a computer. It is indistinguishable from a standard keyboard, mouse, and console output device from the perspective of the computer. Unlike existing devices, the input and output data is in a form suitable for transmission over long haul networks. An embodiment of the invention provides the access capabilities of the hardware products in concert with the virtually unlimited distance of the software products. As an added benefit, simultaneous access from multiple remote stations is available since monitor specific timing and identification information is eliminated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic block diagram of an embodiment of the invention.
[0015] FIG. 2 is a block diagram of the target environment for an embodiment of the invention.
[0016] FIG. 3 is a schematic block of the environment for the preferred embodiments of the invention in the target environment.
[0017] FIG. 4 is a schematic block diagram of the hardware in the preferred embodiments of the invention. The relationship between the hardware blocks and the blocks shown in FIG. 1 is shown.
[0018] FIG. 5 is a schematic block diagram of the firmware in the preferred embodiments of the invention.
DETAILED DESCRIPTION
[0019] A block diagram of an embodiment of the invention is shown in FIG. 1 .
[0020] An embodiment of the invention connects to a local computer 1 via the local computer interface 2 .
[0021] The graphics device 3 converts commands from the local computer 1 into data suitable for transmission over the network interface 5 as described in Patent Application No. (Attorney Docket ZUHL 2849).
[0022] The keyboard/mouse interface 4 receives keyboard and mouse input from the network interface 6 . It emulates standard keyboard and mouse devices that are recognized by the local computer 1 and sends this data to the local computer 1 over the local computer interface 2 .
[0023] The network interface 5 allows a remote station 6 to communicate with an embodiment of the invention. It transmits display information and receives keyboard and mouse information. There may also be associated control information.
[0024] FIG. 2 shows the prior-art target environment for an embodiment of the invention. This environment is a local computer 1 connected to a local keyboard 10 , local mouse 11 , and local display 12 . The arrows in FIG. 2 indicate the predominate flow of data; small amounts of control information may flow in the opposite direction.
[0025] FIG. 3 shows an embodiment of the invention in its target environment. There is no local keyboard 10 , local mouse 11 , or local display 12 attached to the local computer 1 . Instead, an embodiment of the invention 7 is connected to the local computer 1 by the local computer interface 2 . Keyboard, mouse, and display data are sent to and from a remote station 6 across the network 20 . Communication across the network 20 is accomplished by layering the RFB (Remote FrameBuffer) protocol used by the open source VNC (Virtual Network Console) software on top of the TCP/IP protocol. The remote station 6 is a remote computer 22 with a remote keyboard 24 , remote mouse 25 , and remote display 26 . The remote computer 22 includes VNC client software 23 . The result is that the remote keyboard 24 , remote mouse 25 , and remote display 26 appear to the local computer 1 as if they are a local keyboard 10 , local mouse 11 , and local display 12 . A single remote station 6 can simultaneously operate multiple instances of an embodiment of the invention 7 .
[0026] The use of industry standard Ethernet hardware and industry standard TCP/IP protocols allows the remote station 6 to be connected to the computer using commonly available, low cost hardware. The remote station 6 can be anywhere in the world since the TCP/IP protocols are the foundation of the Internet. The use of the RFB protocol and VNC software allow a remote station 6 to be easily constructed using off-the-shelf hardware and software.
[0027] A schematic block diagram of the hardware for the preferred embodiment of the invention is shown in FIG. 4 . This diagram adds detail to the overall block diagram in FIG. 1 above.
[0028] The graphics device 3 in the preferred embodiments is that which is described in Patent Application No. (Attorney Docket ZUHL 2849). This graphics device 3 includes a bus interface 30 , network interface 5 , and a microprocessor system 31 . This embodiment of the invention leverages those components by adding additional functionality rather than duplicating those components.
[0029] The addition of the keyboard/mouse interface 4 differentiates this embodiment of the invention from Patent Application No. (Attorney Docket ZUHL 2849). Keyboard/mouse support is provided in three different ways in order to accommodate the evolution of computer architectures.
[0030] An industry standard keyboard/mouse interface 33 presents keyboard and mouse information from the remote station 6 to the local computer 1 in a form indistinguishable from an industry standard keyboard controller and industry standard mouse interface. The PS/2 keyboard interface 34 presents keyboard information from the remote station 6 to the local computer 1 in a form that is indistinguishable from an industry standard PS/2 keyboard. The PS/2 mouse interface 35 presents mouse information from the remote station 6 to the local computer 1 in a form that is indistinguishable from an industry standard PS/2 mouse. The USB keyboard interface 36 presents keyboard information from the remote station 6 to the local computer 1 in a form that is indistinguishable from an industry standard USB keyboard. The USB mouse interface 37 presents mouse information from the remote station 6 to the local computer 1 in a form that is indistinguishable from an industry standard USB mouse.
[0031] The combination of the bus interface 30 and the keyboard/mouse interface 4 signals is the local computer interface 2 .
[0032] An embodiment of the invention communicates with a remote station 6 across the network 20 .
[0033] FIG. 5 is a block diagram of the firmware in the preferred embodiments of the invention.
[0034] The firmware performs initialization 40 after power on 53 .
[0035] The initialized system has an Ethernet address set by the network interface 5 . It maps that to an IP (Internet Protocol) address in the acquire IP address 41 block. There are several possible ways to acquire an IP address due to the evolution of the Internet. The system tries to acquire an address using DHCP, RARP, and BOOTP.
[0036] A remote station 6 can connect to an embodiment the invention once an IP address is established. An embodiment of the invention waits for a request from the remote station 6 in the wait for connection request block 42 .
[0037] A connection with the remote station 6 is established in the establish connection block 43 after a connection request is received. This may include handshaking to agree on compression methods and data formats that can be handled by both ends of the connection.
[0038] Steady state operation begins once the connection is established. An embodiment of the invention waits for an internal or external event as shown in wait for event 44 and then processes the event. There are five events:
[0039] 1. A lost IP address 52 , in which case the system goes back to 41 to get a new one,
[0040] 2. A lost connection 51 , in which case the system goes back to 42 to get a new one, or
[0041] 3. A keyboard event 48 is received from the remote station 6 across the network 20 . Send key code 47 translates this event into a key code recognized by the local computer 1 and sends that code to the local computer 1 .
[0042] 4. A mouse event 50 is received from the remote station 6 across the network 20 . Send mouse code 49 translates this event into a mouse code recognized by the local computer 1 and sends that code to the local computer 1 .
[0043] 5. A display update request 53 is received from the remote station 6 across the network 20 . New image data is sent to the remote station 6 . The data is first encoded by encode image 45 and then sent to the remote station 6 by transmit compressed image 46 .
[0044] The changes for this invention 54 firmware blocks are the only firmware changes to Patent Application No. (Attorney Docket ZUHL 2849) required for this embodiment of the invention.
[0045] It will be appreciated that the invention is not restricted to the particular embodiment that has been described, and that variations may be made therein without departing from the scope of the invention as defined in the appended claims and equivalents thereof. Unless the context indicates otherwise, a reference in a claim to the number of instances of an element, be it a reference to one instance or more than one instance, requires at least the stated number of instances of the element but is not intended to exclude from the scope of the claim a structure or method having more instances of that element than stated.
|
A remote access device is disclosed for remote interaction with a computer. A local computer transmits graphics data to a remote station over a network. The remote station transmits keyboard and mouse data to the local computer over a network. The remote access device is a circuit module that is connected to the local computer. This module facilitates the transmission of graphics data, keyboard data, and mouse data.
| 6
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 10/253,470, filed Sep. 24, 2002 and now issued as U.S. Pat. No. 7,376,704 (Attorney Docket 00304), which is incorporated herein by reference in its entirety. This application also relates to co-pending application Ser. No. 10/253,500, entitled “Network-Based Healthcare Information Systems” (Attorney Docket 00233 ), filed Sep. 24, 2002 and now issued as U.S. Pat. No. 7,298,836, which is also incorporated herein by reference in its entirety.
NOTICE OF COPYRIGHT PROTECTION
[0002] A portion of the disclosure of this patent document and its figures contain material subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, but the copyright owner otherwise reserves all copyrights whatsoever.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention generally relates to computer networks and to telephony. More particularly, this invention is directed to methods and systems for more efficient and effective communication and processing of electronic data in a telecommunications network-based information system.
[0005] 2. Description of the Related Art
[0006] In Epidemics , Hippocrates wrote “[t]he art of medicine has three factors: the disease, the patient and the physician.” Were he writing today, the Father of Medicine would also likely include “access to information” as a fourth factor. Why? Because today's marketplace is driven by increasing pressure for cost controls, by the increased strength, of the consumer voice, by a shift from hospital inpatient care towards primary, ambulatory, and home care, by an emphasis on “case management,” by increased competition, and by the focus on quality that is necessary for better patient care. This relentless drive to improve efficiencies and cut costs makes many traditional procedures inefficient. This relentless drive also presents great opportunities for healthcare professionals, organizations, and patients to enter into new types of multi-institution partnerships (e.g., strategic alliances between physician's offices, hospitals, clinics, labs, diagnostic centers, medical record repositories, insurers, patients, pharmaceutical and surgical suppliers, other vendors, etc.) that utilize many different computing systems and other communications technologies to manage and share electronic healthcare information. One of the biggest harriers facing these multi-institution partnerships is creating and maintaining an integrated delivery system (IDS) that facilitates an information-exchange of standardized or otherwise compatible data so that each participant in the partnership has efficient and effective access to the information.
[0007] Thousands, if not hundreds of thousands or more, of electronic documents, emails, and proprietary information are generated each day and shared among these multi-institution partnerships. For example, a physician might order a complex lab test from the local hospital. Instead of waiting on the results to arrive by hand delivery, the physician's office may get online and requests it via secure, encrypted email. The hospital's lab staff either manually attaches the lab result to a return email, or, in more advanced systems, the lab system responds automatically to the request and returns the results to a legacy system accessible by the physician. Another example is when a physician needs to admit a patient to the hospital. Instead of having the staff call the admission office and spend upwards of thirty (30) minutes talking and waiting on hold, the office sends the pre-admission information electronically, including patient record information and pre-admission orders to the hospital via an email attachment or directly to the hospital's legacy system. As used herein, the term “legacy systems” includes data processing, storage, management, and information systems, such as, for example, electronic patient health history, patient insurance information, demographic information, and physical records. Typically, the legacy systems are customized in terms of software, hardware, and network configuration for each participant of the multi-institution partnership. Typically, the legacy system includes a network of multiple computer systems; however, the legacy system may also be a stand-alone computer system.
[0008] In both of the above examples, the shared healthcare information may be processed in a variety of ways. For example, the hospital may provide information to the physician by transmitting healthcare data over a Local Area Network (LAN) connection into a database on a web server. This healthcare information could then be transmitted to the physician's computer system over a data connection, such as the Internet, Intranet or Extranet, or over a direct connection, such as dial up access, using push technology that automatically broadcasts the data to the physician's computer system and allows the physician to view the transmitted healthcare data using an appropriate software package, such as a browser. While the goal of the IDS interface of an information-exchange system is to translate and reformat the healthcare information from one legacy system so that it is compatible with another legacy system(s), thus far, the IDS systems have been primarily limited to very specialized healthcare information and limited in the features and services offered between linked legacy systems.
[0009] In addition to the challenges of implementing a successful IDS that enables the exchange of electronic healthcare information, most of the participants in the multi-institution partnerships must also comply with a variety of federal, state, local and other rules that protect the privacy and security of healthcare information associated with a patient. For example, the Health Insurance Portability and Accountability Act (HIPAA), signed into law by President Clinton on Aug. 21, 1996 (Pub. L. 104-191, 110 Stat. 1936), covers health plans, healthcare clearinghouses, and healthcare providers who conduct certain financial and administrative transactions (e.g., electronic billing and funds transfers) electronically. Providers (e.g., physicians, hospitals, etc.) and health plans are required to give patients a clear written explanation of how a covered entity may use and disclose a patient's healthcare information. Further, healthcare providers are required to obtain patient consent before sharing information for treatment, payment, and healthcare operations. In addition, HIPPA also requires that a provider adopt and implement privacy procedures to ensure the privacy and security of the healthcare information.
[0010] The above discussion illustrates how the sharing of healthcare information and technology are creating a new foundation for a virtual healthcare setting. With this emerging virtual healthcare setting, what are needed are improved network-based information systems that build communications infrastructures to support different organizational needs and capitalize on emerging trends in the healthcare setting. Accordingly, network-based information systems and components are needed that enable multiple legacy systems to share, transfer, and/or access standardized or otherwise compatible data of the various participants in the multi-institution partnership. Further, a need exists to improve notification, access, and management of the electronically shared healthcare information without investing millions of dollars in computer equipment, in a networking infrastructure, in maintenance, and in training while also complying with security, authenticity, and/or privacy requirements.
BRIEF SUMMARY OF THE INVENTION
[0011] The aforementioned problems and others are reduced by a telecommunications network-based information system (NBIS). The NBIS comprises systems and methods that leverage the assets of a telecommunications network to facilitate improved access, sharing, notification, security, and/or management of electronic data exchanged between or among different legacy systems. Some advantages of NBIS include increased ability of each participant to flexibly manage and categorize electronic data that is exchanged with other participants, provide faster access to electronic data, and utilize a local proprietary network to reduce or prevent, electronic data from entering traffic in a public data network, such as the Internet.
[0012] An embodiment of this invention describes a method that includes receiving electronic data associated with a sender's legacy system, interpreting tire electronic data according to a rule-based engine to categorize the electronic data, and processing the electronic data into a receiver's legacy system. The sender's legacy system and the receiver's legacy system are associated with an integrated delivery system that enables an exchange of selected electronic data between one or more networks of communications devices associated with, a telecommunications service provider. In a preferred embodiment, a rule-based application dataserver is used to categorize the electronic data. The rule-based application dataserver allows a customer (e.g., a participant) to control access, sharing, notification, security, and/or management of electronic data exchanged between or among different legacy systems. Typically, the rule-based application dataserver is associated with a central office (“CO”), a mobile telephone switching center (“MTSO”), or a combination CO/MTSO.
[0013] Another embodiment describes a method for communicating electronic data to a rule-based application dataserver associated with a telecommunications facility and allowing a customer (e.g., a participant) to manage the rule-based application dataserver including one or more databases associated with a rule-based profile. Similar to the first embodiment described above, the sender's legacy system and the receiver's legacy system are associated with an integrated delivery system that enables an exchange of selected electronic data between one or more networks of communications devices associated with a telecommunications service provider.
[0014] Another embodiment describes a method for establishing a data connection between a sender legacy system and a receiver legacy system that uses a rule-based application dataserver, communicating electronic data via the data connection, and allowing a customer to manage the rule-based application dataserver including one or more databases associated with a rule-based profile. The rule-based application dataserver is provided by a telecommunications provider and controls access between the sender legacy system and the receiver legacy system. Typically, the electronic data includes an electronic message having an attached object, a transaction reply, a transaction notification, a compatible object, and/or other electronic communications.
[0015] Another embodiment describes a system for remotely managing electronic data shared between different legacy systems communicating via a telecommunications connection that uses a rule-based application dataserver associated with a telecommunications facility. The system includes a network of interconnected communications devices serviced by a telecommunications service provider and a rule-based application dataserver for managing the exchange of electronic data between different legacy systems connected with the communications devices. The system further includes an application program, referred to herein as a NBIS Management Module, that is installed in a customer's communications device, such as a computer system. The NBIS Management Module provides an interlace for the customer to remotely manage NBIS Management Services including the rule-based application dataserver and its databases.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0016] The above and other embodiments, objects, uses, advantages, and novel features of this invention are more clearly understood by reference to the following description taken in connection with the accompanying figures, wherein:
[0017] FIG. 1 is a block diagram showing of a NBIS Management Module that resides in a computer system according to an embodiment of this invention;
[0018] FIG. 2 is a schematic showing an exemplary operating environment for a telecommunications network-based healthcare information system according to an embodiment of this invention;
[0019] FIG. 3 is a more detailed schematic of a rule-based application dataserver shown in FIG. 2 ;
[0020] FIG. 4 is a more detailed schematic of a hospital's legacy system shown in FIG. 2 ;
[0021] FIG. 5 is a schematic showing an exemplary framework for the flow of electronic message through the telecommunications network-based information system according to an embodiment of this invention;
[0022] FIG. 6 is a schematic showing an exemplary operating environment for a telecommunications network-based real estate information system according to an embodiment of this invention;
[0023] FIG. 7 is a schematic showing an exemplary embodiment of communicating an electronic message using wired and wireless communications devices associated with the telecommunications network-based information system according to an embodiment of this invention;
[0024] FIG. 8 is a schematic showing another exemplary embodiment of communicating an electronic message using wired and wireless communications devices associated with the telecommunications network-based information system according to an embodiment of this invention; and
[0025] FIGS. 9-10 are flowcharts showing a method of providing the telecommunications network-based information system service to a customer according to an embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] This invention now will be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).
[0027] Thus, for example, it will be appreciated by those of ordinary skill in the art that the diagrams, schematics, flowcharts, and the like represent conceptual views or processes illustrating systems and methods embodying this invention. The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing associated software. Similarly, any switches shown in the figures are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, through the interaction of program, control and dedicated logic, or even manually, the particular technique being selectable by the entity implementing this invention. Those of ordinary skill in the art further understand that the exemplary hardware, software, processes, methods, and/or operating systems described herein, are for illustrative purposes and, thus, are not intended to be limited to any particular named manufacturer.
[0028] A telecommunications network-based information system (NBIS) is typically a subject-specific group of related client, vendor, and service-oriented participants that leverage the assets of a telecommunications network. The purpose of NBIS is to efficiently share information, automate business processes, and enhance market position of the participants. In the case of a healthcare NBIS, participants may include a local hospital, insurance companies, HMOs, affiliated hospitals, clinics, physicians' offices, medical schools, universities, and strategic partners. Patients, as well as vendors, could also be included, as could service providers, such as clinical laboratories, pharmacy services, temporary agencies, private ambulance services, and subspecialty services. After all, rapid communication and exchange of information between these participants can make a critical difference in the quality of patient care. Alternatively, as is apparent to those of ordinary skill in the art, other subject specific groups of related client, vendor, and service-oriented participants may leverage the assets of a telecommunications network to provide an NBIS customized for their needs.
[0029] In most cases, each participant usually has its own legacy systems, including software, hardware, equipment, networks, and/or other information technology assets. For example, a hospital commonly has a local and/or a wide area network that utilizes Ethernet, dedicated private lines. Frame Relay, ISDN, ATM, ADSL, and the like. Further, these legacy systems provide an interface to a data network, such as the Internet, Intranet, and/or Extranet, that may be locally or remotely accessed by a participant's user (e.g., a hospital employee using a computer system within the hospital's legacy system).
[0030] This invention provides improved access, sharing, notification, routing, security, and/or management of electronic data exchanged between or among different legacy systems. These legacy systems are associated with a rule-based application dataserver provided by a telecommunications service provider. These legacy systems are also associated with an integrated delivery system (IDS) that uses associated rules, fields, and/or files to process exchanged information into a selected legacy system. As used herein, the term “electronic data” includes electronic messages such as email, attached objects (e.g., an attached file to the email), and compatible objects (e.g., an attached object that has been processed by the rule-based application dataserver and the IDS to format and/or standardize electronic information shared between a first and a second legacy system). The term “electronic data” also includes transaction notifications and/or transaction replies generated by the rule-based application dataserver and/or the IDS, and/or other means of communicating electronic information between or among NBIS participants.
[0031] Referring now to the figures, FIG. 1 is a block diagram showing a NBIS Management Module 110 residing in a computer system 100 . The NBIS Management Module 110 operates within a system memory device. The NBIS Management Module 110 , for example, is shown residing in a memory subsystem 112 . The NBIS Management Module 110 , however, could also reside in flash memory 114 or peripheral storage device 116 . The computer system 100 also has one or more central processors 120 executing an operating system. The operating system, as is well known, has a set of instructions that control the internal functions of the computer system 100 . A system bus 122 communicates signals, such as data signals, control signals, and address signals, between the central processor and a system controller 34 (typically called a “Northbridge”). The system controller provides a bridging function between the one or more central processors 120 , a graphics subsystem 126 , the memory subsystem 112 , and a PCI (Peripheral Controller Interface) bus 128 . The PCI bus 128 Is controlled by a Peripheral Bus Controller 130 . The Peripheral Bus Controller 130 (typically called a “Southbridge”) is an integrated circuit that serves as an input/output hub for various peripheral ports. These peripheral ports could include, for example, a keyboard port 132 , a mouse port 134 , a serial port 136 and/or a parallel port 138 for a video display unit, one or more external device ports 140 , and networking ports 142 (such as SCSI or Ethernet). The Peripheral Bus Controller 130 could also include an audio subsystem 144 .
[0032] The processor 120 is typically a microprocessor. Advanced Micro Devices, Inc., for example, manufactures a full line of ATHLON™ microprocessors (ATHLON™ is a trademark of Advanced Micro Devices, Inc., One AMD Place, P.O. Box 3453, Sunnyvale, Calif. 94088-3453, 408.732.2400, 800.5128.8450, www.amd.com). The Intel Corporation also manufactures a family of X86 and P86 microprocessors (Intel Corporation, 2200 Mission College Blvd., Santa Clara, Calif. 95052-8119, 408.765.8080, www.intel.com). Other manufacturers also offer microprocessors. Such other manufacturers include Motorola, Inc. (1303 East Algonquin Road, P.O. Box A3309 Schaumburg, Ill. 60196, www.Motorola.com), International Business Machines Corp. (New Orchard Road, Armonk, N.Y. 10504, (914) 499-1900, www.ibm.com), and Transmeta Corp. (3940 Freedom Circle, Santa Clara, Calif. 95054, www.transmeta.com).
[0033] The preferred operating system is WINDOWS® (WINDOWS® is a registered trademark of Microsoft Corporation, One Microsoft Way, Redmond Wash. 98052-6399, 425.882.8080, www.Microsoft.com). Other operating systems, however, are also suitable. Such other operating systems would include the UNIX® operating system (UNIX® is a registered trademark of the Open Source Croup, www.opensource.org), the UNIX-based Linux operating system, WINDOWS NT®, and Mac® OS (Mac® is a registered trademark of Apple Computer, Inc., 1 Infinite Loop, Cupertino, Calif. 95014, 408.996.1010, www.apple.com).
[0034] The system memory device (shown as memory subsystem 112 , flash memory 114 , or peripheral storage device 116 ) may also contain an application program. The application program cooperates with the operating system and with a video display unit (via the serial port 136 and/or the parallel port 138 ) to provide a GUI for the NBIS Management Module 110 , The GUI typically includes a combination of signals communicated along the keyboard port 132 and the mouse port 134 . The GUI provides a convenient visual and/or audible interface with the customer or user of the computer system 100 . As is apparent to those of ordinary skill in the art, the selection and arrangement of the NBIS Management Module 110 to manage NBIS Management Services may be programmed over a variety of alternate mediums, such as, for example, a voice-activated menu prompt, an interactive session with an telecommunications network administrator, and the like.
[0035] The NBIS Management Module 110 allows a user to manage NBIS Management Services, such as: (1) allowing the user to customize rules and user groups associated with a rule-based engine of the rule-based dataserver including an access agent, a security agent, a messaging agent, a transaction agent, and a troubleshooting agent; (2) allowing the user to customize presentation, features, and/or management of an incoming electronic message (e.g., an email, an attached object, a compatible object, a transaction reply, a transaction notification, and/or other electronic communications); and (3) allowing the user to control the telecommunications network and/or a data network connection with his/her legacy system. For example, the user may select an Access Agent having a user group list to add, delete, or modify participant information, such as, associated service node addresses, IP addresses, email addresses, and/or other electronic address information associated with each NBIS participant. An address of the user group list is associated with an incoming electronic message (shown as reference numeral 240 in FIG. 2 ) and acts as a trigger (similar to decoding an ICLID signal for telecommunication special service features offered by telecommunication service providers) to send the electronic message to a NBIS rule-based application dataserver (shown as reference numeral 258 in FIG. 2 ). The NBIS Management Module 110 also allows the user to customize features, such as electronic message handling options. For example, the NBIS Management Module may split a user's screen into two viewing areas and present the incoming electronic message in one portion and present information associated with an attached object and/or a compatible object that has been or that might be integrated into the user's legacy system. Further, the NBIS Management Services may allow the user to control whether to accept, decline, or postpone integration of the compatible object into the user's legacy system or might be set to automatically accept, decline, or postpone integration depending on a sending participant's address. Finally, the NBIS Management Module 110 of the computer system may provide the IP address or the like so that the telecommunications network and/or the data network can communicate the electronic message, and, thus integrate telephony events and data network events with the user's computer system.
[0036] FIG. 2 is a schematic showing an exemplary operating environment for a telecommunications network-based information system (NBIS) 200 . The NBIS 200 includes a shared, interconnected network 210 of one or more switches 220 that provide access points of presence for one or more legacy systems 230 . Each legacy system 230 includes at least one computer system 100 having the NBIS Management Module 110 (including the IP address or other communications address associated with a participant's telecommunications network and/or data network, connection) residing within the computer system 100 , a telecommunications network 250 typically including a service switching point (SSP) 252 , a sendee control point (SCP) 254 , an Intranet 256 , and a NBIS Rule-Based Application Dataserver 258 , an Internet Service Provider (e.g., America On-Line) 260 , a data network 262 , a gateway 264 , an Integrated Delivery System (IDS) 270 , and external data sources 280 . Each switch 220 allows the connected legacy systems 230 to communicate electronic messages 240 via the telecommunications network facility 250 , such as, for example, a central office (CO), a mobile telephone switching office (MTSO), and/or a combination CO/MTSO. The telecommunications network facility 250 may use any means of coupling one switch 220 to the telecommunications network facility 250 , but the coupling means is preferably high-capacity, high-bandwidth optical transport services, Gigabit Ethernet services, and/or the like. As those of ordinary skill in the art of telecommunications understand, the telecommunications network facility 250 could also link each switch 220 via other appropriate means, such as, for example a Synchronous Optical Network (SONET) structure with redundant, multiple rings.
[0037] Typically, a customer and/or user of the NBIS Management Sendees uses the computer system 100 to gain access to the NBIS 200 . For example, if a user wishes to send, receive, or access voice, video, and/or data (e.g., read and respond to e-mail, order test results, view video-clips including static images, listen to recorded information, engage in an interactive-diagnosis session, etc.), then the computer system 100 connects with the interconnected network 210 via switch 220 . Each electronic message 240 sent from a computer system 100 of the participant's legacy system 230 is routed through the telecommunications network 250 via switch 220 . Communications signals associated with the address of the electronic message 240 arrive at SSP 252 that analyzes the signals and determines whether the electronic message 240 is addressed to another NBIS participant. Depending on the address and content of the electronic message (e.g., whether or not the electronic message is to a non-participant, whether or not an object is attached, etc.), the SSP 252 may route the electronic message immediately over the telecommunications network 250 to attempt a connection or the SSP may communicate with SCP 254 for further electronic message processing and routing information (including eventual routing to the NBIS Rule-Based Application DataServer 258 if the electronic message 240 is to another NBIS participant). The NBIS 200 may include wired, optical, and/or wireless elements and may further include private network elements, such as private branch exchanges (PBXs), and/or other elements (not shown). The telecommunications network 250 includes Advanced Intelligent Network (AIN) componentry controlling many features of the network. The telecommunications network 250 or switch 220 could also include a packet-based “soft switch” that uses software control to provide voice, video, and/or data services by dynamically changing its connection data rates and protocols types. If the telecommunications network 250 or switch 220 should include a Softswitch, the AIN componentry is replaced by an application server that interfaces with the Softswitch via a packet protocol, such as Session Initiation Protocol (SIP). The signaling between the computer system 100 , the switch 220 , the telecommunications network 250 including AIN componentry, and the data network 262 , however, are well understood in by those of ordinary skill the art and will not be further described. Further, those of ordinary skill in the art will be able to apply the principles of this invention to their own legacy systems including their network configurations which may differ substantially from the telecommunications system shown in the figures.
[0038] The NBIS Rule-Based Application Dataserver 258 communicates with SCP 254 and Intranet 256 to effectively provide NBIS Management Services. These NBIS Management Services allow a NBIS participant to control access, sharing, notification, routing, security, transactions, troubleshooting, management, and/or additional processing of electronic messages exchanged to/from other NBIS participants. For example, NBIS Management Services allows a user to control how the object is processed, into the receiver legacy system including (i) sending the object to a storage device associated with the telecommunications service provider, (ii) archiving the object, (iii) encrypting the object, (iv) copying the object, and (v) associating the object with related electronic data in the receiver legacy system. Further, the NBIS Management Services may be activated, de-activated, administered, and/or otherwise managed by the user or another entity with authorization (e.g., telecommunications service provider),. Thus, NBIS Rule-Based Application Dataserver 258 functions as a computer server, database, and processor that is dedicated to managing NBIS participant, activity including their communication of electronic messages over the interconnected network 210 . In an embodiment, the NBIS Rule-Based Application Dataserver 258 has the ability to communicate with the data network 262 using standard transmission control protocol and Internet protocol (TCP/IP) or other appropriate protocols. Further, the NBIS Management Module 110 , may be downloaded from ISP 260 , NBIS Rule-Based Application Dataserver 258 , Intranet 256 , or provided on a storage media (e.g., diskette, CD-ROM, or installed by the computer system manufacturer) to a subscribing customer or user to install on the computer system 100 to enable, disable, and further control a variety of the NBIS Management Services.
[0039] Referring now to FIG. 3 , the participant interacts with the NBIS Management Module 110 and with Intranet 256 to access and login to the NBIS Rule-Based Application DataServer 258 and to establish the NBIS Rule-Based Profile 300 . The NBIS Rule-Based Application Dataserver 258 stores one or more NBIS Rule-Based Profiles 300 that include data and applications associated, with an Access Agent 311 , a Security Agent 312 , a Messaging Agent 313 , a Transaction Agent, and a Troubleshooting Agent 315 . For example, the Access Agent 311 , Security Agent 312 , Messaging Agent 313 , Transaction Agent, and Troubleshooting Agent 315 may contain a variety of fields and/or files associated with at least one of the following: login information associated with a participant, password entered by the participant, telephone number or Service Node of the participant (this may include a plurality of addresses that are associated with a Service Node or other switch serving the legacy system), TCP/IP address of the participant, profile of the computer system 100 or other communications device associated with the incoming electronic message (e.g., presentation formats for various communications devices), a time or date identifier (e.g., day of week or calendar date), other information associated with the communications signal, size and content of electronic message (including types of files that are transmitted, as an attached object), transaction reply(s), transaction notification(s), display of a GUI (e.g., color, font, placement of NBIS Management Module on screen, etc.), NBIS Management Service defaults (e.g., whether the IDS automatically re-formats the attached object to a compatible object and updates the receiving legacy system with the compatible object), and other selections related to NBIS Management Services, such as electronic message features, electronic message routing, and troubleshooting problems or error messages.
[0040] FIG. 4 illustrates an embodiment of establishing a local NBIS Rule-Based Profile 400 to interact with the NBIS Rule-Based Profile of the interconnected network 210 . The NBIS Management Module 110 of computer system 100 is used to establish, store, and manage the NBIS Rule-Based Profile 400 for legacy system (i.e., the hospital's legacy system). The legacy system stores one or more NBIS Rule-Based Profiles 400 that include data and applications similar to NBIS Rule-Based Profiles 300 . The NBIS Rule-Based Profiles 400 provide increased security by allowing the participant to internally control electronic information, utilize existing databases to add, delete, or otherwise change electronic information, control how the participant's legacy system interacts with the IDS, and control routing instructions within, its legacy system.
[0041] FIG. 5 is a schematic showing an exemplary framework for the flow of the electronic message 240 through the NBIS 200 . Typically, the flow of the electronic message 240 involves the participant using the computer system 100 to create the electronic message 240 with an attached object (step 500 ). The participant may create the electronic message 240 using a variety of software applications including electronic messaging, word processing, and others (e.g., MICROSOFT OUTLOOK® and MICROSOFT WORD® are registered trademarks of Microsoft Corporation, One Microsoft Way, Redmond Wash. 98052-6399, 425.882.8080, www.Microsoft.com). Alternatively, the electronic message 240 may be created using the NBIS Management Module 110 that includes instructions to/for the IDS 270 . The electronic message 240 is routed and received in the telecommunications network 250 (step 510 ). In an embodiment, the NBIS Rule-Based DataServer 258 determines whether external data sources 280 need to be queried for related electronic data or for retrieving an object that is linked rather than attached to the electronic message. Next, the telecommunications network 250 interprets the electronic message including the attached object, related healthcare data, and/or the linked object (step 520 ) using network elements including the NBIS Rule-Based Application DataServer 258 . Thereafter, the NBIS Rule-Based Application. DataServer 258 routes the object (e.g., the attached object, related healthcare date, and/or the linked object) to the IDS 270 so that the object may be interpreted from the sending participant's legacy system for compatible exchange with the receiving participant's legacy system (i.e., from the hospital's legacy system to the physician's legacy system) (step 530 ). The IDS 270 may be a stand alone system (not shown in the figures), the IDS 270 may be integrated into the telecommunications network 250 (as shown in FIG. 2 ), the IDS 270 may be integrated with one of the participant's legacy systems (not shown in the figures) that is accessed by the telecommunications network 250 or data network 262 , or the IDS 270 may be a combination of these systems (not shown). No matter how the IDS 270 is deployed, the interpreted object is received (step 540 ), processed so that the object is compatible for the receiving legacy system, (step 550 ), and associated with a transaction reply (e.g., a communication to the receiving participant about the electronic message including information about the attached object or the compatible object) or with a transaction notification (e.g., a communication to the sending participant about the electronic message including information about the attached object or the compatible object) (step 560 ). Thereafter, the transaction reply and/or the transaction notification are routed through the telecommunications network 250 (step 570 ) and forwarded to the receiving legacy system (step 580 ) or to the sending legacy system (not shown). The NBIS Management Module 110 presents the electronic message 240 so that the receiving participant of the computer system 100 has immediate access, notification, and management of the electronic message 240 including the compatible object and updated data in the receiving legacy system.
[0042] FIG. 6 illustrates a telecommunications network-based real estate information system 600 similar to the telecommunications system disclosed in FIG. 2 . As is apparent to one of ordinary skill in the art, the subject-specific group of participants may be tailored to any industry of participants that seek to leverage the assets of a telecommunications network in order to more efficiently share information, automate business processes, and further enhance market position.
[0043] FIGS. 7-8 are schematics showing a variety of wired and wireless communications devices communicating the electronic message 240 through the shared, interconnected network 210 according to alternate embodiments of this invention. The means of coupling the computer system 100 or other communications device (shown as reference numerals 702 - 716 ) to the switch 220 include a variety of means, including optical transmission of electronic data, wireless transmission of electronic data, and/or fixed-wire transmission of electronic data (e.g., via a local loop of a telecommunications network to communicate electronic data). Fiber optic technologies, spectrum multiplexing (such as Dense Wave Division Multiplexing), Ethernet and Gigabit Ethernet services, and Digital Subscriber Lines (DSL) are just some examples of the coupling means.
[0044] FIG. 7 illustrates a telecommunications network-based information system 700 similar to the telecommunications system disclosed in FIG. 2 ; however, telecommunications network-based information system 700 illustrates an embodiment of the call flow for alternate communications devices. Telecommunications system 700 includes alternate communications devices that include a personal digital assistant (PDA) 702 , an IP cellular phone 704 , a modem 706 , an interactive pager 708 , a global positioning system transceiver 710 , an MP3 player 712 , a digital signal processor (DSP) 714 , and an interactive television 716 . These alternate communications devices communicate via an antenna 720 communicating with an MTSO 730 that transmits the electronic message 240 to the switch 220 . Switch 220 routes the electronic message 240 to the shared, interconnected network 210 . In addition, FIG. 7 illustrates that the computer systems of the legacy system include a variety of communications devices including personal computer systems 100 and wireless communications devices, such as PDA 702 . Alternatively, a remote computer system, such, as personal computer system 100 , may also connect to the shared, interconnected network 210 (typically via a modem connection (not shown)). Regardless of the communications device used to send the electronic messages 240 , the electronic messages 240 may need to be formatted accordingly for the receiving communications device (including audio, text (e.g., ASCII), video, other digital formats, and combination thereof). Thus, the NBIS Rule-Based Application DataServer 258 has the intelligence to associate the presentation capabilities of the alternate communications device.
[0045] FIG. 8 illustrates a telecommunications network-based information, system 800 similar to the telecommunications system 700 disclosed in FIG. 7 ; however, telecommunications network-based information system 800 includes a communications device gateway 810 connected with a data network 820 and a communications server 830 so that the electronic message communicated to/from, switch 220 may be appropriately formatted for presentation on alternate communications devices 702 - 716 . For example, if the alternate communications device uses the Wireless Application Protocol (WAP) technique, then the electronic message 240 is communicated to a communications (“Comm”) server 830 . The communications server 830 formats the electronic message 240 into one or more Wireless Mark-up Language (WML) messages that are communicated over a data network 820 to a communications device gateway 810 . The communications device gateway 810 then interfaces with the MTSO 830 , and the MTSO 830 then wirelessly communicates the electronic message to the pager 708 or the wireless personal data assistant 704 (or a WAP phone). The Wireless Mark-up Language (WML) and the WAP technique are known and will not be further described. This is a description of a solution for a specific wireless protocol, such as WAP. This solution may be clearly extended to other wireless protocol, such as i-mode, VoiceXML (Voice extensible Markup Language), Dual Tone Multi-Frequency (DTMF), and other signaling means.
[0046] FIGS. 9-10 illustrate a flowchart showing an overview of a process of providing the telecommunications network-based information system service to a customer according to an embodiment of this invention. While the process in FIGS. 9-10 are shown in series, these processes may occur in different orders and/or at simultaneous times as one of ordinary skill in the art will understand.
[0047] Referring now to FIG. 9 , a NBIS participant (e.g., a user) associated with a first legacy system transmits an electronic message to a second NBIS participant associated with a second legacy system (block 900 ). A telecommunications network (TN) detects an incoming electronic message from the first NBIS user to the second NBIS user (block 910 ). The telecommunications network decodes the incoming electronic message for (1) an attached object and/or other related electronic data between legacy systems (e.g., queried data from an external data source 280 , a linked object, data that is cut and pasted into tire body of an email, etc.), (2) preliminary security verification, and (3) preliminary authentication (e.g., data and/or participants may be authenticated) (block 920 ). Next, the telecommunications network interprets the attached object and/or other related electronic data using a rule-based application server (e.g., NBIS Rule-Based Application DataServer shown as reference numeral 258 in FIG. 2 ) to categorize and associate rule based agents, fields, and/or files (block 930 ), The attached object and/or other related electronic data is then, processed according to how an Integrated Delivery System (IDS) is configured (e.g., integrated into the telecommunications network or accessed separate from the telecommunications network). If the integrated delivery system is not integrated with the telecommunications network (e.g., the integrated delivery system is accessed separate from the telecommunications network), then the telecommunications network routes the attached object and/or other related electronic data to the integrated delivery system associated with the first and the second legacy systems (block 940 ), and the integrated delivery system processes the attached object and/or other related electronic data so that the attached object and/or other related electronic data can be exchanged between legacy systems (block 950 ). If the integrated delivery system is integrated with the telecommunications network, then the telecommunications network processes the attached object and/or other related electronic data into the integrated delivery system so that the attached object and/or related electronic data can be exchanged between the first and the second legacy systems (block 960 ). By allowing both IDS architects, NBIS Management Services may be dynamically implemented across different platforms.
[0048] The method then continues with block 1000 of FIG. 10 . The rule based engine determines whether to activate a transaction reply and/or a transaction notification (block 1000 ). If there is no transaction reply and/or no transaction notification, then the telecommunications network handles the electronic message and/or other related electronic data according to instructions from the rule-based engine (block 1010 ). Alternatively, if a transaction replay and/or transaction notification is activated, then the telecommunications network selects the appropriate transaction reply and/or transaction notification (block 1020 ), routes the transaction replay and/or transaction notification to a computer system or other communications device (block 1030 ), and a client application (e.g., NBIS Management Module 110 ) residing on the computer system or other communications device presents the transaction reply and/or transaction notification (block 1040 ).
[0049] While several exemplary implementations of embodiments of this invention are described herein, various modifications and alternate embodiments will occur to those of ordinary skill in the art. Accordingly, this invention is intended to include those other variations, modifications, and alternate embodiments that adhere to the spirit and scope of this invention.
|
Methods, systems, and products systems are disclosed for categorizing and converting an attached object. An electronic message is received from a sender's address that is destined for a recipient's address and has the attached object associated with a sender legacy system. The sender's address and the recipient's address are associated to a list of addresses. When both the sender's address and the recipient's address are matched to the list of addresses, then the electronic message is sent to a rule-based engine that interprets the attached object using a set of rules and that categorizes the attached object. The object is converted based on the category. When the sender's address and the recipient's address do not match the list of addresses, then an identifier is received that associates the electronic message with another system.
| 7
|
BACKGROUND OF THE INVENTION
The process of developing software applications involves a structured approach designed to enhance the quality of the finished product. The structured approach to software application development involves a series of stages known as a software application development life cycle. There are several different implementations of the software application development life cycle, but in general, the process of software application development begins with analysis of the needs of an end user, such as a corporation, governmental entity, private individual, etc. The next stage involves designing the software application to meet the needs of the end user, after which the software application itself is created. After testing the software application, the software application is then sent to the end user. Corrective maintenance of, and improvements to, the software application may continue after sending the software application to the end user. Adherence to a structured approach of software application development decreases the number of flaws in the finished software application product.
A bug is generally defined as some flaw in the software application that causes all or some portion of the software application to malfunction or to perform in some unexpected fashion. As the commercial software application marketplace demands ever more powerful and feature-rich software applications, and as the complexity of software applications increases, the number of bugs increases. Although the structured approach to software application development is designed to prevent bugs, software application developers are not perfect and have a limited capacity to deal with complexity, and so therefore mistakes leading to bugs are inevitable. Many bugs are difficult to find and remain hidden until discovered by the end user.
In order to address the problem of bugs that exist in software which is already released to users, software manufacturers often release new versions of software applications in which bugs have been fixed. The users may then obtain the new versions. However, fixing bugs in software applications that have already been released is often costly.
In order to improve software application quality, software application manufacturers may employ bug-tracking systems. Bug-tracking systems help software application manufacturers find out what bugs are in the software application while the software application is being developed or tested prior to release, or after the software application has been released to the end user. Software application developers, software application testers, end users, or other interested parties may report bugs to the bug-tracking system by various means, such as telephone, email, etc. The software application manufacturer then collects reported software application bugs and stores the details of the reported bugs for analysis. Each bug is assigned a unique value, and the bug-tracking system thereby facilitates the fixing of bugs by allowing the software application manufacturer to monitor the progress of fixing the bug.
Independent Software Vendors (ISV's) are software application manufacturers that develop, or are involved with, software applications designed to enhance, improve upon, or work in conjunction with, other software applications developed by—or hardware developed by—another manufacturer. For example, an ISV may create an end user software applications designed to function on a certain computer operating system, such as a database management system meant to run on a computer operating system. ISV-created software applications is often referred to as “third party software applications.” The abundant existence of third party software applications for a software application such as an operating system enhances the value of the operating system for the end user by providing the end user with more choice and functionality in third party software applications for the operating system.
The presence of bugs in the operating system may hinder the development of third party software applications for that operating system. Third party software applications developed specifically for some other software application, such as an operating system, is by nature dependent upon the design of the operating system. Bugs in the operating system may make development of third party software difficult, or may deter ISV's from developing third party software applications for the operating system because of the added cost of dealing with the bugs. Furthermore, bugs in the operating system may also result in lower performance, thereby making the operating system less attractive to users.
A downstream ISV develops third party software applications that depend upon or work in conjunction with other third party software applications developed at some other ISV. For example, an ISV (company “A”) may develop a web browser designed to operate on a certain operating system. Another ISV (company “B”) may develop a software application that depends upon or works in conjunction with the web browser. Company “B” is known as a “downstream ISV.”
A bug advocate is a name given to employees of software application manufacturers appointed the task of eliminating bugs reported to the software application manufacturer by end users, in-house developers, developers working for ISV's, or other interested parties. The bug advocate, through the use of a bug-tracking system, follows through on some or all of the reported bugs, ensuring that bugs are rated and fixed. Thus, the use of the bug advocate and bug-tracking systems by software application manufacturers enhances the quality of the software application by facilitating the process of fixing bugs. Software application quality is enhanced by delivering a better product to the end user, and also by delivering better software applications to the ISV's. The ISV's are then better able to develop third party software applications, which, in turn, makes the software application more attractive to the end user by giving the end user more choice and functionality in third party software applications.
The foregoing statements regarding the problems of bugs in software application development also generally apply to other types of manufacturing besides software application manufacturing. For example, the manufacturers of computer hardware also address flaws in the finished product in order to facilitate the development of third party software applications meant to operate in conjunction with the computer hardware. Furthermore, any entity that creates a commercial product deals with the problems of quality control.
Java™ is a computer language designed by Sun Microsystems, Inc. (“Sun Microsystems”, hereinafter) to allow creation of software applications to run on various computer platforms. Referring to FIG. 1 , in order to create a Java™ software application, the developer first writes the software application in human-readable Java™ source code. As used herein, the term “software application” refers to Java™ 2 Standard Edition (J2SE™) software applications and Java™ “applets” which are essentially small software applications usually embedded in a web page. In the example shown, the software application “Program” ( 11 ) is created as a human-readable text file. The name of this text file is given the required five-character extension “.java.” The Java™ compiler (“javac”, “fastjavac”, “jvc”, et. al.) ( 13 ) is used to compile the source code into a platform independent bytecode ( 15 ). Upon compilation, the resulting binary file ( 15 ) will automatically receive the same file name as the source text file with “.class” extension or the same name of the source file plus a special character “$” plus the name of an inner class with the extension “.class.”
The Java™ runtime environment incorporates a virtual machine ( 16 ) to verify whether a given bytecode ( 15 ) has the proper format (verification process) and convert the “.class” byte codes into actual machine executions ( 17 ). The machine executions (like drawing windows, buttons, and user prompt fields) will occur in accordance to the software application developer's code instructions. Because Sun Microsystems specifically designed the virtual machine ( 16 ) to run on different platforms, a single set of “.class” byte codes will execute on any platform where a virtual machine ( 16 ) has been installed. An Internet web browser such as Netscape® and Microsoft® Internet Explorer that incorporates a virtual machine ( 16 ) is called a “java-enabled” web browser. A discussion of the Java™ language itself is beyond the scope of this document. However, complete information regarding the Java™ programming language and the Java™ platform are available from Sun Microsystems both in print and via the Internet at http://wwwjava.sun.com.
Servlets are software applications that run on a web server through the virtual machine. Servlets deliver HTML web pages to a web browser client. The web browser client requests HTML web pages from the server, and the servlet responds by creating an HTML web page, which the server sends back to the web browser client. Servlets allow the server to respond to deliver web pages dynamically, i.e., the content of the HTML web page may vary from client to client, the client web browser may interact with the servlet, etc. Thus, the servlet may create web pages based upon input from the user operating the web browser client. Examples of dynamic content are e-commerce applications, online tutorials, etc.
In order to respond dynamically to the web browser client, the servlet often makes use of a database. The database is a repository of information stored in computer memory, accessible to a variety of software applications. The servlet is connected to the database via a computer network; the web browser client is also connected to the server and servlet via a computer network. A typical sequence of operations is illustrated in FIG. 2 . The web browser client ( 30 ) sends a request ( 32 ) to the server ( 34 ). The server ( 34 ) passes the request ( 32 ) to the appropriate servlet ( 36 ), which then performs needed processing. The servlet then interacts ( 37 ) with the database ( 38 ), either writing to or reading from the database ( 38 ). The server then responds ( 39 ) to the web browser client ( 30 ).
SUMMARY OF INVENTION
In general, in one aspect, the invention comprises a method of rating a bug. The method comprises reporting the bug to a business entity by an interested party, entering information regarding the bug into a database, assigning a priority number for the bug, calculating a sigma number for the bug using the priority number, evaluating the bug to be fixed using the sigma number, and escalating the bug.
In general, in one aspect, the invention comprises a bug council rating apparatus. The apparatus comprises a database to store the information entered using a graphical user interface, a priority number module configured to generate a priority number, and a sigma number module configured to generate a sigma number.
In general, in one aspect, the invention comprises a computer system to rate a bug. The computer system comprises a processor, a memory, a computer display, and software instructions stored in the memory. The computer system is enabled under control of the processor, to perform reporting the bug to a business entity by an interested party, entering information regarding the bug into a database using a graphical user interface displayed on the computer display, assigning a priority number for the bug, calculating a sigma number for the bug, evaluating the bug to be fixed using the sigma number, and escalating the bug.
In general, in one aspect, the invention comprises a method for computing a priority number of a bug. The method comprises determining the bug severity, determining the bug escalation value, evaluating ease of reproducing a failure caused by the bug, and determining an amount of revenue contributed by a reporting vendor to a business entity. A list of weights is calculated based on the strength of strategic technology. Bug impact on adopting of strategic technology is evaluated. A determination is made a to whether a contractual arrangement exists between the business entity and the reporting vendor. Impact on downstream vendors is determined.
In general, in one aspect, the invention comprises an apparatus for rating a bug. The apparatus comprises means for reporting the bug to a business entity by an interested party, means for entering information regarding the bug into a database, means for assigning a priority number for the bug, means for calculating a sigma number for the bug using the priority number, means for evaluating the bug to be fixed using the sigma number, and means for escalating the bug.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates the creation of a Java software application.
FIG. 2 illustrates a typical sequence of operations between a web browser client, a server, a database, and a servlet.
FIG. 3 illustrates a typical computer system connected to the Internet.
FIG. 4 illustrates interactions involving components of a Bug Rating Apparatus, in accordance with one or more embodiments of the present invention.
FIG. 5 illustrates a sequence of operations of the Bug Rating Apparatus as applied to a bug, in accordance with one or more embodiments of the present invention.
FIG. 6 illustrates a computer screenshot of a collection of bug information via a web browser, in accordance with one or more embodiments of the present invention.
FIG. 7 illustrates a computer screenshot of a display of bug information via a web browser, in accordance with one or more embodiments of the present invention.
FIG. 8 illustrates a flowchart of a computation process that produces a bug priority number, in accordance with one or more embodiments of the present invention.
DETAILED DESCRIPTION
The present invention may be implemented on virtually any type computer regardless of the platform being used. For example, as shown in FIG. 3 , a typical computer ( 40 ) includes a processor ( 41 ), a memory ( 42 ), a storage device ( 43 ), and numerous other elements and functionalities typical of today's computers (not shown). The computer ( 40 ) may also include input means, such as a keyboard ( 44 ) and a mouse ( 45 ), and an output device, such as a monitor ( 46 ). Those skilled in the art will appreciate that these input and output means may take other forms in an accessible environment. The computer ( 40 ) is connected via a network connection ( 47 ) to the Internet ( 48 ).
A business entity, such as Sun Microsystems, produces both computer hardware (e.g., Sun Sparc™, Sun Blade™, etc.) and software applications (e.g., Sun Solaris™ operating system, Forte for Java™, various utilities, etc.). Some of the software applications produced by the business entity are designed to operate on the computer hardware produced by that same business entity. Certain ISV's, such as Oracle™, Peoplesoft™, SAP ™, etc., produce third party software applications that run on, or operate in conjunction with, the business entity's hardware and software.
If bugs exist in hardware or software applications, the business entity has the potential to incur negative economic impact due to lost sales, weakened relationships with ISV's, etc. The presence of bugs in hardware or software applications developed and manufactured by the business entity makes developing third party software applications more difficult and less desirable for ISV's. As the availability of third party software applications for the business entity's hardware and software applications decreases, the sales of the business entity's hardware and software applications are adversely affected.
In one or more embodiments of the present invention, a Bug Rating Apparatus addresses the aforementioned concerns by utilizing a rating system. The rating system involves a cost-benefit analysis as applied to a bug; the primary purpose of the rating system is to determine a priority number for the bug. Some primary considerations of the cost benefit analysis that determine the priority number of the bug include (1) the cost to the business entity to fix the bug, and (2) what effect the bug has on the ISV or ISV's (some bugs may hinder third party software applications development more than other bugs). Another consideration is the type of software application in which the bug is found. For example, a bug in an operating system may be fixed before a bug in a browser utility is fixed, because the operating system may be judged to be more strategic for marketing purposes than the browser utility. Another consideration is the ISV or ISV's involved—certain ISV's are more strategic for marketing purposes than other ISV's because of the type of third party software applications produced, or for other strategic reasons. Another cost-benefit analysis consideration is the nature of any contractual relationships between the involved ISV's and the business entity.
The Bug Rating Apparatus as illustrated in FIG. 4 incorporates several components, including a database ( 50 ), a priority number module ( 52 ), a sigma number module ( 54 ), a reporting module ( 56 ), a graphical user interface (GUI) ( 58 ), and a monitoring module ( 60 ). In the course of operations, modules incorporated in the Bug Rating Apparatus generally exhibit certain interactions between the different components. A first interaction ( 62 ) involves the database ( 50 ) and the GUI ( 58 ). A second interaction ( 64 ) involves the database ( 50 ) and the sigma number module ( 54 ). A third interaction ( 66 ) involves the database ( 50 ) and the priority number module ( 52 ). A fourth interaction ( 68 ) involves the sigma number module ( 54 ) and the priority number module ( 52 ). A fifth interaction ( 70 ) involves the sigma number module ( 54 ) and the reporting module ( 56 ). A sixth interaction ( 72 ) involves the sigma number module ( 54 ) and the monitoring module ( 60 ). A seventh interaction ( 74 ) involves the priority number module ( 52 ) and the reporting module ( 56 ). An eighth interaction ( 78 ) involves the GUI ( 58 ) and the reporting module ( 56 ). A ninth interaction ( 80 ) involves the GUI ( 58 ) and the monitoring module ( 60 ). Those skilled in the art will appreciate that there may be fewer or greater interactions than those listed above. Particularly, the GUI ( 58 ) interacts with the database ( 50 ) by displaying an interface, such as a web page on a web browser, allowing information relating to a bug to be entered. The GUI ( 58 ) interacts with the reporting module ( 56 ) by displaying the information generated by the modules to an interface, such as a web page on a web browser. Those skilled in the art will realize that, with respect to the matters discussed in this paragraph, a text-based interface may substitute for a GUI.
In order to determine the priority of a particular bug, each bug is evaluated in terms of cost-benefit analysis. The Bug Rating Apparatus assigns a priority number to each bug. The priority number module ( 52 ), as shown in FIG. 4 , generates a priority number that is used to determine the priority of the bug to be fixed. Potentially, some bugs may receive a priority number that results in the bug not being fixed. As the business entity's actual and potential losses change, so, too, does the priority number of the bug.
The sigma number module ( 54 ), as shown in FIG. 4 , generates a sigma number for each bug. The sigma number is based in part on the bug's priority number. Another factor in calculating the sigma number is the difficulty of fixing the bug and the impact of the bug on the ISV and the business entity over time. The sigma number dynamically reflects the financial impact on the business entity due to the bug; as time elapses, the financial impact changes, and so, therefore, the sigma number changes in order to reflect the changing financial impact of the bug upon the business entity. At certain threshold sigma number values, alerts may be initiated by the monitoring module ( 60 ), as shown in FIG. 4 , to ensure the bug receives the proper treatment. For example, bugs with sigma numbers that indicate high potential losses are elevated in priority so that those bugs may be more quickly fixed.
In one or more embodiments of the present invention, the Bug Rating Apparatus as applied to a bug is represented in FIG. 5 . First, an interested party, e.g., a reporting vendor, such as an ISV, reports the bug (Step 90 ) to an employee of the business entity, such as a bug advocate. The bug advocate then enters information regarding the bug (Step 91 ) into a database, including such items as (a) the data associated with the bug, (b) the data associated with the reporting ISV, and (c) the data related to the software application in which the bug exists. The priority number is assigned (Step 92 ) using, among other sources, information regarding the bug in the database. Next, the sigma number is calculated (Step 93 ) using among other sources, the priority number, information regarding the bug in the database, etc. The sigma number is evaluated (Step 94 ) to determine a ranking by comparing the sigma number of each sigma in the Bug Rating Apparatus. Based on the ranking done during the evaluation, the bug is either escalated (Step 95 ) to be fixed (Step 97 ) or the sigma number is re-calculated (Step 93 ) until such a point as the bug is escalated to be fixed. If the bug is escalated to be fixed, then an engineer (or some other appropriate party within the business entity) fixes the bug (Step 97 ). After the bug is fixed, the bug advocate relays the information that the bug has been fixed to a Market Development Engineering (MDE) group, which is an organization that functions as an ISV liaison for the business entity. The MDE group, after appropriate review of the data associated with the bug (Step 98 ), contacts the ISV (Step 99 ) in order to obtain feedback as to whether the bug has indeed been fixed to the satisfaction of the ISV.
In one or more embodiments of the present invention, the Bug Rating Apparatus may be implemented manually or may be automated or augmented through the use of software applications or some other mechanism. For example, one possible method of collecting reported bug-related data is via a GUI, such as a web browser.
As shown in FIG. 6 , the web browser ( 100 ) collects data by allowing the bug advocate (or other appropriate party) to enter data into a variety of labeled web browser elements (referred to as “fields”, herein). In the top section of the web browser, concerning development of third party software applications, the bug advocate may enter data into fields for the name of an ISV ( 101 ) reporting the bug (the reporting ISV), the email for the bug advocate ( 102 ), and the BugID ( 103 ) (a unique identifier for the bug). The bug advocate may indicate with the one-line test case field ( 104 ) whether the bug has a one-line test case addressing the degree to which the failure caused by the bug is easily reproducible. The bug advocate may indicate with the “Has DTS-plus contract” field ( 105 ) whether the reporting ISV has a contractual relationship for service with the business entity.
The next section of the web browser, shown in FIG. 6 , deals with the potential annual revenue impact of the bug. The bug advocate may use a field, such as the field labeled “Is MDDR global ISV” ( 106 ), to indicate whether the reporting ISV contributes a certain amount of money, e.g., at least $100 million per year, towards the business entity's revenue. The bug advocate may use a field, such as the “less than US$20,000,000” field ( 107 ), to allow an estimation of the annual revenue due to the bug.
The next section of the web browser, shown in FIG. 6 , deals with the annual revenue impact on the business entity due to downstream ISV's affected by the bug. The bug advocate may use a field, such as the field labeled “Impacts downstream ISV's” ( 108 ), to indicate whether the bug affects ISV's that create third party software applications which depends upon or work in conjunction with third party software created by the reporting ISV. The bug advocate may enter the names of any affected downstream ISV's in a specified text entry area ( 109 ). The bug advocate may use a field, such as the field labeled “less than US$20,000,000” ( 110 ), to allow an estimation of the annual revenue lost due to the bug. Those skilled in the art will realize that although large dollar amounts are used herein, dollars amounts both larger and smaller may be used as appropriate for any particular business entity, e.g., for larger or smaller business entities.
The next section of the web browser, shown in FIG. 6 , deals with strategic technologies and reporting ISV's. Certain ISV's are deemed to play a strategic marketing role with respect to the business entity's products and services, and so, therefore, bugs reported by those ISV's are elevated in priority. The bug advocate may select a strategic ISV from a list, such as the list labeled “Current ISV is strategic” ( 111 ). Bugs in certain technologies are determined to be more important and are accordingly granted higher priority. The bug advocate may select appropriate items from fields, such as the fields labeled “IAPT/J2EE Technology” ( 112 ), “Java Products” ( 113 ), “Operating Systems” ( 114 ), “Network & Solstice Prod” ( 115 ), and “User Environment” ( 116 ), which allow the bug advocate to indicate what technology or technologies are affected by or involved with the bug.
The bottom section of the web browser, shown in FIG. 6 , allows the bug advocate to enter a user name ( 117 ) and a password ( 118 ). The web browser presentation shown in FIG. 6 may be implemented by a servlet or similar technology in order to allow local use, or remote use over a computer network. The information entered by the bug advocate into the GUI, such as the web browser, becomes part of the bug database holding the bug information.
The process of collecting data associated with a bug may be further automated. For example, data entry by the bug advocate may be minimized by using a software application that performs queries on various databases to gather information. For example, as shown in FIG. 6 , the field labeled “Is MDDR global ISV” ( 106 ) need not be completed by the bug advocate if a software application is able to access databases containing information that describes the reporting ISV.
Another aspect of the Bug Rating Apparatus that may be augmented using a software application is the reporting functionality of the Bug Rating Apparatus. Bugs with the most loss potential and bugs that involve strategic technology or strategic ISV's are escalated to a list such as an MDE top 10 list of bugs. Other factors, such as the degree of difficulty of fixing the bug, play a role as well. The GUI may be used to display the major bug tracking goals and statistics, such as statistics relating to bug resolution timeframes (how long it takes to fix bugs), etc. The Bug Rating Apparatus allows further analysis of bug-related data through the use of an MDE Top 10 Drilldown report, which may be constructed manually or through some other form, such as a web browser. The MDE Top 10 Drilldown report may itemize bug-related data in terms of the technology in which the bug is found. For example, each row of the report may be linked to a certain technology, and the columns of the report may list such items as the average resolution time for bugs found in the technology, or the resolution rate for bugs found in the technology, etc. The aforementioned reporting functions are encapsulated as part of the reporting module ( 56 ) as shown in FIG. 4 .
In one or more embodiments of the present invention, an implementation of the GUI to augment the reporting functionality of the Bug Rating Apparatus is shown in FIG. 7 in the form of the web browser ( 100 ). A Year-End Dashboard ( 121 ) displays current values for Total Unresolved Bugs ( 122 ), Total Resolved Bugs ( 123 ) and compares yearly goals with actual values for Resolution Rate ( 124 , 125 ), and Average Days to Resolve ( 126 , 127 ). A sigma value ( 128 ) is representative of the sigma number for unresolved bugs. Historical values of Resolve Rate ( 129 ) and Average Days Unresolved ( 130 ) are graphed, as are goals for the rate of fixed bugs ( 131 ) and number of days to fix bugs ( 132 ). A graph of the sigma number ( 133 ) is based on the sigma number for all unresolved bugs. The list of bugs placed on the MDE top 10 list is updated at a periodic interval, such as twice monthly. The aforementioned reporting and tracking mechanisms are encapsulated as part of the reporting module ( 56 ) as shown in FIG. 4 .
Another aspect of the Bug Rating Apparatus that may be automated is the determination of the bug priority number. A software application may be constructed to compute the bug priority number, instead of calculating the bug priority number manually. The flowchart shown in FIG. 8 illustrates the computation process which produces the bug priority number for each bug. The computation process begins with a bug priority number equal to zero points. Next, the bug severity value is determined (Step 141 ). If the bug severity is equal to one (Step 142 ), then one point is added (Step 144 ). Then, the bug escalation value is determined (Step 145 ). If the associated escalation is Red or Yellow (Step 146 ), two points are added (Step 148 ). A Red escalation indicates first highest urgency factor (i.e., there is a need to fix the bug in a time span of hours or days). A Yellow escalation is the second highest urgency factor (i.e., there is a need to fix the bug in a time span of days or weeks). If the bug has a reproducible one-step command/script test case of product failure exemplifying an ease of reproducing the failure caused by the bug (Step 150 ), one point is added (Step 152 ).
A next step in the computation process asks whether the reporting ISV is a global ISV (Step 154 ) (a global ISV is an ISV that contributes a large number of dollars (e.g., $200,000) annually to the revenue of the business entity). If the reporting ISV is indeed a global ISV, then five points are added for ISV lost revenue due to the bug (Step 156 ). If the reporting ISV is not a global ISV, then for a set number of every additional dollars of revenue lost by the ISV (Step 158 ) (e.g., $20 million) above the initial number, one point is added (Step 160 , Step 162 ).
A next step in the computation process asks if the bug impacts adoption of the business entity's strategic technology (Step 164 ). A list of weights is calculated and consulted for the various technologies of the business entity in order to obtain a weight. The computation process adds up to two points if strategic technology is impacted (Step 166 ). A next step adds up to two points if the involved ISV is deemed to be strategic (Step 168 , Step 170 ). Again, a list of weights is calculated and consulted.
If the reporting ISV has a service contract or other contractual arrangement with the business entity (Step 172 ), one point is added (Step 174 ). Finally, the effect on downstream ISV's is considered (Step 176 ). If downstream ISV's are impacted, then a percentage, such as 60% of downstream ISV strategic technology and strategic ISV weightings values is added (Step 178 ). The output of the computation process is the bug priority number, which is a factor in the sigma number for the bug. The automated version of the top ten bug list may be frequently updated, e.g., daily. Using the automatically-created priority number and information in the database, the calculation of the sigma number may also be calculated automatically. Those skilled in the art will realize that the steps shown in FIG. 8 may be configured and changed in order to fit the needs of an individual business entity. For example, the amounts of points added for any particular step may be adjusted as needed; also, the determination and usage of strategic technologies and business entity relationships may be customized to fit the needs of an individual business entity.
The invention offers the ability to consolidate bug information in the database. The ability to consolidate bug information enhances the ability of the business entity to track the progress of work done on the bug, and thereby saves the business entity money. The use of the sigma number consolidates information regarding financial impact of the bug on the business entity, and thereby saves the business entity money. The invention, with the use of the GUI in conjunction with a web server and a servlet (or other similar technology) operating on a computer network (e.g., the Internet), enhances feedback from interested parties that have information relating to bugs. The invention enhances the cost-benefit ratio of fixing bugs by selecting to be fixed bugs with favorable ratio of cost-to-fix versus benefits-of-fixing. The invention enhances end user satisfaction by facilitating the fixing of bugs in the business entity's products.
|
A method of rating a bug, including reporting the bug to a business entity by an interested party, entering information regarding the bug into a database, assigning a priority number for the bug, calculating a sigma number for the bug using the priority number, evaluating the bug to be fixed using the sigma number, and escalating the bug. A bug council rating apparatus, including a database to store the information entered using a graphical user interface, a priority number module configured to generate a priority number, and a sigma number module configured to generate a sigma number.
| 6
|
RELATIONSHIP TO OTHER CO-PENDING APPLICATIONS
This application is related in subject matter to application Ser. No. 742,994, filed Jun. 10, 1985, and assigned to the Assignee of the instant application, now U.S. Pat. No. 4,605,062.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a subsurface well tool for use in oil and gas wells for injecting fluids into perforations of a production formation traversed by the well casing; more specifically, to a well tool mechanically set by axial manipulation of the tubing string and providing for pressure equalization across packing elements on opposite sides of a selected group of perforations and additionally effecting pressure equalization between the well annulus and the bore of the tubing string carrying the tool by rotation of the tubing string to facilitate release of the well too from its set condition.
2. Description of the Prior Art
It is often necessary to inject fluids, such as water, acid or various types of chemicals, into an underground formation through perforations in the casing which provide for communication between perforations in the formation and the bore of the casing. Most conventional tools used to inject fluids into a selected vertical group of perforations contained within a specified interval of the well require the use of two tools, suspended in series by a tubing string, one above the interval and one below the interval, and connected together to permit fluid injection. Thus, an upper packer can be secured to a ported tubing section which is in turn secured to a lower packer, thus providing isolation for the intermediate interval.
These tools are suitable only for injecting fluids into intervals of six feet or greater height. Prior art tools are not suitable for injecting fluids into selected intervals as small as six inches in vertical height, which may be desirable if fluids must be selectively injected into a single or closely adjacent well perforations. The conventional multipacker device is unsuitable for use in injecting fluids into such small intervals because the mechanism necessary to set each packer renders it virtually impossible to position the packers closely adjacent each other.
In the above identified co-pending application, an injection tool is disclosed wherein a plurality of vertically spaced packing elements are actuated by axial movements of a common mandrel traversing the bore of the packer body that mounts the packing element. For optimum efficiency, it is desirable to selectively open and close a recirculation or equalization fluid passage between the bore of the tubing string and the casing annulus above the upper most tool, and the provision of such apparatus in combination with the injection tool of the above-identified application is the object of the instant invention.
SUMMARY OF THE INVENTION
The invention relates to a tool for use in a well bore for producing hydrocarbons through a tubing string from a subterranean hydrocarbon bearing formation which has been perforated by a plurality of vertically spaced perforations. The tool includes a valving unit connected to a tubing string at its upper end and connected at its lower end to a packing unit. The packing unit includes a tubular body assembly, and, mounted on such assembly are upper and lower packing elements, each suitable for sealing the annular area between the tubing string and a casing or liner upon axial compression and radial expansion of the packing element. The packing elements can be set by longitudinal manipulation of a mandrel which is secured to the bottom end of a valving unit and is insertable into the tubular body assembly. An injection path is established through a port in the mandrel between the bore of the mandrel and the exterior of the packing unit. Such injection path includes an outer injection port in the tubular body assembly communicatin with the mandrel injection port and positioned between the upper and lower packing elements.
When a removable plug is positioned in the mandrel bore below the injection port, fluid supplied through the tubing string and valving unit can be injected through the mandrel port and through a small interval determined by the vertical spacing between the upper and lower packing elements.
A longitudinal bypass on the exterior of the mandrel provides a path for releasing annulus pressure acting on the expanded packing elements to facilitate the contraction or unsetting of the packing elements. Additionally, a radial port in the valving unit can be opened by rotation of the tubing string while the packing unit is set to establish communication between the tubing bore and the annulus, thus permitting recirculation and recovery of unused treatment fluid and also equalizing fluid pressures between the tubing string and the casing annulus to facilitate the release of the packing unit.
Further advantages of the invention will be readily apparent to those skilled in the art from the following detailed description, taken in conjunction with the annexed sheets of drawings, on which is shown a preferred embodiment of the invention.
BRIEF DESCRCIPTION OF THE DRAWINGS
FIGS. 1A through 1D comprise longitudinal continuations, vertical sectional views of the injection tool in its retracted position suitable for running into the well.
FIGS. 2A through 2D comprise longitudinal continuations, vertical sectional views of the injection tool positioned to inject fluids into the perforations in the casing communciating with a subterranean formation.
FIG. 3 is a schematic view illustrating the injection of fluids through the injection tool of FIGS. 2A through 2D into one of several closely adjacent formations.
FIG. 4A is a sectional view taken on the plane 4A--4A of FIG. 1D.
FIG. 4B is a sectional view taken on the plane 4B--4B of FIG. 2D.
FIG. 5 is a perspective view of the drag block housing.
FIG. 6 is a sectional view taken on the plane 6--6 of FIG. 5.
FIGS. 7A and 7B collectively represent a vertical sectional view of a tool embodying this invention shown in position in a well bore for injecting chemical treatment fluid into a selected group of well perforations.
FIGS. 8A and 8B are views respectively similar to FIGS. 7A and 7B but showing the position of the tool elements when the valving tool is opened as a preliminary to unset the packing unit.
FIGS. 9A-9B collectively constitute an enlarged scale vertical quarter sectional view of the valving unit incorporated in the injection apparatus.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 7 shows schematically all of the elements of a well tool 1 embodying this invention inserted in a well casing C having a plurality of vertically spaced perforations P communicating with a production zone. Tool 1 essentially comprises a packing or injection tool 2 connected in series relation with a valving unit 100 by an internally threaded coupling TC.
Packing tool 2 is identical to the tool described and claimed in the aforementioned co-pending parent application.
Packing tool 2 includes an upwardly projecting, hollow mandrel assembly 4 which has external threads 4a connecting with threaded coupling TC. Valving unit 100 is of annular configuration and has its upper end connected by a coupling sleeve TC-2 to a tubing string (not shown) which extends upwardly to the surface. A continuous fluid passage is thus defined between the bore of the tubing string, the bore 101 of valving unit 100 and the bore of mandrel assembly 4.
Referring now to Figs. 1A-1D, an upper unloader seal assembly including an annular elastomeric seal 14 is positioned adjacent the upper end of the mandrel 4. This upper unloader seal assembly comprises an upper seal retainer 6 secured to a lower seal retainer 8 by means of a threaded connection therebetween. A split ring retainer 10 held within an annular groove on the exterior of mandrel 4 engages the upper seal retainer member 6 and also engages a seal spacer 12. The retainer ring 10 and the seal spacer 12 are trapped between the upper seal retainer 6 and the lower seal retainer 8. Lower seal retainer 8 has a lower shoulder extending radially inwardly over a portion of the annular elastomeric upper seal ring 14 to hold the seal ring firmly secured around the exterior of mandrel 4.
Immediately below the upper seal assembly, including seal 14, the exterior of the mandrel 4 slopes inwardly to an outer diameter equivalent to that in section 4b. The outer diameter and thickness of the mandrel 4 remains essentially the same as shown at section 4b for that portion of the mandrel extending from the upper seal assembly to the lower end of the mandrel. A hydraulic hold-down housing 18 forming a portion of the exterior housing of the injection tool 2 extends around the upper portion of the mandrel section 4b and is attached by means of a threaded connection 18b to a cylindrical seal compressor 16. A rim 16a located at the upper end of seal compressor 16 has a reduced thickness and is opposed to the elastomeric seal 14. Seal compressor 16 is radially spaced from the exterior surface of mandrel section 4b by an amount sufficient to be radially coextensive with elastomeric seal 14.
A port 18a extends through the exterior of housing section 18 and communicates with a cavity formed between the outer housing section 18 and a balance sleeve 20. Conventional seals 19 and 21 establish sealing integrity with balance sleeve 20. The diameter of O-ring seal 19 and the surface which it engages is greater than the diameter of O-ring seal 21 and the surface which it engages, thus creating a net pressure area on balance sleeve 20. Balance sleeve 20 is spaced from the mandrel 4 below the seal compressor 16. In FIG. 1A, balance sleeve 20 is located in its uppermost position. The bottom end of balance sleeve 20 engages a radially outwardly protruding lug 4f forming a part of the exterior of mandrel 4. Hydraulic hold-down receptacle 22 is positioned on the interior of the outer housing 18 and is secured thereto by threads l8c located adjacent the upper end of the hydraulic hold-down receptacle 22. O-ring 21 is positioned within an inner groove on hydraulic hold-down receptacle 22 and a reduced diameter lower section 20a of balance sleeve 20 contacts the inner surface of hydraulic seal receptacle 22. The receptacle 22 constitutes the upper portion of what may be called the tubular body assembly of the tool.
The hydraulic seal receptacle 22 has a plurality of radially extending cylindrical apertures 22b, each containing a hydraulic hold-down piston or button 26. In the preferred embodiment of this invention, a plurality of hold-down buttons are positioned circumferentially around the injection tool. As shown in FIGS. 1A and 1B, a pair 26a and 26b of hold-down buttons are positioned one above the other at each circumferential position The hold-down buttons are shown in FIGS. 1A and 1B in their retracted position. A retainer bracket 24 secured to the receptacle 22 extends longitudinally over the exterior of each hold-down button 26. The retainer bracket 24 is secured to the receptacle or body 22 by a plurality of flat-head screws 30. A pair of springs 28a and 28b engages each of the hold-down buttons 26a and 26b at each circumferential location. The hold-down buttons 26a and 26b each have an O-ring 26c extending therearound engaging radial cylinders defined in receptacle 22. Each hold-down button or piston is cylindrical and has a longitudinally extending groove 26d for receiving springs 28 and through which the bracket 24 extends.
An upper intermediate housing or body section 32 is attached to the hydraulic hold-down seal receptacle 22 by a threaded connection 22d and an O-ring seal retainer 34 is in turn secured to hydraulic hold-down receptacle 22 by internal threads 22e with O-rings 33 and 35 establishing sealing integrity. An upper portion 36 of a longitudinally extending bypass area is defined on the interior of the upper intermediate housing or body 32 and extends between the mandrel 4 and the seal receptacle 22 upwardly through the balance sleeve 20 and through the seal compressor 16 to communicate with the exterior of the injection tool in the configuration shown in FIGS. 1A and 1B.
A packing element mandrel 42 having an opposing shoulder 42a engaging the lower end of upper intermediate housing 32 extends concentrically relative to the inner mandrel portion 4b from the lower end of housing 32. An annular gage ring 38 engages the exterior lower end of housing 32 and forms an upper abutment for the uppermost packing element 40a. Three packing elements 40a, 40b, and 40c, each of conventional annular construction, surround the packing element mandrel 42. Two packing elements separators 4la and 4lb are positioned on opposite ends of the intermediate packing element 40b. The packing elements can comprise a conventional elastomeric material. If desired, the packing elements can be fabricated of elastomeric elements of different durometers. A lower gauge ring 46 similar in construction to upper gauge ring 38 is positioned in abutting relationship to the lower end of packing element 40c which comprises the lowermost of the upper set of three packing elements.
As shown in FIG.. 1B, an inner injection port 4d extending through mandrel 4 establishes communication between the mandrel bore and the longitudinal bypass 36 formed around the exterior of mandrel 4. An outer ported section 48 (FIG. 1C) threadably secured at its upper end to gage ring 46 defines an exterior radial port 50 communicating between longitudinal bypass section 36 and the exterior of the tool immediately below the upper set of packing elements 40a, 40b, and 40c. The outer ported section 48 has an inner diameter which is greater than the inner diameter of the upper packing element mandrel 42 and which is also greater than the inner diameter of a lower packing element mandrel 58 secured to the lower end of the ported section 48 by threads 48a. Therefore the thickness of the longitudinal bypass longitudinally above and below the ported section 48 is less than the thickness of the bypass on the interior of ported section 48.
In the preferred embodiment of this invention, the inner mandrel 4 can comprise a plurality of threaded sections. A lower unloader seal support comprising a tubular metallic section 52 (FIG. 1C) having annular elastomeric sections 54 secured to the exterior thereof, is threadably secured between the sections 4b and 4c of mandrel 4. In the configuration shown in FIG. 1C, the lower unloader seals 54 can be positioned in the portion of the longitudinal bypass adjacent port 50. In this section of the longitudinal bypass, seals 54 do not engage an interior surface and the longitudinal bypass is continuous between the upper section 36 and a lower section 66.
Additionally, the unloader seal support 52 comprises a seal bore portion 52a immediately above a constricted bore portion 52b. The upwardly facing shoulder 4g thus defined provides a mounting for a wireline removable plug 94 having seal elements 94b and a fishing neck 94a. If desired, a conventional locking type, wireline removable plug may be substituted for plug 94 which will facilitate selective swabbing of the perforations.
A gauge ring 56 is secured to the lower end of ported section 48 by the threads 48b and abuts the upper end of the uppermost of three lower packing elements, 60a, 60b, and 60c.Each of these packing elements is conventional in nature and can be similar in construction to the corresponding packing elements 40a, 40b, and 40c located above the ported section 48. Similar packing elements separators 61a and 61b are located above and below the central packing element 60b of the lowermost set of three packing elements. These packing elements 60a, 60b, and 60c surround and engage the lower packing element mandrel 58 in the same manner that the upper packing elements 40a, 40b, and 40c engage the upper packing element mandrel 42. The lower section 66 of the longitudinal bypass extends between packing element mandrel 58 and the adjacent portion of the mandrel 4.
A lower gauge ring 62 is secured by threads 62a to a tie sleeve 64 which comprises a cylindrical member defining the portion of the outer tool housing below packing element 60. A radial port 68 extending through tie sleeve 64 establishes communication between the lower section 66 of the longitudinal bypass and the exterior of the tool.
An expander cone 70 is secured to the lower end of tie sleeve 64 by means of conventional threaded connection 70a. A rocker slip sleeve 72 is secured to the upper cone 70 by means of an annular snap ring 71. The rocker slip sleeve 72 has a plurality of grooves 72a located circumferentially therearound for receiving the inner portions of conventional rocker slips 74. Each of the several rocker slips 74 located circumferentially around the lower end of the injection tool is spring loaded relative to the lower end of the rocker slip sleeve 72 by a plurality of springs 76, which engage the inner surface of lower drag section 74b of the rocker slip. The rocker slip assembly, comprising a plurality of equally spaced rocker slips is held in position by a rocker slip retainer ring 75 located just above the rocker slip drag sections 74b. In the configuration shown in FIG. 1D, the springs 76 bias the lower section of the rocker slip outwardly so that drag section 74b is the outermost section of the injection tool.
The upper end 74a of each rocker slip 74 comprises a section having a serrated outer surface 74c and an inclined inner surface 74d opposed to a cooperable camming surface 70b on the lower end of cone 70. In the retracted configuration shown in FIGS. 1C and 1D, the rocker slips 74 are spaced from the cone 70. The lower end of the rocker slip 74 is captured by an outer lip 78a on sleeve 78 to hold the rocker slip 74 in the run-in position
Sleeve 78 is secured to a cross-over sleeve 80 by conventional threads 78b. The cross-over sleeve 80 is in turn secured to a drag block segment retainer housing 82 (FIG. 5) by threaded connections 80a. A plurality of peripherally spaced, longitudinal dove-tailed recesses 82b are provided in housing 82 to respectivelY accomodate drag blocks 83 which are urged outwardly by springs 87.
At the lower end of the housing 82, an outer lock segment retainer 88 is secured by threaded connection 82a to lock segment housing 82. A lock segment 90 having teeth 90a on its inner surface and a dummy lock segment 91 having no teeth are retained within the lock segment housin 82 by the outer retainer 88. Coil springs 92 (FIGS. 4A and 4B) extend circumferentially around the grooves 82f in housing 82 and the lock segments 90 and 91 to hold the segments in a radially retracted position. The horizontal teeth 90a on the inner surface of lock segment 90 engage cooperating horizontal grooves 4e extending partially around the lower portion of the mandrel 4 (FIG. 4A) to prevent axial movement of mandrel 4 relative to the rest of the tool.
The mandrel 4 may thus be released from the lock segment by limited angular rotation. The limit to the rotation is provided by an axial tab 82d (FIG. 5) on the top end of drag block housing 82 which engages a key 85 which is secured in a longitudinal slot 4h in the periphery of the mandrel 4 by the cross over sleeve 80. If the opposite direction of rotation of mandrel 4 is desired to release the mandrel to set the packer, then it is only necessary to reverse the positions of threaded lock segment 90 with unthreaded lock segment 91. A bevel 82e on each axial edge of tab 82 forces key 85 into slot 4h and improves the reliability of the key.
At the lower end of the mandrel 4, threads 4h provide a means for securing the mandrel 4 to a portion of the tubing string extending below the packing or injection tool 2.
FIG. 2 shows the actuation of the packing or injection tool 2 to permit injection of fluids through a single selected set of perforations, without injecting into closely adjacent perforations axially spaced from the selected perforations by distances of as little as 6 inches. As shown in FIG. 3, the upper set of packing elements 40 can be positioned above the selected set of perforations P while the lower set of packing elements 60 can be positioned below this same selected set of perforations. Expansion of packing elements 40 and 60 will then seal the annulus above and below the selected set of perforations and isolate the annular area surrounding the selected set of perforations from closely adjacent perforations above and below.
To position the packing tool 2 as shown in FIGS. 2A, 2B, 2C, and 2D the tool is lowered into a position adjacent the selected perforations P, with the tool in the configuration shown in FIGS. 1A, 1B, 1C and 1D. The lock segment 90 engagement with grooves 4e (FIG. 4A) prevents expansion of slips 74 and of the packing elements 40 and 60. When the outer injection port 50 has been positioned adjacent a designated set of perforations P as shown in FIG. 2B, partial rotation of the tubing T in a previous selected direction releases mandrel 4 for axial movement relative to the lock segment 90. As the tubing T is rotated, the grooves 4e are disengaged from lock segment 90 (FIG. 4B) to permit downward movement of the mandrel 4. During the partial rotation of the mandrel 4, the drag block section 74b of the rocker slips 74 and drag blocks 83 engage the casing C to prevent rotation of the lock segment and the lock segment housing relative to the casing.
Downward movement of mandrel 4 relative to the rocker slips 74 brings the inclined surface 70b of expander cone 70 into engagement with the lower surface of the slip portion 74a of the rocker slips. Slip portion 74a is thus firmly wedged into engagement with the casing and the teeth bite into the casing and prevent further downward movement of rocker slip 74 relative to the casing. Continued downward movement of the mandrel 4, after the slips 74 are firmly wedged into engagement with the casing, is transmitted through the upper unloading assembly which is shifted downwardly into engagement with seal compressor 16. This downward movement of the mandrel 4 is transmitted through the retainer housing 18 and the hydraulic hold-down receptacle 22 to outer housing 32. Downward force applied to inner mandrel 4 is thus transmitted to packing elements 40 and 60, which are compressed by continued downward movement of the mandrel 4 relative to the now stationary lower housing section 64. Thus, the compressive force applied to the packing elements 40 and 60 causes radial expansion of the packing elements into engagement with the casing to seal the annulus between the tubing T and the casing C.
The packing tool 2 is now in position to inject fluids through the selected perforations P adjacent the outer injection port 50. If not positioned in the tool as it is run into the well, the removable plug 94 can be positioned in engagement with mandrel seat 4g by conventional means. The removable plug 94 shown here can be lowered into the well by wireline means. With the plug in place and in engagement with seat 4g, fluid injected through the tubing would pass through mandrel port 4d into the longitudinal bypass upper section 36 adjacent the outer injection port 50. During setting of the injection tool, the lower seals 54 will have been shifted into a position in engagement with the more restricted portion of the longitudinal bypass 66, as shown in FIG. 2C. Thus, fluid cannot pass through the longitudinal bypass past seals 54. Fluid injected through mandrel port 4d cannot communicate with the annulus above packing elements 40 through longitudinal bypass portion 36 because the upper unloader seal 14 is held in engagement with the seal compressor 16 by the downward force applied to the mandrel 4. The injection pressure is, however, communicated through longitudinal bypass portion 36 to the balance sleeve 20. A differential pressure force equal to the difference between the injection pressure within longitudinal bypass 36 and the pressure in the annulus acting on balance sleeve 20 through port 18a acts across an area between seals 19 and 21. This pressure force shifts the balance sleeve 20 downwardly, maintaining it in engagement with the mandrel lug 4c. Thus any force due to injection pressure exceeding annulus pressure will act through balance sleeve 20 downwardly on mandrel 4 to insure that the mandrel stays in its downwardly shifted position.
Pressure of fluid injected through mandrel 4 will not act upwardly on the outer portion of the injection tool to release the tool since this pressure will act through longitudinal bypass portion 36 on the hydraulic hold-down buttons 26a and 26b. This pressure will shift the buttons outwardly, compressing springs 28a and 28b. In the preferred embodiment of this invention, the hydraulic hold-down members have serrated teeth 26e and these teeth engage the casing to secure the injection tool against upward movement.
In the event the annulus pressure below lower packing element 66 were to exceed the annulus pressure above the tool, this pressure would be transmitted through the open bottom end of the lower portion 4c of the mandrel 4 through port 4d into the upper section of the longitudinal bypass 36. Of course, the removable plug 94 would be unseated by this excess pressure existing below the tool. Thus, in the event of a greater pressure below than above the tool, this pressure would be transmitted through longitudinal bypass section 36 to act on the hydraulic hold-down buttons 26a and 26b in the manner just described. Thus, the tool will not be unseated or forced to move up the well bore.
The injection tool is fully retrievable and is resetable within the well. Thus, the tool 2 could be repeatedly shifted from the location of perforations through which fluid has just been injected and can be repositioned with the outer injection port in proximity to other perforations. Normal injection procedure would involve positioning the injection tool adjacent the lower set of perforations and then sequentially repositioning the injection tool to inject at each subsequent set of perforations above the first set of perforations. At each subsequent set of perforations, the mandrel merely needs to be lowered to set the slip 74 and packing elements 40 and 60 as previously described. When the tool 2 is shifted upwardly, the mandrel is moved in an upward direction. Thus, the compressive force supplied by the mandrel 4 to the packing elements 40 and 60 would be released and the cone 70 can be moved form beneath the slip portion 74a of the rocker slip 74.
The packing elements 40 and 60 would not tend to remain in their expanded configurations due to any pressure differential acting in the annulus across either set of packing elements. Upward movement of mandrel 4 will equalize the pressure across upper packing elements 40 by establishing communication between the annulus above the injection tool through longitudinal bypass section 36 and through the injection port 50 to the annulus below packing elements 40. Movement of the unloader seal 14 out of engagement with seal compressor 16, serves to establish such pressure equalization and pressure communication. After pressure is equalized across upper packing elements 40, as a result of movement of unloader seal 14 away from seal compressor 16, any pressure differential existing across packing element 60 can be relieved as the lower unloader seal 54 moves from within the restriction in lower bypass section 66 to the larger diameter portion proximate to outer injection port 50. A pressure equalization path is then established from the annulus below the packing element 60 through port 68, through the lower longitudinal bypass portion 66, through the injection port 50 to the annulus above lower packing element 60. This tool therefore provides an easily repeatable releasing procedure in which the mandrel 4 is merely manipulated in a longitudinal fashion to both release the packing elements 40 and 60 and the slips 74 and to equalize pressure across both sets of packing elements 40 and 60.
Lastly, the mandrel 4 may be partially rotated to re-engage grooves 4e with lock segment 90, thus permitting lowering of all the components of the tool 2 to a new lower position.
During the aforedescribed operation of the packing tool 2, the valving tool 100 remains in the position illustrated in FIG. 7A, wherein the bore 101 of the valving tool 100 provides communication between the bore of the tubing string and the bore of the hollow mandrel assembly 4 of the injection too 2. It has been found that when an attempt is made to unset the injection tool 2 to move to a new location relative to the vertically spaced perforations, difficulty is encountered in the unsetting operation if any fluid pressure differential exists between the casing annulus and the bore of the hollow mandrel assembly 4. The valving tool 100 permits the opening of a large passage between the bore 101 of such tool and the casing annulus in response to rotation of the tubing string through a number of turns. Thus, the fluid pressure between the casing annulus and the bore of the hollow mandrel assembly 4 is completely equalized.
The valving tool 100 comprises a tubular inner valve body 104 having the threads 102 at its upper end for connection to the threaded coupling TC 2 and thus to the end of the tubing string (not shown). The tubular inner body 104 is surrounded by and sealably engaged with the bore of an outer tubular body assemblage 110. The outer tubular body assemblage 110 is provided at its lower end with internal threads 112 for connection to a connecting sub 114 which in turn is externally threaded at its bottom end for connection with the threaded coupling TC 1 which connects with the injection tool 2. An O-ring 106 is provided in a radially enlarged shoulder portion 105 of the tubular inner body 104 and provides a sealing engagement with the inner bore wall 110a of the outer tubular body assemblage 110.
A bearing support sleeve 120 is provided having external threads 120a on its lower end which is threadably engaged with internal threads provided on the upper end of the primary body member 111 of the outer tubular body assemblage 110. Bearing support sleeve 120 mounts a shear screw 122 which engages a suitable depression 104b provided in the inner tubular body 104. Shear pin 122 thus prevents relative rotation of the inner tubular body 104 with respect to the outer tubular body assemblage 110 until sufficient force is applied to effect the shearing of shear screw 122.
Additionally, the bearing support sleeve 120 forming the upper part of outer tubular body assemblage 110 is provided with external threads 120b to which is secured a bearing retainer sleeve 125. Bearing retainer sleeve 125 has an inwardly projecting radial shoulder 125a which engages the top of a thrust bearing 126a, which is preferably fabricated from a self lubricating material such as that sold under the trademark "Teflon". A steel thrust bearing 126b underlies the Teflon bearing 126a and abuts the top end 120c of bearing support sleeve 120. A Teflon, bearing 126c is disposed between the radial shoulder 105 on inner body 104 and the bottom end 120d of bearing support sleeve 120.
Bearing support sleeve 120 further defines an internal cylindrical surface 125c which cooperates with an annular groove 104c formed in the inner body assembly 104 to provide a mounting for a C-ring 127 which locks the outer tublar assemblage 110 to the inner tubular body assemblage 104 but permits unrestricted rotation between such elements. Additionally, the upper end 125b of bearing retainer sleeve 125 projects inwardly to a position closely adjacent to the surface of the inner tubular body 104 and mounts an O-ring 125d for effecting a seal between the inner tubular body 104 and the outer tubular body assemblage 110.
The lower primary portion 111 of tubular body assemblage 110 is provided with a plurality of peripherally spaced, axially extending fluid flow slots 115. A valving sleeve 140 is mounted within the bore of the lower primary portion 111 of the tubular outer body assemblage 110 for axial movements with respect to the outer tubular body assemblage 110, hence with respect to the flow slots 115. Valving sleeve 140 is provided with internal threads 140a which cooperate with similarly shaped external threads 104d provided on the lower end of the inner tubular body 104. A pair of bolts 116 mounted in valving sleeve 104 respectively engage the flow slots 115 to prevent rotational movement of valving sleeve 104 when the packing tool 2 is set. Accordingly, the rotational movement of the tubing string will effect an axial displacement of the valving sleeve 140 relative to the peripherally spaced slots 115. A conventional helical stop 141 is machined into threads 104d and 140a to limit the upward movement of valving sleeve 140 without binding.
In the closed position of the valving sleeve 140, (FIG. 7A), which corresponds to the sleeve being displaced downwardly by rotation of the tubing string, the peripherally spaced flow slots 115 are sealed at their upper end by an O-ring 142 mounted in an annular groove 140b provided on the exterior of the valving sleeve 140. The lower ends of the flow slots 115 are sealed by engagement of a molded seal 144 secured to the bottom end of the valving sleeve 140 by an internally threaded retaining sleeve 146 which is screwed onto external threads 140d provided on the bottom end of the valving sleeve 140. Molded sleeve 144 cooperates with an internally projecting cylindrical sealing surface 111a provided in the lower primary body portion 111 at a location below the peripherally spaced slots 115. Thus the slots 115 are bracketed by the O-ring seal 142 and the molded seal 144 so that fluid passage through the peripherally spaced slots 115 is prevented.
When it is desired to equalize fluid pressure between the casing annulus and the bore of the tubing string, the tubing string is rotated to the right, shears pin 122 and effects an upward displacement of the valving sleeve 140, removing the molded seal 144 from engagement with the sealing surface 111a and opening a radial path for fluid flow through the peripherally spaced flow slots 115.
The provision of the valving tool 100 is not only desirable for equalizing annulus and tubing pressure prior to effecting the unsetting of the injection tool 2 but also may be utilized at the conclusion of a chemical treatment operation to reverse flow the chemical treatment fluids contained in the bore of the tubing string by opening the valving tool 100 and applying fluid pressure to the annulus fluid to effect an upward flow of the remaining chemical treatment fluid through the tubing bore to the surface for recovery.
Those skilled in the art will recognize that the described construction of the valving tool 100 depends for successful operation on the prevention of trash accumulation between the threads 104d on the inner tubular body 104 and the cooperating internal threads 140a on the valving sleeve 140. The accumulation of any such trash may be prevented through the provision of a plurality of peripherally spaced, axially extending grooves 104e which traverse the threads 104d. A radial port 104f connects each of the grooves 104e to the bore 101 of the valving tool 100 and permits any trash to drain downwardly through such bore.
In addition to equalizing annulus pressure with tubing bore pressure, the tool embodying this invention has further utility in that it permits a change of well fluid, or removal of treatment fluid without imposing circulation pressure on the formation. By opening the valving tool 100, any acid or other treating fluid contained in the bore of the tubing string may be pumped out of the tubing string by applying a pressure to an appropriate annulus fluid. For example, at the conclusion of an acid treatment job, the packing tool 2 of this invention would be unset and moved up above the production formation with the mandrel plug still in the setting tool 2. The packing tool would be reset at the new location, the valving tool 100 would be opened by rotation of the tubing string and the acid contained in the bore of the tubing string would be reversed out of the tubing string through the application of pressure to the annulus fluid. In this manner, the fluid in the tubing bore can be replaced with a lighter completion fluid without putting any circulation pressure on the formation.
In the event that the injection and packing tool 2 should plug during the chemical treatment process, the valving tool 100 can be opened and through the application of pressure down the casing annulus, the acid or other treatment fluid can be removed from the tubing. Appropriate remedial action to remove the plugging could then be taken either by inserting tools through the tubing bore or pulling the tubing string which is now free of acid.
Those skilled in the art will recognize that any standard injection valve may be interposed between valving tool 100 and the tubing string. For example, the valve shown in co-pending application Ser. No: 790,876, filed Oct. 24, 1985, (BST-75), and assigned to the Assignee of this application may be utilized to control the quantity and the rate of chemical treatment fluid supplied to any selected vertical group of perforations.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.
|
An injection tool for use in injecting fluids into perforations of a production formation of an oil or gas well is mechanically set in the bore of the casing traversing the production formation, and mechanically releasable therefrom so that chemical treatment fluid can be injected between upper and lower packing elements into a single or a selected vertical group of perforations. The injection tool is connected to the tubing string by a circulation valve operable by rotational movement of the tubing string. Injection of the chemical fluid treatment is accomplished with the circulation valve in the closed position, while the circulation valve is opened to equalize tubing and annulus pressure whenever required.
| 4
|
CROSS REFERENCES TO RELATED APPLICATIONS
This application claims priority from German patent application 10 2013 104 271.6, filed on Apr. 26, 2013. The entire content of this priority application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to a motor-driven machine tool with a drive motor, the motor shaft of which is driven in rotation, with a tool drive shaft, which is driven in rotation or in oscillation about its longitudinal axis, and with a coupling drive for converting the rotational movement of the motor shaft into a driving movement of the tool drive shaft.
Machine tools of this type have been known for decades and are used in many different ways particularly as hand-held electric tools. In this context, there are both machines in which the tool drive shaft executes a rotating rotational movement, such as, for example, in drilling machines or angle grinders. Furthermore, in recent years, machines with an oscillating driving movement of the tool drive shaft have become increasingly common, and in this case the tool drive shaft can be driven in oscillation about its longitudinal axis. Oscillating machines tools of this type are used in many different ways for grinding, cutting or sawing, etc.
Particularly in the case of machine tools driven in oscillation, but also in specific machine tools having a tool drive shaft driven in rotation, such as in angle grinders, there is a problem that vibrations may occur which have an adverse effect upon the service life of the machine and are felt by the user to be a disadvantage.
If the motor shafts and the tool drive shaft are not oriented concentrically or axially parallel to one another, one-sided stresses upon the bearings occur, and, in course of time, overloads, premature defects or failures may possibly arise.
In machine tools driven in oscillation, the rotary driving movement of the motor shaft is converted into an oscillating driving movement of the tool drive shaft by means of a suitable coupling drive. In this case, a relative movement may occur between the drive motor and the coupling drive as a result of vibrational decoupling or damping. In this case, too, concentric and axially parallel orientation of the motor axis and tool drive shaft is therefore no longer possible.
EP 2 139 647 B1 discloses a machine tool driven in oscillation, according to the precharacterizing clause of Claim 1 , in which length compensation, for example using a star-shaped profile which engages into a bore with corresponding profiling, is provided between the drive shaft and motor drive shaft.
However, a design of this kind allows only length compensation in the region of the drive chain.
SUMMARY OF THE INVENTION
In view of this, it is a first object on which the invention to disclose a machine tool which tolerates a non-axially parallel arrangement of a motor shaft and tool drive shaft.
It is a second object of the invention to disclose a machine tool which reduces oscillations.
It is a third object of the invention to disclose a machine tool which keeps the loads of the mounting and coupling drive between the motor shaft and tool drive shaft at a small level.
In one aspect of the invention these and other objects are solved by a motor-driven machine tool, comprising:
a drive motor rotatingly driving a motor shaft; a tool drive shaft having a longitudinal axis about which said tool drive shaft is driven oscillatingly; a coupling drive coupled to said tool drive shaft for driving said tool drive shaft oscillatingly about said longitudinal axis thereof; and a coupling coupled to said motor shaft at one end thereof and coupled to said coupling drive at another end thereof configured for transferring a rotary motion of said motor shaft to said coupling drive and for compensating an angular offset between said motor shaft and tool drive shaft deviating from an axially parallel or a right-angled arrangement of said motor shaft and said tool drive shaft.
According to another aspect of the invention these and other objects are solved by a motor-driven machine tool, comprising:
a drive motor rotatingly driving a motor shaft; a tool drive shaft having a longitudinal axis about which said tool drive shaft is driven oscillatingly or rotatingly; a coupling drive coupled to said tool drive shaft for driving said tool drive shaft about said longitudinal axis thereof; and a coupling coupled to said motor shaft at one end thereof and coupled to said coupling drive at another end thereof configured for transferring a rotary motion of said motor shaft to said coupling drive and for compensating an angular offset between said motor shaft and tool drive shaft deviating from an axially parallel or a right-angled arrangement of said motor shaft and said tool drive shaft; wherein said coupling further comprises: a coupling shaft having a drive side and a driven side; a first articulated connection comprising a first spherical head and two first drive bolts, said first spherical head being guided on an inner surface of said coupling shaft and driving said coupling shaft via said two first drive bolts; a second articulated connection comprising a second spherical head and two second drive bolts, said second spherical head being guided on an inner surface of said coupling shaft and driving said coupling shaft via said two second drive bolts; and a sliding articulated connection being arranged between said drive side and said driven side of said coupling shaft.
According to another aspect of the invention these and other objects are solved by a motor-driven machine tool, comprising:
a drive motor rotatingly driving a motor shaft; a tool drive shaft having a longitudinal axis about which said tool drive shaft is oscillatingly driven; an eccentric coupling being configured for converting a rotary driving movement of said motor shaft into an oscillating movement of said tool drive shaft about said longitudinal axis thereof; a coupling coupled to said motor shaft at one end thereof and coupled to said coupling drive at another end thereof configured for transferring a rotary motion of said motor shaft to said coupling drive and for compensating an angular offset between said motor shaft and tool drive shaft deviating from an axially parallel or a right-angled arrangement of said motor shaft and said tool drive shaft; wherein said coupling further comprises: a coupling shaft having a drive side and a driven side; a first articulated connection comprising a first spherical head and two first drive bolts, said first spherical head being guided on an inner surface of said coupling shaft and driving said coupling shaft via said two first drive bolts; a second articulated connection comprising a second spherical head and two second drive bolts, said second spherical head being guided on an inner surface of said coupling shaft and driving said coupling shaft via said two second drive bolts; and a sliding articulated connection being arranged between said drive side and said driven side of said coupling shaft.
According to the invention, by means of the additional coupling, the risk of vibrations as a consequence of a design-induced offset or angular errors of the motor axis with respect to a concentric or axially parallel orientation to the tool drive shaft is markedly reduced. Moreover, the risk of overloads of the bearing points and of the material in the drive chain is markedly reduced. In the case of vibrationally decoupled machine tools with a tool drive shaft driven in oscillation, the risk of overloads of the bearing points is markedly reduced and at the same time the vibrational load is restricted.
In an advantageous refinement of the invention, the coupling comprises a coupling shaft which is coupled on a drive shaft to the motor shaft via a first articulated connection and which is coupled on a driven side to the coupling drive via a second articulated connection, at least one sliding articulated connection being provided between the drive side and the driven side.
By means of a design of this kind, angular errors and variations in position between the motor shaft and the tool drive shaft or the coupling drive arranged between them can be compensated.
In this case, the first articulated connection may comprise, for example, a first spherical head which is guided on an inner surface of the coupling shaft and which drives the coupling shaft via two first drive bolts, the second articulated connection comprising a second spherical head which is guided on an inner surface of the coupling shaft and which is driven by the coupling shaft via two second drive bolts.
According to a development of this design, the coupling shaft is designed as a hollow shaft with an inner surface, on which the first and the second spherical head are guided.
According to a further refinement of this design, the first or the second drive bolts are received longitudinally displaceably in grooves of the coupling shaft.
Preferably, both the first and the second drive bolts are guided longitudinally displaceably in slots in a wall of the coupling shaft.
These measures make it possible to have a simple configuration of the coupling which compensates both an angular offset and an offset in position between the motor shaft and tool drive shaft or between the motor shaft and coupling drive.
In an alternative design of the invention, at least one of the articulated connections may also be designed as a cardan joint, or both articulated connections may be designed as a cardan joint, in addition, a sliding articulated connection being integrated into the coupling shaft.
In this way, too, an angular offset or variation in position between the motor shaft and tool drive shaft or between the motor shaft and coupling drive is compensated. However, the design with one or two articulated connections as a cardan joint is more complicated than the abovementioned design and may possibly lead to somewhat higher bearing stress or somewhat increased load due to vibrations.
Even such a design nevertheless makes it basically possible to reduce the bearing load and the vibration load, as compared with conventional machine tools without a coupling of this type.
According to a further refinement of the invention, a housing is provided, with a motor housing portion for receiving the drive motor and with a gear housing portion for receiving the tool drive shaft and preferably the coupling drive, means being provided which allow relative movements between the tool drive shaft and the drive motor.
In this case, for example, the motor housing portion and the gear housing portion may be connected flexibly to one another.
Alternatively or additionally, at least one damping element for vibrational decoupling may be provided between the coupling drive and the drive motor.
If relative movements between the tool drive shaft and the drive motor are possible, fewer vibrations are transmitted to the drive motor. If the machine tool is held by hand in the region of the motor housing, markedly fewer vibrations are transmitted to the user. The reduction of vibrations of the drive motor and the accumulator in connection with the latter also has an advantageous effect upon the service life.
Compensating movements between the drive motor and tool drive shaft or coupling drive or between the gear housing and the motor housing are absorbed by the coupling.
By at least one damping element being arranged between the coupling drive and the drive motor, the vibrations are further reduced.
According to a further refinement of the invention, the coupling drive has an eccentric coupling drive for converting a rotary driving movement of the motor shaft into an oscillating movement of the tool drive shaft about its longitudinal axis.
In an alternative way according to the invention, the tool drive shaft is driven in rotation, the machine being designed as an angle grinder in which the coupling drive is designed as an angular gear, in particular as a bevel gear.
Even in a design of this kind, the advantages of the invention are afforded by a reduction in the bearing load and the possible compensational vibrations which may occur during operation.
It would be appreciated that the features of the invention which are mentioned above and those which are yet to be explained below can be used not only in the combination specified in each case, but also in other combinations or alone, without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention may be gathered from the description of preferred exemplary embodiments and are explained in more detail with reference to the drawing in which:
FIG. 1 shows a first perspective view of a machine tool according to the invention with a tool drive shaft driven in oscillation, one housing half being removed;
FIG. 2 shows a partially cut away view according to FIG. 1 , from which further details are clear;
FIG. 3 shows a longitudinal section through a machine tool according to FIG. 1 ;
FIGS. 4 and 5 show perspective views of the coupling according to FIGS. 1 to 3 in an enlarged illustration in two different rotary positions;
FIG. 6 shows in perspective a detail in the region of the drive motor, of the coupling and of the coupling gear according to FIG. 3 ;
FIG. 7 shows a view according to FIG. 6 with a slightly changed arrangement between the motor shaft and coupling gear;
FIG. 8 shows a perspective view of a further machine tool according to the invention with a rotating tool drive shaft in the form of an angle grinder;
FIG. 9 shows a diagrammatic illustration of a modification of the coupling according to FIGS. 4 and 5 , and
FIG. 10 shows a simplified diagrammatic illustration of the gear arrangement in the angle grinder according to FIG. 8 .
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIGS. 1 to 3 , a first version of a machine tool according to the invention is designated as a whole by the numeral 10 . This is a machine tool 10 driven in oscillation, with a motor housing 12 , in which a drive motor 14 is received, and with a gear housing 13 , in which a tool drive shaft 24 is received. A rotational movement of the motor shaft 18 is converted via a coupling 22 and an assigned coupling drive 20 into an oscillatingly driven driving movement of the tool drive shaft 24 about its longitudinal axis 25 .
At the outer end of the tool drive shaft 24 , which end projects outwards from the housing 12 , a tool-holding fixture 43 ( FIG. 3 ) is provided, to which an assigned tool, for example a grinding, cutting or sawing tool, can be fastened by means of a quick-action chucking device (not illustrated) with the aid of a tension lever 26 . The tool drive shaft 24 is mounted on the housing 12 with the aid of two bearings 38 , 40 ( FIGS. 2 and 3 ).
The drive motor 14 , via its motor shaft 18 , drives a coupling 22 , having a first articulated connection 44 on the side of the motor shaft 18 with a first spherical head 45 and having a second articulated connection 46 on the driven side with a second spherical head 47 . The second spherical head 47 is connected to an intermediate shaft 51 which is mounted on the housing 12 by means of two bearings 28 , 30 and which drives the tool drive shaft 24 in oscillation via the coupling drive 20 .
For this purpose, an eccentric coupling drive 32 is provided, which has on the intermediate shaft 51 an eccentric bearing 36 , on which an eccentric lever 34 connected fixedly in terms of rotation to the tool drive shaft 24 engages on both sides. The eccentric lever 34 can be seen in more detail particularly from FIG. 2 . It has a fork of U-shaped design, both ends of which surround the eccentric bearing 36 from outside. An eccentric movement of the eccentric bearing 36 on the end of the intermediate shaft 51 is thereby converted into an oscillating movement of the tool drive shaft 24 about its longitudinal axis 25 .
The eccentric coupling drive 32 and the tool drive shaft 24 are decoupled vibrationally from the drive motor 14 . For this purpose, a damping element 15 is arranged on each of the two sides in the transitional region between the motor housing 12 and the gear housing 13 , so that certain flexibility between the motor housing 12 and gear housing 13 and, in addition, vibration damping are afforded. Only a receptacle for a damping element 15 can be seen in FIG. 1 . A rubber plug is received therein as a damping element.
The transmission of vibrations from the tool drive shaft 24 and the eccentric coupling drive 32 to the drive motor 14 and the accumulator 16 connected to the latter is thereby reduced. The user who holds the machine tool 10 at the motor housing 12 experiences appreciably fewer vibrations.
The more detailed configuration of the coupling 22 provided between the coupling drive 20 and the drive motor 14 can be seen particularly from FIGS. 4 and 5 .
The coupling 22 has a hollow-cylindrical coupling shaft 42 which is driven by the motor shaft 18 via a first articulated connection 44 and which drives the intermediate shaft 51 via a second articulated connection 46 .
The first articulated connection 44 has a first spherical head 45 which is connected rigidly and fixedly in terms of rotation to the end of the motor shaft 18 . Two first drive bolts 48 project laterally from the first spherical head 45 towards the two sides lying opposite one another and are guided in assigned slots 52 in the surface area of the coupling shaft 42 . The first spherical head 45 is guided circumferentially on a cylindrical inner surface 49 of the coupling shaft 42 .
The second articulated connection 46 has a second spherical head 47 which is connected to the tool drive shaft 24 and which is likewise guided on the hollow-cylindrical inner surface 49 of the coupling shaft 42 . Also provided on the second spherical head 47 are two second drive bolts 50 which lie opposite one another and which are guided longitudinally displaceably in assigned slots 54 in the surface area of the coupling shaft 42 . The second spherical head 47 is connected rigidly and fixedly in terms of rotation to the intermediate shaft 51 .
The coupling 22 allows an angular offset and a variation in position between the motor shaft 18 and the intermediate shaft 51 .
Should an exact orientation between the intermediate shaft 51 and the motor shaft 18 therefore vary, for example as a result of vibrations, the coupling 22 makes flexible compensation possible. It is likewise conceivable to arrange the intermediate shaft 51 and the motor shaft 18 so as to be offset angularly or positionally with respect to one another.
FIGS. 6 and 7 show different arrangements between the intermediate shaft 51 and the motor shaft 18 . Whereas, in the version according to FIG. 6 , these are oriented in alignment with one another, in the version according to FIG. 7 there is a marked angular offset between the motor shaft 18 and the intermediate shaft 51 . This angular offset is compensated by the coupling 22 .
FIGS. 6 and 7 additionally illustrate on the intermediate shaft 51 a balancing weight 56 which is provided for mass balancing during the rotation of the eccentric bearing 36 .
One possible modification of the coupling described above is illustrated in FIG. 9 and is designated as a whole by 22 a . In this case, corresponding reference numerals are used for corresponding parts and are partially supplemented by “a”.
In this case, the motor shaft 18 drives the coupling shaft 42 a via a first articulated connection 44 a in the form of a cardan joint, while the driven end of the coupling shaft 42 a drives the intermediate shaft 51 via a second articulated connection 46 a in the form of a cardan joint connection. The coupling shaft 42 a comprises, furthermore, a sliding articulated connection which is indicated diagrammatically by 66 and which may comprise, for example, a slot 68 , into which an assigned slide 70 engages.
It would be appreciated that other configurations of a sliding articulated connection may also be used, for example a slide, for example in the form of a polygon, which is guided on an assigned inner surface of a counterpiece.
In principle, a coupling 22 a of this type with two cardan joint connections 44 a , 46 a and with a sliding articulated connection 66 is also possible in order to bring about angular compensation and positional compensation between the motor shaft 18 and intermediate shaft 51 . However, the above-described version of the coupling 22 according to FIGS. 1 to 7 , which has overall a simpler set-up, is preferred.
A modification of the machine tool according to the invention is illustrated in FIGS. 8 and 10 and is designated as a whole by 10 a.
This is a configuration of the machine tool in the form of an angle grinder with a gear head 58 according to FIG. 8 , with a lateral handle 60 for holding the machine and with a conventional protective hood 62 which serves as burst protection for a tool in the form of a grinding wheel or cut-off wheel.
As is clear from FIG. 10 , in this case the coupling drive 20 a received in the gear head 58 is constructed as an angular bevel gear. The tool drive shaft 24 mounted by means of two bearings 38 , 40 is thus driven in rotation. The motor shaft 18 of the drive motor 14 drives the intermediate shaft, mounted by means of two bearings 28 , 30 , via a coupling 22 according to the configuration described above with reference to FIGS. 4 and 5 . Located on the intermediate shaft 51 is a driving pinion in the form of a bevel gearwheel which drives an assigned driven wheel in the form of a bevel gearwheel on the tool drive shaft 24 .
In this version, too, the additional coupling 22 serves for the reduction of vibrations which may occur when the angle grinder is in operation. Moreover, the coupling 22 makes it possible to use an angular or positional offset between the motor shaft 18 and intermediate shaft 51 . The coupling drive 20 a with the bevel gear could also be designed to be at an angle deviating from 90°.
The coupling 22 or 22 a allows positional and angular variations between the drive shaft 24 and motor shaft 18 during operation. It is therefore expedient to provide certain flexibility in the mounting of, for example, the coupling drive 20 or 20 a or of the tool drive shaft 24 or motor shaft 18 , in order to permit compensating movements which may arise during operation. For this purpose, it is sufficient to provide certain flexibility between the motor housing 12 and the gear housing 13 . Advantageously, however, damping elements 15 are additionally provided for vibration damping in the transitional region between the motor housing 12 and gear housing 13 , as has already been explained above.
|
A motor-driven machine tool has a drive motor, the motor shaft of which is driven in rotation, with a tool drive shaft, which is driven in rotation or in oscillation about its longitudinal axis, and with a coupling drive for converting the rotational movement of the motor shaft into a driving movement of the tool drive shaft. Furthermore, a coupling is provided, which compensates an angular offset or change in position between the motor shaft and tool drive shaft which deviates from an axially parallel or right-angled arrangement of the two shafts.
| 5
|
PRIORITY CLAIM
[0001] This application claims the benefit of provisional application Ser. No. 61/421,011, filed Dec. 8, 2010, which is hereby relied upon and incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates generally to fuel dispensers. More specifically, the invention relates to detection and prevention of fraud caused by tampering with a fuel flow meter associated with a fuel dispenser.
BACKGROUND OF THE INVENTION
[0003] Fuel dispensers in retail service station environments include flow meters that measure the volumetric flow rate of fuel as it is dispensed. Such flow meters are typically required to comply with weights and measures regulatory requirements that mandate a high level of accuracy. This ensures that the customer is neither overcharged nor undercharged for the fuel purchase. Typically, either positive displacement meters or inferential meters have been used for this purpose.
[0004] In modern service station fuel dispensers, a control system processes signals generated by a displacement sensor to monitor the amount of fuel delivered to a customer's vehicle. One displacement sensor for this purpose is referred to as a pulser. Pulsers are typically variable reluctance sensors operatively connected to the flow meter to measure rotation of a flow meter shaft. As fuel is dispensed, causing the shaft to rotate, the pulser generates a pulse train. Each pulse represents a known volume of fuel (e.g., 0.001 gallons) passing through the meter.
[0005] However, other types of sensors have been used to sense flow rate of various fluids, including magnetic sensors and optical sensors. Magnetic sensors often comprise one or more magnets coupled to and rotating with a flow meter shaft. In some sensors, the magnet(s) may be disposed on a disc that attaches via a threaded aperture at an end of the flow meter shaft and is aligned with the shaft longitudinal axis. Magnetic sensors further include a flux detecting device, such as a Hall-effect sensor, to detect shaft rotation speed and direction.
[0006] Optical sensors typically comprise a disc with a pattern of transparent and opaque segments which form a number of concentric tracks. The disc rotates through a read head, which may comprise a light source, a mask, and a photodetector. The read head photodetector outputs the light intensity reaching its surface as the disc rotates, thus providing a signal indicative of the motion of the disc.
[0007] Attempts have been made to interfere with the displacement sensor on a fuel flow meter in order to modify the calculated volume of fuel dispensed. For example, a dishonest consumer may disconnect the sensor (or one of its components) from the fuel flow meter prior to a fueling transaction. Also, a dishonest consumer may disable either or both of the fuel dispenser or displacement sensor electronics and force fuel through the fuel flow meter.
SUMMARY OF THE INVENTION
[0008] According to one aspect, the present invention provides a method for detecting fraud caused by tampering with a fuel flow meter. The method comprises the step of providing a fuel flow meter for measuring the flow of liquid fuel. The flow meter has at least one shaft supporting a rotor. The method further comprises providing the flow meter with a rotary displacement sensor. Also, the method comprises recording data indicative of a first angular position of the shaft upon termination of a first fueling transaction and recording data indicative of a second angular position of the shaft upon initiation of a second fueling transaction. Finally, the method comprises comparing data indicative of the first and second shaft angular positions to determine whether a difference exists.
[0009] According to a further aspect, the present invention provides a fuel flow meter comprising a shaft supporting at least one rotor. The fuel flow meter also comprises a rotary displacement sensor comprising at least one sensing element, a processor, and memory. The displacement sensor is adapted to store first data indicative of an angular position of the shaft in the memory upon termination of a first fueling transaction. The displacement sensor is further adapted to generate second data indicative of an angular position of the shaft upon initiation of a second fueling transaction. Finally, the processor is adapted to compare the first and second data to determine whether a difference exists.
[0010] In another aspect, the present invention provides a fuel dispenser comprising a control system having control system memory and internal fuel flow piping adapted for connection to a fuel flow path from a bulk storage tank (e.g., an underground storage tank) to a nozzle. The fuel dispenser further comprises a fuel flow meter having a shaft, wherein said fuel flow meter is located along the piping. Also, the fuel dispenser comprises a rotary displacement sensor coupled to the fuel flow meter and in communication with the control system, wherein the displacement sensor comprises displacement sensor memory. The displacement sensor is adapted to determine data indicative of the angular position of the shaft, and the data indicative of the angular position is stored in both the control system memory and the displacement sensor memory.
[0011] According to a further aspect, the present invention provides a fuel flow meter comprising a shaft supporting at least one rotor and a rotary displacement sensor comprising a processor and memory. The displacement sensor comprises an optical encoder adapted to output an expected number of position signals per revolution of the shaft and one or more reference signals per revolution of the shaft. Also, the displacement sensor is adapted to store data indicative of the position signals and the one or more reference signals in memory. Finally, the displacement sensor is adapted to compare a first number of position signals received after receiving a reference signal before termination of a first fueling transaction and a second number of position signals received after initiation of a second fueling transaction to the expected number of position signals to determine whether fraud has occurred.
[0012] In accordance with another aspect, the present invention provides a method for detecting fraud caused by tampering with a fuel flow meter. The method for detecting fraud comprises providing a fuel flow meter for measuring the flow of liquid fuel, the flow meter having a housing and at least one shaft supporting a rotor. Also, the method comprises providing the flow meter with a rotary displacement sensor having a housing and a shaft. Further, the method comprises providing a first coupling between the flow meter shaft and the rotary displacement sensor shaft. Notably, the first coupling is operative to cause one of the rotary displacement sensor shaft and the flow meter shaft to rotate relative to the other of the rotary displacement sensor shaft and the flow meter shaft upon removal of the rotary displacement sensor from the flow meter housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A full and enabling disclosure of the present invention, including the best mode thereof directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended drawings, in which:
[0014] FIG. 1 is perspective view of an exemplary fuel dispenser according to one embodiment of the present invention.
[0015] FIG. 2 is a schematic diagram of internal fuel flow components of the fuel dispenser of FIG. 1 according to one embodiment of the present invention.
[0016] FIG. 3 is a schematic diagram illustrating the relationship between the control system, flow meter, and displacement sensor according to one embodiment of the present invention.
[0017] FIG. 4 is a flow chart outlining the operation of the components of FIG. 3 according to one embodiment of the present invention.
[0018] FIG. 5 is a schematic cross-sectional view of a positive displacement flow meter according to one embodiment of the present invention.
[0019] FIG. 6 is a flow chart outlining the operation of a fuel dispenser flow meter having an optical displacement sensor according to one embodiment of the present invention.
[0020] FIG. 7A is a partial cross-sectional view illustrating a coupling between a flow meter and a displacement sensor and their respective shafts according to one embodiment of the present invention.
[0021] FIG. 7B is a partial top view of the flow meter of FIG. 7A .
[0022] FIG. 7C is a bottom view of the displacement sensor of FIG. 7A .
[0023] FIG. 7D is a top view of the flow meter shaft of FIG. 7A .
[0024] FIG. 7E is a bottom view of the encoder shaft of FIG. 7A .
[0025] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0026] Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
[0027] Embodiments of the present invention relate to detection and prevention of fraud caused by tampering with a fuel flow meter associated with a fuel dispenser. Generally, the fuel flow meter comprises a rotary displacement sensor capable of determining the absolute shaft angle of the flow meter. Data indicative of the shaft angle may be stored in one or more memory devices, for example at the end of each fueling transaction. Then, at the beginning of a new transaction or when power is applied to the dispenser, for example, an algorithm may be run to ascertain the current shaft angle. The algorithm may then compare the detected shaft angle to the shaft angle previously stored in memory. As discussed below, if fraud has occurred during the time between when data indicative of the shaft angle is stored in memory and when the algorithm is run, it is likely that the current shaft angle will differ from the previously stored shaft angle. In this case, appropriate action may be taken to alert the operator that fraud has occurred, such as generating an alarm or disabling the fuel dispenser.
[0028] It is contemplated that the present invention may be used with many types of rotary displacement sensors. Thus, as used below, the term “displacement sensor” comprises any device which converts shaft angular position to an analog or digital signal that can be detected and further processed. The term includes, but is not limited to, any type of noncontact rotary position sensor or encoder. In preferred embodiments, the rotary displacement sensor is an absolute sensor. Further, as described in more detail below, the present invention may be used with both positive displacement and inferential fuel flow meters.
[0029] Referring now to FIG. 1 , a perspective view of an exemplary fuel dispenser 10 is provided according to one embodiment of the present invention. For example, fuel dispenser 10 may be the ENCORE® fuel dispenser sold by Gilbarco Inc. of Greensboro, N.C., U.S.A. Those of skill in the art will appreciate, however, that the present invention may be used with flow meters in any fuel dispenser.
[0030] Fuel dispenser 10 includes a housing 12 with at least one flexible fuel hose 14 extending therefrom. Fuel hose 14 terminates in a manually-operated nozzle 16 adapted to be inserted into a fill neck of a vehicle's fuel tank. Nozzle 16 includes a fuel valve. Various fuel handling components, such as valves and meters, are also located inside of housing 12 . These fuel handling components allow fuel to be received from underground piping and delivered through hose 14 and nozzle 16 to a vehicle's tank, as is well understood.
[0031] The fuel dispenser 10 has a customer interface 18 . Customer interface 18 may include an information display 20 that shows the amount of fuel dispensed and the price of the dispensed fuel. Further, customer interface 18 may include a media display 22 to provide advertising, merchandising, and multimedia presentations to a customer in addition to basic transaction functions. The graphical user interface provided by the dispenser allows customers to purchase goods and services other than fuel at the dispenser. The dispenser also preferably includes a payment card reader to allow the customer to pay for the fuel at the dispenser.
[0032] FIG. 2 is a schematic illustration of exemplary internal fuel flow components of fuel dispenser 10 . In general, fuel may travel from an underground storage tank (UST) via main fuel piping 24 , which may be a double-walled pipe having secondary containment as is well known, to fuel dispenser 10 and nozzle 16 for delivery. An exemplary underground fuel delivery system is illustrated in U.S. Pat. No. 6,435,204 to White et al., hereby incorporated by reference in its entirety for all purposes. In many cases, a submersible turbine pump (STP) associated with the UST is used to pump fuel to the fuel dispenser 10 . However, some fuel dispensers may be equipped with a pump and motor within housing 12 to draw fuel from the UST to the fuel dispenser 10 .
[0033] Main fuel piping 24 may pass into housing 12 first through shear valve 26 . As is well known, shear valve 26 is designed to close the fuel flow path in the event of an impact to fuel dispenser 10 . U.S. Patent App. Pub. No. 2006/0260680 to Reid et al., now U.S. Pat. No. 7,946,309, hereby incorporated by reference in its entirety for all purposes, discloses an exemplary secondarily-contained shear valve adapted for use in service station environments. Shear valve 26 contains an internal fuel flow path to carry fuel from main fuel piping 24 to internal fuel piping 28 , which may also be double-walled.
[0034] After fuel exits the outlet of the shear valve 26 and enters into the internal fuel piping 28 , it may encounter a flow control valve 30 positioned upstream of a flow meter 32 . In some fuel dispensers, the valve 30 may be positioned downstream of the flow meter 32 . The valve 30 may preferably be a proportional solenoid controlled valve, such as described in U.S. Pat. No. 5,954,080 to Leatherman, hereby incorporated by reference in its entirety for all purposes.
[0035] Flow control valve 30 is under control of a control system 34 via a flow control valve signal line 36 . Control system 34 may be a suitable microprocessor, microcontroller, or other electronics with associated memory and software programs running thereon. In this manner, the control system 34 can control the opening and closing of the flow control valve 30 to either allow fuel to flow or not flow through meter 32 and on to hose 14 and nozzle 16 .
[0036] Flow control valve 30 is located below a vapor barrier 38 delimiting a hydraulics compartment 40 of the fuel dispenser 10 . The control system 34 is typically located in an electronics compartment 42 of fuel dispenser 10 above vapor barrier 38 . In this embodiment, after fuel exits flow control valve 30 , it flows through meter 32 , which measures the volume and/or flow rate of the fuel.
[0037] Flow meter 32 may preferably be a positive displacement or inferential flow meter having one or more rotors which rotate on one or more shafts. Examples of positive displacement flow meter technology which may be modified for use with the present invention are provided in U.S. Pat. Nos. 6,250,151 to Tingleff et al., 6,397,686 to Taivalkoski et al., and 5,447,062 to Köpl et al., each of which is hereby incorporated by reference in its entirety for all purposes. Likewise, examples of inferential flow meter technology with may be modified for use with the present invention are provided in U.S. Pat. Nos. 7,111,520 to Payne et al. and 5,689,071 to Ruffner et al. and U.S. Patent App. Pub. No. 2010/0122990 to Carapelli.
[0038] Meter 32 comprises a rotary displacement sensor 44 that generates a signal indicative of the volumetric flow rate of fuel and periodically transmits the signal to control system 34 via a signal line 46 . In this manner, the control system 34 can update the total gallons dispensed and the price of the fuel dispensed on information display 20 via a communications line 47 .
[0039] As fuel leaves flow meter 32 it enters a flow switch 48 . Flow switch 48 , which preferably includes a one-way check valve that prevents rearward flow through fuel dispenser 10 , provides a flow switch communication signal to control system 34 via the flow switch signal line 50 . The flow switch communication signal indicates to control system 34 that fuel is actually flowing in the fuel delivery path and that subsequent signals from flow meter 32 are due to actual fuel flow.
[0040] After the fuel leaves flow switch 48 , it exits through internal fuel piping 28 to be delivered through fuel hose 14 and nozzle 16 for delivery to the customer's vehicle.
[0041] As noted above, embodiments of the present invention advantageously provide a fuel flow meter with a rotary displacement sensor capable of determining the absolute angle of the flow meter shaft. Thus, the rotary displacement sensor may preferably be an absolute, as opposed to an incremental, sensor.
[0042] Incremental displacement sensors indicate the amount of change between a previous position of a shaft and the present position of the shaft. If a power loss or other disturbance, such as an error in signal transmission, causes information regarding the present position to be lost, an incremental sensor must be reset to place the sensor in a reference position. In contrast, absolute displacement sensors are capable of measuring the shaft's position relative to a predetermined point, rather than from a previous position. After a power loss when power is restored, an absolute sensor indicates the current sensor position without the need to be moved to a reference position.
[0043] Those of skill in the art are able to identify suitable rotary displacement sensor technologies. As an example, the following companies offer rotary displacement sensor technology: Eltomatic A/S of Denmark and Metrom, LLC of Lake Zurich, Ill. In a preferred embodiment, the rotary displacement sensor may be a magnetic displacement sensor. Commercially available magnetic displacement sensor technologies that may be suitable for use in embodiments of the present invention include magnetoresistive, hall effect, inductive, and magnetic encoders. However, non-magnetic displacement sensors, such as optical or mechanical encoders, may also be used.
[0044] Magnetic displacement sensors may typically comprise one or more permanent magnets coupled to a rotating shaft to apply a variable magnetic field over a sensing element and obtain a response indicating angular position. In some cases, the magnet(s) may be disposed on a disc coupled to the shaft and centered on the shaft's longitudinal axis. (See, e.g., U.S. Pat. No. 7,546,778 to Amante et al., hereby incorporated by reference in its entirety for all purposes.) Other displacement sensors may comprise one or more sensing elements positioned over a magnetic rotor having at least one region of discontinuity defined in its outer circumferential surface such that the rotor generates a characteristic magnetic flux. (See, e.g., U.S. Pat. No. 6,397,686 to Taivalkoski et al.)
[0045] In many cases, the sensing element may be packaged as an integrated circuit. Further, the sensing element may provide a variety of outputs indicative of angular position, such as a multi-bit digital word for each distinct shaft angle, analog sine and cosine voltage outputs, or a change in electrical resistance. The absolute displacement sensor preferably has a high measurement resolution.
[0046] In this regard, FIG. 3 is a schematic diagram illustrating the relationship between control system 34 , fuel flow meter 32 , and displacement sensor 44 according to one embodiment of the present invention. For example, control system 34 , which preferably comprises memory 52 , may typically control various aspects of fuel dispenser 10 , such as valves, displays, and the like as is well understood. Control system 34 may be communicably coupled via signal line 46 to displacement sensor 44 , which may be operatively connected to flow meter 32 . Thereby, control system 34 may communicate with displacement sensor 44 to obtain data regarding operation of flow meter 32 , described in more detail below. In some preferred embodiments, communications between control system 34 and displacement sensor 44 are encrypted using suitable encryption algorithms known to those of skill in the art.
[0047] Additionally, in a further aspect, a communication link 54 may provide communication between control system 34 and a site controller or the like. In some embodiments, the site controller functions may preferably be provided by the PASSPORT® point-of-sale system manufactured by Gilbarco Inc. Communication link 54 may be any suitable link for providing communication between control system 34 and the site controller, such as two wire, RS 422, Ethernet, wireless, etc. if needed or desired. By way of communication link 54 , control system 34 may communicate any of the data communicated thereto on to the site controller, which may use any of this information for reporting or decision purposes. For example, the site controller may communicate with a remote location for credit/debit card authorization or it may communicate information to a remote location for logging, tracking, or problem identification.
[0048] Displacement sensor 44 , which may preferably comprise a magnetic rotary encoder adapted to determine absolute shaft position as described above, comprises sensor electronics 56 . Sensor electronics 56 , which may be formed as one or more programmable logic devices or application-specific integrated circuits (ASICs), preferably comprise memory 58 in electronic communication with a processor 60 . Processor 60 , which may be a microcontroller, microprocessor, or the like, is adapted to communicate with control system 34 via signal line 46 . Thus, for example, processor 60 may read from memory 52 and control system 34 may read from memory 58 . It should be understood that processor 60 may preferably include an operating program permanently stored in a read-only memory (ROM), and may also store information temporarily in a random access memory (RAM) on an as-needed basis. Processor 60 may typically employ a variety of conventional items, such as counters, registers, flags, and indexes as necessary or desired.
[0049] Further, in some embodiments the sensor electronics may comprise signal processing circuitry. As shown, sensor electronics 56 comprise signal processing circuitry 62 . In embodiments where the sensing element outputs analog signals, the signal processing circuitry may comprise an analog to digital converter and/or an interpolator to increase measurement resolution. In addition, other signal processing operations may be performed, such as calculation of flow direction, flow rate from shaft rotation, or correction of measurement error at high or low flow rates. One skilled in the art will appreciate that signal processing circuitry 62 may be incorporated into processor 60 .
[0050] The flow meter shaft angle is preferably stored in memory at least at the start and end of each transaction to enable a determination of whether the flow meter shaft angle has changed since it was last stored, which may indicate that fraud has occurred. However, the shaft angle may be recorded at any time, including when power is applied to the fuel dispenser after an outage and/or throughout each transaction.
[0051] For example, the shaft angle may be stored in the control system memory or the displacement sensor memory. In a preferred embodiment, however, the shaft angle may be stored in both memories (at least at both the start and end of each transaction). Those of skill in the art will appreciate that this may provide an additional safeguard against fraud, in that even where a dishonest consumer modifies the memory of one of the control system and displacement sensor, the correct shaft angle stored at the end of a previous transaction will still be stored in the other's memory. Thus, the fraud may still be detected as described below.
[0052] Memory 52 and memory 58 are preferably nonvolatile so that the data is preserved during electrical power loss. Desirable nonvolatile memory types include electronically programmable read only memory (EPROM), electronically erasable programmable read only memory (EEPROM), ferro-electric nonvolatile memory devices, flash memory devices, and other suitable types of alterable nonvolatile memory. The practice of the present invention contemplates using any suitable memory device as necessary or desired.
[0053] As noted above, fraud may occur when a perpetrator disconnects a displacement sensor from the fuel flow meter prior to a fueling transaction or disables either or both of the fuel dispenser or displacement sensor electronics and forces fuel through the fuel flow meter. Thus, embodiments of the present invention preferably provide a checking algorithm to determine whether the flow meter, displacement sensor, or controller has been tampered with and fraud has occurred. As described below, either or both of the dispenser control system and the fuel meter displacement sensor may perform the checking algorithm.
[0054] Generally, according to one embodiment, the algorithm may output whether a shaft angle detected prior to fuel dispensing, Θ S , is equal to a shaft angle stored in the control system or displacement sensor memory, Θ E , at the end of a previous transaction. If not, the control system or displacement sensor may take appropriate action to prevent fraud, such as generating an alarm or the like, disabling the fuel dispenser, and/or notifying appropriate authorities via the communication link.
[0055] In this regard, FIG. 4 is a flow chart outlining the operation of flow meter 32 according to one embodiment of the present invention. The process starts (step 100 ) and control system 34 receives a signal indicative of the start of a fueling transaction (step 102 ). For example, control system 34 may receive a signal that a customer has lifted a nozzle pedestal to the “on” position. Those of skill in the art will appreciate, however, that other signals may be used to indicate the start of fueling.
[0056] Next, control system 34 may instruct displacement sensor 44 to determine the current shaft angle Θ S (step 104 ). Data indicative of angle Θ S may preferably then be stored in both control system memory 52 and displacement sensor memory 58 , although in some embodiments the data may only be stored in either memory 52 or memory 58 (step 106 ).
[0057] Then, shaft angle Θ S is compared to shaft angle Θ E (step 108 ), which will have previously been stored in memory as described below. Regardless of where the shaft angles Θ S and Θ E are stored, either control system 34 or displacement sensor 44 may perform this comparison. Those of skill in the art will appreciate that because of the displacement sensor's high measurement resolution, it is exceedingly unlikely that a perpetrator will be able to reset the flow meter shaft and/or magnetic element to a position close enough to Θ E to escape detection. Thus, if the values are not equal, either control system 34 or displacement sensor 44 may take appropriate action to report or prevent fraud (step 110 ). Preferably, however, both control system 34 and displacement sensor 44 may compare the values of Θ S and Θ E in their respective memories 52 , 56 . Thereby, either control system 34 or displacement sensor 44 may take appropriate action to report or prevent fraud if the value of Θ E differs from the value of Θ S .
[0058] If angles Θ S and Θ E are equal, the fueling process begins and displacement sensor 44 may measure the position of a shaft of flow meter 32 (step 112 ). When control system 34 receives a signal indicative of the end of the transaction (step 114 ), it may instruct displacement sensor 44 to determine the current shaft angle, Θ E (step 116 ). In some embodiments, the displacement sensor may reset this position as the reference point (or “zero position”) relative to which it measures angular position each transaction, although this is not required. Finally, shaft angle Θ E may be stored in memory (step 118 ). As noted above, it is preferred that Θ E be stored in both control system 34 memory 52 and displacement sensor 44 memory 58 . The process then ends (step 120 ).
[0059] In a further embodiment, the above-described process may also be performed when power is applied to a fuel dispenser after an outage. This may be the case, for example, when a perpetrator disconnects the power from a dispenser and forces fuel through the fuel flow meter.
[0060] In a further embodiment, the shaft angle Θ E may be stored in both the control system and displacement sensor memories and these values may be compared for parity. Those of skill in the art will appreciate that this may provide additional fraud deterrence where a perpetrator attempts to alter one of the control system memory and displacement sensor memory (e.g., to hide the fact that fraud has occurred). Either or both of the control system and the displacement sensor may perform this comparison, preferably at all dispenser states (e.g., when power is applied and the start and end of each transaction, among others). Additionally, a site controller or the like in electronic communication with the fuel dispenser may perform this function. If the comparison does not yield equal shaft angles Θ E , appropriate action may be taken as described above.
[0061] FIG. 5 is a schematic cross-sectional view of a positive displacement flow meter according to one embodiment of the present invention. In particular, flow meter 200 comprises a body 202 defining a longitudinal bore therethrough between an inlet 204 and an outlet 206 . As shown, flow meter 200 comprises a displacement sensor 208 positioned in a sensor housing 210 . Displacement sensor 208 is preferably analogous to displacement sensor 44 , described above, and thus displacement sensor 208 may comprise a magnetic encoder. Sensor housing 210 may be removably attached to an end of flow meter 200 .
[0062] Flow meter 200 further comprises a rotor assembly 212 comprising a pair of screw spindles 214 , 216 , shown in simplified form to facilitate illustration. Screw spindles 214 , 216 may be elongate cylindrical rotors defining a helical blade, and as those of skill in the art will appreciate, spindles 214 , 216 may mesh and rotate together. Spindles 214 , 216 may rotate on shafts 218 , 220 , respectively, which are mounted at each end on bearings 222 .
[0063] Displacement sensor 208 , which may preferably be an absolute displacement sensor, comprises a magnetic element 224 which may be coupled to shaft 218 via an encoder shaft 226 (although in other embodiments element 224 may be coupled to shaft 220 ). For example, in one embodiment, encoder shaft 226 may be operatively connected to magnetic element 224 and threadably received in an axial bore 228 defined in an end of shaft 218 . Magnetic element 224 , which as shown comprises a disc having one or more magnets disposed thereon, is preferably adapted to apply a variable magnetic field to a sensing element 230 as shafts 218 , 226 rotate. However, magnetic element 224 may take other forms, as those of skill in the art will appreciate. In some embodiments, for example, magnetic element 224 may simply be a magnet partially or completely received in a bore defined in an end of shaft 218 . Element 224 may also comprise more than one magnet in some embodiments. Sensing element 230 , which may comprise an integrated circuit, is preferably adapted to detect the variable magnetic field applied by element 224 and provide outputs indicative of the angular position of shaft 218 .
[0064] Sensor housing 210 may comprise a radial measurement structure 232 defining an electronics compartment 234 therein. To maintain sensing element 230 isolated from flowing fuel, sensing element 230 may preferably be positioned in electronics compartment 234 . Thereby, sensing element 230 may be positioned proximate to and in axial alignment with element 224 . Electronics compartment 234 also houses other displacement sensor electronics 236 in electronic communication with sensing element 230 . Displacement sensor electronics 236 are preferably analogous to sensor electronics 56 described above, and thus sensor electronics 236 may comprise a processor, memory, and signal processing circuitry. As described above, the sensor electronics 236 may include one or more ASICs.
[0065] In operation, fuel may flow from internal fuel dispenser piping into inlet 204 . As fuel flows through meter 200 , screw spindles 214 , 216 rotate on their associated shafts 218 , 220 . Magnetic element 224 rotates with shaft 218 to apply a varying magnetic field over sensing element 230 . Sensing element 230 detects changes in the magnetic field and produces signals indicative of the absolute angular position of shaft 218 . Sensor electronics 236 (or, in some embodiments, control system 34 ) may then process these signals to determine the volume of fuel flowing through meter 200 . Further, as described above, the absolute angle of shaft 218 may be stored in memory at various points during a fueling transaction.
[0066] In a further embodiment, the displacement sensor may comprise an optical encoder. Incremental optical encoders typically output quadrature signals indicative of the motion of a flow meter shaft to a counter. Signal generation techniques include using geometric masking, Moiré fringing, or diffraction. However, incremental optical sensors are not suitable for storing absolute shaft angular position information. For example, digital output signals from these encoders consist of two square waves 90° out of phase and these signals have only four possible states. Analog signals from these encoders, which consist of sine and cosine signals output a number of times per revolution, are likewise insufficient. Further, problems in signal quality (e.g., quadrature separation and pulse “jitter”) can cause errors in encoding.
[0067] Some incremental optical encoders may include a reference signal or “check pulse” in a fixed location in order to define a reference position. Because the number of signals per revolution is known, these reference signals have been provided to check for counting errors which can occur due to an error in signal transmission, for example. However, as noted above, if power loss occurs, position information is lost and the sensor must return to the reference position to reset its counter.
[0068] Absolute optical encoders, on the other hand, may be suitable for determining and storing absolute shaft angle. Each track on the disc of an absolute optical sensor represents one bit of a binary number. As the disc rotates past a read head, a photodetector outputs a unique digital word for each shaft angle. Absolute optical encoders typically employ Gray code over direct binary coding because with Gray code, only one bit of data changes between representations of two consecutive positions. Those of skill in the art will appreciate, however, that to provide an absolute encoder with sufficient measurement resolution, the encoder should include a disc with a large number of tracks and sophisticated signal processing circuitry. For example, to provide an encoder with a resolution of 0.1° (i.e., 360°/2 12 ), twelve tracks are needed. Thus, while these encoders are within the scope of the present invention, a less expensive alternative may be preferable for some embodiments.
[0069] Thus, according to one embodiment of the present invention, the displacement sensor preferably comprises an optical encoder having a shaft-mounted disc analogous to that of an incremental optical encoder. The encoder disc may be provided with two tracks for analog or digital quadrature output signals and a third track for a reference position output signal. The displacement sensor further comprises sensor electronics which may preferably be analogous to sensor electronics 56 . Thus, the sensor electronics may receive a predefined and known number of output signals per revolution of a flow meter shaft. Further, the sensor electronics are preferably adapted to record in nonvolatile memory at the end of a fueling transaction the number of quadrature signals received since the last reference position output signal. This number, N E , is indicative of absolute shaft angle.
[0070] Depending on the needs of the operator and the memory available, recording of each output signal may occur for each revolution of the flow meter shaft, for the entire transaction, or for a plurality of transactions. Further, N E may be recorded in either or both of the control system and displacement sensor memories. Then, if a dishonest customer attempts fraud by disconnecting power or disconnecting the displacement sensor from the flow meter prior to forcing fuel through the fuel flow meter, when a new valid transaction begins the control system and/or displacement sensor will know the angular position of the shaft at the end of the last valid transaction.
[0071] In one embodiment, the displacement sensor may count the number, N S , of quadrature output signals received until the next reference position signal is received and transmit this information to the control system. If either or both of the control system and displacement sensor determine that, when subtracted from the expected number of signals per revolution, N S does not yield a number within one of N E , appropriate action may be taken to prevent or report fraud. As noted above, this may include generating an alarm or the like, disabling the fuel dispenser, and/or notifying appropriate authorities via the communication link. Those of skill in the art will appreciate that this arrangement may be less expensive than traditional absolute optical encoders and thus may be suitable for deployment in a retail fueling environment.
[0072] FIG. 6 is a flow chart outlining this process according to one embodiment of the present invention. This process may in many respects be similar to the process described with reference to FIG. 4 . In particular, the process starts (step 300 ) and a fuel dispenser control system (preferably analogous to control system 34 ) receives a signal indicative of the start of a fueling transaction (step 302 ). Next, as fuel begins to flow through the flow meter, an optical displacement sensor as described above may count the number of quadrature output signals received until the next reference position signal is received (step 304 ). The result, N S , may be stored in either or both of the control system and displacement sensor memories, where the number of quadrature output signals received since the previous reference position output signal, N E , will have preferably been stored at the end of the previous transaction.
[0073] Regardless of where N E is stored, either or both of the control system and displacement sensor may then perform the following steps. N S may be subtracted from the expected number of quadrature output signals per revolution of the flow meter shaft (step 306 ). Then, the result of this calculation may be compared to N E , which has been previously stored in memory (step 308 ). Specifically, in one embodiment, if the absolute value of the result minus N E is not equal to one, fueling may be interrupted and appropriate action may be taken to report or prevent fraud (step 310 ). Those of skill in the art will appreciate that in other embodiments, the values of N S and N E may be determined differently, such that the result of the above calculation yields a different expected amount. For example, the outcome could be zero rather than one.
[0074] However, in this embodiment, where the calculation yields an answer of one, fueling may not be interrupted and the transaction may continue (step 312 ). The displacement sensor preferably maintains the count of output signals in memory throughout the transaction. When the control system receives a signal indicative of the end of the transaction (step 314 ), it may instruct the displacement sensor to store a new value of N E in memory, and this information may also preferably be stored in the control system memory (step 316 ). The process then ends (step 318 ).
[0075] In a further embodiment, it may be desirable to force a nonnegligible rotation of an encoder shaft of a displacement sensor when a displacement sensor is removed from a flow meter. As explained below with reference to FIGS. 7A-7E , this may aid in the detection of fraud because it decreases the likelihood that a perpetrator could replace the displacement sensor such that its encoder shaft is in the same angular position it was before removal.
[0076] In this regard, FIG. 7A is a partial cross-sectional view illustrating a coupling between a flow meter 400 and a displacement sensor 402 and their respective shafts 404 , 406 according to one embodiment of the present invention. Shafts 404 , 406 may rotate in axial bores defined in respective housings 408 , 410 . To facilitate illustration, flow meter 400 and displacement sensor 402 are decoupled in FIG. 7A . FIG. 7B is a partial top view of flow meter 400 and FIG. 7C is a bottom view of displacement sensor 402 . Also, FIG. 7D is a top view of flow meter shaft 404 and FIG. 7E is a bottom view of encoder shaft 406 .
[0077] According to one embodiment, the coupling may prevent rotation of the displacement sensor housing relative to the flow meter housing when the displacement sensor is removed. For example, flow meter 400 preferably defines a socket 412 adapted to receive a protrusion 414 of displacement sensor 402 such that a bottom surface 416 of displacement sensor housing 410 rests flush against a top surface 418 of flow meter housing 408 when coupled. Socket 412 may preferably be non-round, defining a key 420 adapted to be received in a keyway 422 defined in protrusion 414 . Similarly, protrusion 414 may define a key 424 adapted to be received in a keyway 426 defined in socket 412 . One skilled in the art will recognize that other suitable methods for preventing relative rotation of the displacement sensor housing 410 and flow meter 400 during removal may be used and are within the scope of the present invention.
[0078] At the same time, the coupling may force rotation of one of the encoder shaft and flow meter shaft relative to the other when the displacement sensor is removed. In one example, encoder shaft 406 may define a bore 428 at a proximal end 430 thereof. Bore 428 may preferably have a depth equal to the height of protrusion 414 . Also, at least at an end portion thereof equal to the depth of bore 428 , flow meter shaft 404 may define a slightly smaller diameter D 1 than outer diameter D 2 of encoder shaft 406 such that shaft 404 may be snugly received in bore 428 when displacement sensor 402 is coupled to flow meter 400 .
[0079] Further, flow meter shaft 404 may include pins 432 diametrically opposed on its periphery. The diametric distance between the distal ends of pins 432 may be equal to diameter D 2 . In addition, encoder shaft 406 may define slots 434 extending in an upward helical fashion from bottom edge 436 and adapted to receive pins 432 when shafts 404 , 406 are coupled together. In one embodiment, slot 434 may travel through 90° of rotation from the bottom edge 436 to its terminus 438 . Thus, when displacement sensor 402 is coupled to flow meter 400 , flow meter shaft 404 may be inserted into bore 428 of encoder shaft 406 in a twisting motion as pins 432 follow the rotation of slot 434 .
[0080] A greater torque is preferably required to rotate flow meter shaft 404 than to rotate encoder shaft 406 . Thus, when displacement sensor 402 is removed from flow meter 400 , it will be appreciated that encoder shaft 406 may be forced to rotate in a clockwise direction while flow meter shaft 404 , flow meter 400 , and the housing 410 of displacement sensor 402 remain stationary.
[0081] Because shaft 406 has changed position, it will be extremely difficult, if not impossible, for a dishonest customer to replace displacement sensor 402 with shaft 406 in the same position as prior to removal. It will also be appreciated that because of the coupling between socket 412 and protrusion 414 , shafts 404 , 406 are inaccessible until displacement sensor 402 is decoupled from flow meter 400 . Thus, a dishonest customer cannot lock either shaft to prevent rotation during removal of displacement sensor 402 .
[0082] Additionally, in a further embodiment, the optical encoder disc or magnetic element (depending on the type of displacement sensor used) may be coupled to encoder shaft 406 via a one-way clutch which transmits torque in only one direction of rotation. In other words, shaft 406 may transmit torque when rotated clockwise but may “freewheel” when rotated counterclockwise. Thereby, reassembly cannot reproduce the exact prior angular position of the optical encoder disc or magnetic element because it will not turn as displacement sensor 402 is replaced (although shaft 406 will turn). Those of skill in the art can select a suitable one-way clutch, such as a roller clutch or the like.
[0083] In a further embodiment, the above-described physical couplings between flow meter 400 /displacement sensor 402 and flow meter shaft 404 /encoder shaft 406 may be reversed. In particular, when displacement sensor 402 is coupled to or decoupled from flow meter 400 , a physical screw or bayonet fitting may force rotation of displacement sensor 402 relative to flow meter 400 . At the same time, shafts 404 , 406 may be coupled in a manner that prevents relative rotation during attachment and removal of displacement sensor 402 . For example, pins 432 and slots 434 may not be provided and shafts 404 , 406 may be coupled using keys and keyways as described above. As a result, the relative position of the sensor element inside the housing 410 and the optical encoder disc (or magnetic element) will change. Those of skill in the art will appreciate that this embodiment may provide maintenance advantages in some applications.
[0084] While one or more preferred embodiments of the invention have been described above, it should be understood that any and all equivalent realizations of the present invention are included within the scope and spirit thereof. The embodiments depicted are presented by way of example only and are not intended as limitations upon the present invention. Thus, it should be understood by those of ordinary skill in this art that the present invention is not limited to these embodiments since modifications can be made. Therefore, it is contemplated that any and all such embodiments are included in the present invention as may fall within the scope and spirit thereof.
|
Methods and systems for detecting fraud caused by tampering with a fuel flow meter. In one embodiment, the method comprises providing a fuel flow meter for measuring the flow of liquid fuel. The flow meter has at least one shaft supporting a rotor. The method further comprises providing the flow meter with a rotary displacement sensor. Also, the method comprises measuring a first angular position of the shaft upon termination of a first fueling transaction and measuring a second angular position of the shaft upon initiation of a second fueling transaction. Finally, the method comprises comparing data indicative of the first and second shaft angular positions to determine whether fraud has occurred.
| 6
|
CLAIM OF PRIORITY
[0001] This application claims the benefit of U.S. Application No. 60/316,964 filed on Sep. 5, 2001, which is incorporated by reference in its entirety.
CROSS REFERENCE TO RELATED APPLICATIONS
[0002] The present application is related to co-pending application (Attorney Docket No. 10897-008001) entitled “Method and Apparatus For Generation of Nitric Oxide,” filed concurrently herewith, and co-pending application (Attorney Docket No. 10897-022001) entitled “Controlled Generation of Nitric Oxide,” also filed concurrently herewith, each of which is incorporated by reference in its entirety.
TECHNICAL FIELD
[0003] This invention relates to an apparatus and a method for controllably generating nitric oxide.
BACKGROUND
[0004] Nitric oxide plays an important role in the regulation of biochemical pathways in living organisms. The inhalation of low levels (20 to 100 ppm) of nitric oxide has been shown to have a major therapeutic value in treatment of a diverse range of disorders ranging from reversible and irreversible pulmonary hypertension to treatment of neonates exhibiting hypoxemic respiratory failure and persistent pulmonary hypertension. Conventional medical uses of nitric oxide gas can involve dilution of a nitric oxide gas stream with gases immediately before administration of the nitric oxide gas to a mammal. Precise delivery of nitric oxide at therapeutic levels of 20 to 100 ppm and inhibition of reaction of nitric oxide with oxygen to form toxic impurities such as nitrogen dioxide gas is needed for effective inhalation therapy.
SUMMARY
[0005] Nitric oxide, also known as nitrosyl radical, is a free radical that is an important signaling molecule in pulmonary vessels. Nitric oxide can moderate pulmonary hypertension caused by elevation of the pulmonary arterial pressure. Inhaling low concentrations of nitric oxide, for example, in the range of 20-100 ppm can rapidly and safely decrease pulmonary hypertension in a mammal by vasodilation of pulmonary vessels.
[0006] Some disorders or physiological conditions can be mediated by inhalation of nitric oxide. The use of low concentrations of inhaled nitric oxide can prevent, reverse, or limit the progression of disorders which can include, but are not limited to, acute pulmonary vasoconstriction, traumatic injury, aspiration or inhalation injury, fat embolism in the lung, acidosis, inflammation of the lung, adult respiratory distress syndrome, acute pulmonary edema, acute mountain sickness, post cardiac surgery acute pulmonary hypertension, persistent pulmonary hypertension of a newborn, perinatal aspiration syndrome, haline membrane disease, acute pulmonary thromboembolism, heparin-protamine reactions, sepsis, asthma and status asthmaticus or hypoxia. Nitric oxide can also be used to treat chronic pulmonary hypertension, bronchopulmonary dysplasia, chronic pulmonary thromboembolism and idiopathic or primary pulmonary hypertension or chronic hypoxia. Advantageously, nitric oxide can be generated and delivered in the absence of harmful side products, such as nitrogen dioxide. The nitric oxide can be generated at a concentration suitable for delivery to a mammal in need of treatment.
[0007] A nitric oxide delivery system can be a controlled drug delivery system, which produces steady-state levels of nitric oxide. The system can provide for zero-order, first order or second order drug release kinetics. Controlled drug delivery devices can provide a constant level of pharmaceutical drug to a mammal which can optimize the drug input rate into the systemic circulation, improve mammal compliance, minimize side effects, and maximize drug product efficacy.
[0008] Controlled nitric oxide delivery can include controlling the diffusion/dissolution of the nitric oxide. The nitric oxide precursor composition can include a matrix and a contained phase of a nitric oxide precursor, for slow or controlled release of nitric oxide into the surrounding or external medium. Controlling the release of nitric oxide can result in greater longevity of the nitric oxide precursor and longer availability of the nitric oxide precursor for its intended purpose while providing a means for greater control in the concentration of nitric oxide into the surrounding medium.
[0009] In one aspect, a method of delivering nitric oxide to a mammal includes disposing a cathode and an anode in a solution of a nitric oxide precursor, applying a voltage across the cathode and anode to generate nitric oxide substantially devoid of nitrogen dioxide, contacting a transport gas with the solution of nitric oxide precursor to form a therapeutic gas; and transporting the therapeutic gas in the transport gas to a mammal. The nitric oxide precursor can be a precursor salt. The precursor salt can be an alkali metal nitrite, alkali metal nitrate, alkaline earth metal nitrite, alkaline earth metal nitrate or ammonium nitrate. The concentration of the precursor salt can be between 0.1% to 20%. The nitric oxide precursor can be potassium nitrite, sodium nitrite, rubidium nitrite, strontium nitrite, barium nitrite, calcium nitrite, copper nitrite, zinc nitrite, potassium nitrate, sodium nitrate, rubidium nitrate, strontium nitrate, barium nitrate, calcium nitrate, copper nitrate and zinc nitrate. The nitric oxide precursor can be, for example, sodium nitrite. The therapeutic gas can include 20 to 60 ppm of nitric oxide. The transport gas can be oxygen, ambient air or a mixture of air and oxygen. The transport gas can be ambient air which can flow over or through the solution of nitric oxide precursor and can transport the therapeutic gas for at least one hour. The therapeutic gas can be substantially devoid of nitrogen dioxide.
[0010] In another aspect, a method of delivering nitric oxide from an electrochemical cell to a mammal includes disposing a cathode and an anode in a solution of dilute nitric acid, the anode including copper, applying a voltage across the cathode and the anode to generate nitric oxide substantially devoid of nitrogen dioxide; contacting a transport gas through the solution of dilute nitric acid to form a therapeutic gas including the nitric oxide and transporting the therapeutic gas to the mammal. The dilute nitric acid can be at least 0.5 M.
[0011] In another aspect, a kit includes a nitric oxide precursor and instructional material describing a method of generating a therapeutic gas and transporting the therapeutic gas. The therapeutic gas can include nitric oxide and can be substantially devoid of nitrogen dioxide.
[0012] Other features or advantages will be apparent from the following detailed description of several embodiments, and also from the appended claims.
DESCRIPTION OF DRAWING
[0013] [0013]FIG. 1 is a drawing depicting a schematic view of a nitric oxide generation and delivery system.
DETAILED DESCRIPTION
[0014] Various nitric oxide precursors can be used in a nitric oxide delivery system. Nitric oxide precursors can include a nitrogen-containing compound with a structure X-Nitric Oxide, when X is an organic residue or a precursor salt. For example, the nitric oxide precursor can include an alkali metal nitrite, an alkaline earth metal nitrite, a transition metal nitrite or an ammonium nitrite, for example, potassium nitrite, sodium nitrite, rubidium nitrite, strontium nitrite, barium nitrite, calcium nitrite, copper nitrite, zinc nitrite, or mixtures thereof. The nitric oxide precursor can include nitrogen-containing acids, such as nitric acid. Physical characteristics of the nitric oxide precursor, such as the dissolution rate, can be used to control delivery of nitric oxide.
[0015] The nitric oxide precursor can be dissolved in a solution in which the precursor can dissociate to form anions, including nitrite anions, and cations. The solution can include a buffer solution. A buffer solution can include a pH buffer combination which is a solution containing either a weak acid or a weak base at a concentration that renders the solution resistant to change in pH. The buffer solution provides a source of hydrogen cations, which can combine with the nitrite anions to form nitrous acid (HNO 2 ). Nitrous acid can decompose into several products in water. One of these products is nitric oxide. The reactions are summarized below in equations (I), (II) and (III):
NaNO 2 ⇄Na + +NO 2 − (I)
NO 2 − +H + ⇄HNO 2 (II)
3HNO 2 ⇄H 2 O+H + +NO 3 − +2NO (III)
[0016] The nitric oxide precursor can include sodium nitrite, which dissociates into sodium cations and nitrite anions, as shown in equation (I). The nitrite anions in the buffer solution can form nitrous acid as shown in equation (II), which can decompose into water, nitrate and hydrogen ions and two molecules of gaseous nitric oxide, as shown in equation (III).
[0017] The generated nitric oxide gas formed by the above reactions has a low solubility in the pH buffer combination (e.g., 0.00983 g nitric oxide per liter at 0° C.; 4.6 mL/100 mL at 20° C. in water (Merck Index, 10th Edition, 1983)). The relatively insoluble nitric oxide can be removed from the solution by a transport gas stream to form a therapeutic gas. The transport gas can be 100% oxygen, a mixture of air and oxygen or ambient air. The transport gas stream can be bubbled, otherwise distributed through the solution or swept over the solution. Other byproducts such as, for example, nitrous acid and nitrogen dioxide, can be volatile and can be carried with the transport gas stream along with nitric oxide formed in the reaction.
[0018] When delivering nitric oxide for therapeutic use to a mammal, it can be important to avoid delivery of nitrogen dioxide to the mammal. Nitrogen dioxide can be formed by the oxidation of nitric oxide with oxygen. The rate of formation of nitrogen dioxide is proportional to the square power of the nitric oxide concentration and the single power of the oxygen concentration. Reducing the nitric oxide concentration by a factor of ten reduces the nitrogen dioxide concentration by a factor of one hundred. Thus, by limiting the nitric oxide concentration in a therapeutic gas, the therapeutic gas can be substantially devoid of nitrogen dioxide. For example, when nitric oxide concentration in the transport gas is below 100 ppm, the resulting therapeutic gas generated from the nitric oxide precursor in a solution is substantially devoid of nitrogen dioxide.
[0019] In certain circumstances, the concentration of nitric oxide generated in the therapeutic gas is controlled, for example, by the concentration of nitric oxide precursor provided to the solution, the concentration of hydrogen cations in the solution, and the characteristics of the pH buffer combination. Other factors that can affect the nitric oxide concentration in the therapeutic gas can include, for example, physical form of the nitric oxide precursor, presence of a reduction-oxidation reaction in an optional gas purifier, and rate of flow of the transport gas through the solution.
[0020] The concentrations of hydrogen cations and the nitric oxide precursor can control the rate of generation of nitric oxide. Since the concentration of nitric oxide is low, about 20 to 100 ppm, reaction conditions, that increase the concentration of nitric oxide precursor and decrease the concentration of hydrogen ions lead to a stoichiometrically inefficient reaction. Decreasing the concentration of hydrogen ions, for example, by using a weak acid, shifts the equilibrium in equation (II) toward the nitrite anions. A reservoir of nitrite ions can be created such that the nitrous acid concentration is maintained at a relatively constant level.
[0021] A kit includes the nitric oxide precursor and an instructional material describing a method of generating the therapeutic gas and transporting the therapeutic gas in the transport gas. The therapeutic gas including nitric oxide is substantially devoid of impurities such as nitrogen dioxide.
[0022] A therapeutic gas can contain at least 1 ppm of nitric oxide. The therapeutic gas can include less than 100 ppm of nitric oxide. For example, the nitric oxide concentration in the therapeutic gas can be from 20 to 100 ppm. The nitric oxide can be released from the precursor over a period of time ranging from 1 minute to 7 days, 2 days to 3 days, or two hours to twenty four hours.
[0023] Oxidation-reduction reactions can assist in the production of nitric oxide. For example, a second salt, such as a nitric oxide-releasing reactant, can be added to the solution. A nitric oxide-releasing reactant, for example, an iodide salt or ferrous salt, assists the production of nitric oxide as shown below:
2NO 2 − +2I − +4H + →I 2 +2H 2 O+2NO
[0024] or
2NO 2 − +2Fe +2 +6e − →2Fe +3 +2H 2 O+2NO
[0025] For example, the nitric oxide-releasing reactant can be 1 molar ferrous sulfate solution or 10% wt/wt aqueous solution of sodium iodide.
[0026] Controlled-release delivery systems can include chemical reactions, for example, generation of nitric oxide by an electrochemical cell. For example, the reaction of potassium nitrite and potassium nitrate with chromium oxide forms potassium chromate and nitric oxide. This reaction can be controlled to generate nitric oxide.
3KNO 2 +KNO 3 +Cr 2 O 3 →2K 2 CrO 4 +4NO.
[0027] Alternatively, nitric oxide can be generated, for example, by the chemical reduction reactions. Metallic copper, for example, and dilute nitric acid can react to generate nitric oxide. For every six electrons transferred, three copper cations are reduced and two molecules of NO gas are generated. The reaction is shown below:
3Cu+8HNO 3 →2NO+3Cu(NO 3 ) 2 +4H 2 O
[0028] Referring to FIG. 1, a nitric oxide generation and delivery system 100 includes a pump 105 with a restrictor valve 115 , an electrochemical cell 110 with a cathode 120 , an anode 130 , an inlet tube 125 , an inlet 135 , an outlet tube 145 , an outlet 140 and a headspace 150 . The cell 110 is connected to an optional gas purifier 160 , a tube 170 and a mask 180 . The cell 110 is filled with a weak aqueous solution of nitric oxide precursor salt. The position of the anode and cathode in the cell can be modified.
[0029] In a general process for generating a stream of nitric oxide, the cathode 120 and anode 130 are immersed in the aqueous solution of nitric oxide precursor and the headspace 150 can be flushed with the transport gas. Alternatively, the transport gas can be bubbled through the solution. Various nitric oxide precursors can be used in the nitric oxide delivery system as described above. The concentration of the precursor salt can be 0.1% to 50%, 0.5% to 35%, or 1% to 20% by weight. A voltage is applied between the cathode and anode to generate the nitric oxide. The transport gas is swept over the solution of nitric oxide precursor to generate nitric oxide. The nitric oxide generated can be transported with the transport gas stream as a therapeutic gas to an optional gas purifier 160 . The optional gas purifier 160 removes any impurities such as nitrogen dioxide and nitrous acid as well as any other residual impurities, if present, as described above. The purified therapeutic gas can be transported through tube 170 to mask 180 to the mammal. Several parameters affect the production of nitric oxide in this process. The reaction conditions, for example, electrode material, applied voltage, applied current and nitric oxide precursor concentration can be controlled to generate 10 to 100 ppm of NO in the therapeutic gas.
[0030] In certain circumstances, the therapeutic gas can be passed through an optional therapeutic gas purifier 160 . When the therapeutic gas stream contacts the optional therapeutic gas purifier, residual impurities, such as nitrous acid and nitrogen dioxide, are removed from the therapeutic gas stream. The optional gas purifier can include a filter, which can be, for example, a semi-permeable membrane or barrier, a scrubbing solution, a reduction-oxidation solution, or a pyrolizer. The semi-permeable membrane is a barrier which allows the nitric oxide and transport gas to pass and retains the impurities. The scrubbing solution is a solution that removes impurities by neutralizing them, for example, a solution of 10% sodium bicarbonate, a 1M ferrous salt solution or an acidified 1M ferrous sulfate solution. A series of aqueous reservoirs can be used to completely decompose the nitrous acid and dissolve any nitric acid or nitrogen dioxide impurities. The reduction-oxidation solution contains a reduction-oxidation agent, which converts impurities completely into nitric oxide. The reduction-oxidation agent can include a ferrous salt. The pyrolizer is a chamber or other component which decomposes the impurities such as nitrous acid and nitrogen dioxide by irradiation or heating. A catalyst, for example, platinum, nickel or silver, can be used to decrease the pyrolysis temperature. For example, the impurities such as nitrous acid and nitrogen dioxide can be passed through a 12 inch long silver tube, ⅛ inch in diameter, heated at 800° C. at a flow rate of 1 L/minute. The removal of impurities can be enhanced by using a convoluted or a long path for the bubbling of the therapeutic gas stream through the filter. Additionally, the surface-to-volume ratio of the bubbles can be increased for effective filtration of impurities. For example, a gas sparger can be used to make smaller bubbles. Alternatively, filter media can also be coated onto a filter or walls of a tube, which can produce a dry therapeutic gas stream upon filtration.
[0031] A detector can be included in the therapeutic gas delivery system to detect the concentration of nitric oxide in the therapeutic gas stream. The detector can also detect the concentration of nitrogen dioxide in the therapeutic gas, if necessary, and may provide a warning if the nitric oxide concentration is outside a predetermined range or if the concentration of nitrogen dioxide is above a threshold value. Examples of monitoring techniques include chemiluminescence and electrochemical techniques, and are discussed in, for example, in Francoe et al., “Inhaled nitric oxide: Technical Aspects of Administration and Monitoring,” Critical Care Medicine, 24(4):782-796 (1998), which is incorporated by reference in its entirety. The presence of nitric oxide can be detected by for example, a modified version of a Thermo-Electron chemiluminescence (CL) detector.
[0032] Another design variation which achieves controlled-release delivery includes delivery of nitric oxide by reaction of copper in a dilute nitric acid solution, the nitric oxide precursor, in which case anode 130 can include copper and cell 110 can be filled with, for example, an aqueous solution of dilute nitric acid as the nitric oxide precursor. The dilute nitric acid can be at least 0.5M in concentration of nitric acid in water. Unexpectedly, the nitric oxide generated as a therapeutic gas is free of impurities such as nitrogen dioxide and nitrous acid.
[0033] The following examples describe nitric oxide generation.
EXAMPLE 1
[0034] Referring to FIG. 1, an electrochemical cell was prepared by fitting a 50 mL glass sample jar with a plastic TEFLON lined lid. Holes were drilled in the lid to accommodate the electrodes. The electrodes are immersed in the 1-20% sodium nitrite as a nitric oxide precursor solution and the headspace is swept with the flowing transport gas. A 0.5 to 5 VDC voltage was applied across the cathode and anode. The transport gas swept the generated nitric oxide as therapeutic gas into the optional gas purifier. Depending upon the voltage applied, the nitric oxide precursor concentration and the type of cathode and anode used, nitric oxide levels between 10 and 100 ppm were present in the therapeutic gas.
TABLE 1 ppm of nitric Nitric oxide oxide generated precursor in the Voltage (volts) concentration Cathode Anode therapeutic gas 2 3% NaNO 2 Nichrome Nichrome 10-100 2 1% NaNO 2 Nichrome Copper 2 20% NaNO 2 Nicbrome Copper 1-5 20% NaNO 2 Nichrome Copper 0.5 20% NaNO 2 26 5 20% NaNO 2 100 5 1% NaNO 2 10 5 3% NaNO 2 100
[0035] Other embodiments are within the scope of the following claims.
|
Inhalation of low levels of nitric oxide can rapidly and safely decrease pulmonary hypertension in mammals. Precise delivery of nitric oxide at therapeutic levels of 20 to 100 ppm and inhibition of reaction of nitric oxide with oxygen to form toxic impurities such as nitrogen dioxide can provide effective inhalation therapy for pulmonary hypertension.
| 2
|
This is a continuation, of application Ser. No. 776,928, filed Mar. 11, 1977.
FIELD AND BACKGROUND OF THE INVENTION
This invention relates to an apparatus for the production of moulds composed of identical mould parts produced successively in a pressing chamber from where they are displaced on to a guide pathway on which the mould parts are juxtaposed and advanced in intermittent time with their production.
In an apparatus of this type disclosed in British Specification No. 1,419,592, the guide path is a travelling grate or walking beam conveyor, at least one set of grate bars or beams is both reciprocable in the longitudinal direction of the guide pathway and movable in the vertical direction, whereas the other set of grate bars or beams perferably is prevented from longitudinal movement and is arranged for being raised to the level of the first set of grate bars prior to the initiation of the lowering movement thereof, and for being again lowered after the termination of the raising movement of the first set of grate bars. Such arrangement means that the mould is kept at one and the same level during the stepwise advance thereof, i.e. is not subject to any unwanted movement in the vertical direction and is subject to the necessary step-by-step movement.
In this prior art apparatus the area of the total effective supporting face of each set of grate bars must necessarily be somewhat less than half of the mould bottom area which results in the occurrence of a relatively high specific surface pressure between the mould and the grate bars. In the case of breaks in the normally continuous operation of the apparatus, difficulties may arise due to the fact that after the pouring operation, vapour makes its way towards the outside of the mould, thus also towards its bottom, whereby the compressive strength of the mould sand, on account of its increased moisture content, can be reduced so much that the grate bars form grooves in the mould bottom face. Also, the increased moisture content may make the mould sand so sticky as to cause it to adhere to the grate bars.
Heretofore, these difficulties have been overcome by emptying the guide path in the case of interruptions in the mould part production, i.e. by continuing the advancing of mould subsequent to a casual stop in the production of mould parts.
An object of the invention is to provide an apparatus in which such emptying process becomes unnecessary so that interruptions in the production process will only result in minimum production losses and require no particular attention on part of the operators as far as the function of the guide path is concerned.
SUMMARY OF THE INVENTION
In the apparatus according to the invention the guide pathway comprises a travelling grate or walking beam conveyor associated with a mould supporting belt or endless conveyor including closely spaced rod members resting on the travelling grate bars and extending transversely thereof. The supporting area of such a belt may amount to substantially more than half of the mould bottom area because the joints or spaces between successive rod members may have a width that is only a small fraction of the width of the rods, or may even be almost entirely closed in the operative position of the rods. The specific surface pressure on the underside of the mould may thus be reduced so much as to make the disadvantages aforesaid insignificant in practice.
If the rod members are sufficiently rigid they will furthermore render possible a substantial simplification and cost-reduction of the travelling grate conveyor in that each set of grate bars may be reduced to only two bars for supporting the belt rod members at, or in the vicinity of, their ends.
The reduced specific surface pressure moreover has the effect that there is less risk of causing damage to the moulds which, in particularly disadvantageous circumstances may cause the poured liquid metal to break through the bottom of the mould. If, in spite of all, such accident should occur in the apparatus according to the invention, the damage caused to the guide pathway may readily and quickly be remedied, namely by simply replacing the damaged belt rod or rods which in this situation will have protected the travelling grate proper against damage.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the apparatus according to the invention shall now be more fully described with reference to the accompanying drawing, in which
FIG. 1 is a rather diagrammatical longitudinal section along line I--I in FIG. 2;
FIG. 2 is a cross-sectional view along line II--II in FIG. 1;
FIG. 3 is a longitudinal section taken on line III--III of FIG. 1, at one end of a belt rod on a substantially larger scale, and
FIG. 4 is an elevational view of the left-hand or delivery end of the machine disclosed in the British Pat. Specification No. 1,419,592.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The machine in British Pat. Specification No. 1,419,592 is depicted in FIG. 4. The guideway formed by the travelling grate conveyor bars 102, 103 comprises a bottom frame 106 resting on supports 107 and carrying the grate bars 102 via rotatable transverse shafts 108 having eccentric ends that are journalled in bearings 110 on the bottom frame 106. Each shaft 108 is coupled through a connecting rod 111 to a draw bar 112 extending along the guideway and reciprocated lengthwise by means of a pneumatic cylinder 113.
Each transverse shaft 108 associated with the longitudinally movable grate bats 102 carries a pair of freely rotatable rollers 114 which support a pair of short rails 115 that are interconnected via a cross-member 116. By means of appropriate fork pieces the grate bars 102 are supported by the cross-member 116 to which a hydraulic cylinder 117 is connected and is operative to impart a reciprocating movement to the grate bars 102. During such movement the rails 115 run on the rollers 114.
The grate bars 103 are prevented from lengthwise movement but may be supported for vertical movement in a manner corresponding to the bars 102 by means of eccentric transverse shafts, cross-members, rollers, and a pneumatic cylinder corresponding to cylinder 113. However, at one or more points the bars 103 are secured in such a way that they cannot, in their entirety, run on the rollers which, nevertheless, permit unimpeded expansion and contraction of these grate bars 103 caused by changing temperature conditions.
FIG. 1 shows a bottom plate 1 belonging to a mould part pressing chamber, not otherwise shown, which may be of conventional construction. From this bottom plate the successively produced mould parts, or blocks, are displaced on to a guide channel or conveyor pathway comprising a travelling grate or walking beam conveyor 2 and an endless rod belt 3 associated therewith.
In principle the travelling grate or walking beam conveyor 2 may be built up in the same way as disclosed in British Patent Specification No. 1,419,592 with the modification that each set of grate bars comprises only two single bars 4 and 5, respectively. The bars 4 are movable only in the vertical direction, whereas the bars 5 are also reciprocable in the horizontal direction. In the situation shown in the drawing, both sets of grate bars are shown in their topmost position, and the bars 4 are ready for being lowered, whereupon the bars 5 are displaced to the left for advancing the mould, not shown.
However, the mould is not supported directly by the travelling grate 2. In fact, this grate is surrounded or enclosed by endless rod belt 3, the upper run of which is supported and stepwise or intermittently advanced by the travelling grate with its upper side at exactly the same level as the bottom plate 1 of the pressing chamber.
In the embodiment shown, the belt 3 consists of tubes 6 which are of substantially square section and so interconnected that the belt may be regarded as non-extensible in the longitudinal direction. This can be important for maintaining the required "weighting" or pressing together of the individual parts of the mould. In the drawing, the square tubes 6 are interconnected by means of a pair of steel wires 7 received in notches 8 in the tubes near their ends, and the connection between the wires 7 and the tubes 6 may expediently be established by releasable clamping as shown in FIG. 3. In this case provision has been made for a pair of clamps 9 and 9' at the end of square tube 6 which by means of screws 10 can be clamped together with the wire 7. Said clamps may, as shown, be provided with double grooves or seats 11 and 11', of which the latter serves for facilitating repairs to the belt in the case of any damage. In such case the damaged portion or section of the belt need only be cut free and replaced by a new portion or section of the same length and with its wires clamped between seats 11'. Initially, the rod belt may also consist of such sections of a suitable length which provide ease of replacement according to need.
The rod belt 3 runs in a well-known manner on supporting rollers 12 with shafts 13 journalled in bearings, not shown, and can, if desired, be kept suitably tensed in a well-known manner.
The rod members may be otherwise assembled than shown in the drawing, for example by means of chain links at their ends, or by means of an embracing band of a suitable material, such as a steel band or wire gauze, or they may be embedded in, and function as cross braces in, a belt of rubber or the like material. At the end adjacent the bottom plate 1 an additional supporting plate 14 may be provided to ensure that the belt is always situated at the correct level.
|
A travelling grate conveyor for advancing a mould consisting of juxtaposed identical mould parts is associated with an endless mould supporting belt or conveyor formed by a plurality of closely spaced and interconnected rod members extending transversely of the longitudinal direction of the conveyor. The upper run of the belt rests on and is advanced by the travelling grate walking wacking beam conveyor.
| 1
|
FIELD OF INVENTION
[0001] The invention to which this application relates is to a method of applying a coating to a surface of a substrate or article, apparatus for the application of said coating, and the completed substrate or article themselves, said coating having a liquid repellent characteristic of an improved nature with regard to the prior art which is herein defined.
[0002] In particular, although not necessarily exclusively, the coating to which the invention applies includes a crosslinked fluoropolymer material.
BACKGROUND OF THE INVENTION
[0003] Coatings of this type can have a wide range of uses and the substrate to which the same is applied can be solid surfaces such as metal, glass, ceramics, semiconductors, flexible surfaces such as paper, textiles and/or polymers and the like and indeed any surface which is capable of supporting and retaining the coating thereon. The coating can be controlled to be either generally repellent to all liquids or specifically repellent of particular liquids to suit particular purposes.
[0004] The extent or degree of the liquid repellency is known to be a function of the number of fluorocarbon moieties that can be generated and located with respect to the available surface area and also a function of the surface roughness characteristics. In general, the greater the concentration of fluorocarbon moieties and the greater the degree of surface roughness then the greater the repellent characteristic of the coating.
[0005] Conventionally a coating of the type of interest in this patent is applied to the surface of a substrate by any of sputter deposition of material from a polytetrafluorethylene (PTFE) target, exposure to F 2 gas or using plasma techniques including exposure to fluorine-containing electrical discharges and/or plasma polymerisation of fluorocarbon monomers.
[0006] The known technique most often used is the plasma technique which is recognised as being clean, dry, and generating little waste material compared to the conventional wet chemical methods. A plasma is generated from molecules which are subjected to ionising electrical fields and, when completed, and performed in the presence of the substrate, the ions, radicals and excited molecules in the plasma react directly with the substrate or polymerise in the gas phase and react with growing polymer films on the substrate to form the coating thereon.
[0007] As stated, it is also known to improve the repellence of the coating by controlling the surface roughness. One method of increasing the surface roughness is to first apply to the surface of the substrate, an intermediate layer of material which has a surface roughness greater than that of the surface of the substrate. The provision of this intermediate layer is described by the Cassie-Baxter equation where surface roughness causes air to be trapped in a void which prevents the liquid from penetrating the surface hence increasing the repellence characteristic of the coating.
[0008] The trapping of the air in voids minimises the contact angle hysteresis and results in the provision of what are known as “super hydrophobic” coatings upon which a liquid drop spontaneously or easily move across the substrate coating even in horizontal or substantially horizontal planes.
[0009] The provision of intermediate layers applied to the substrate surface to improve the surface roughness are normally achieved by any or any combination of the following:
[0010] Sublimation of aluminium acetylacetonate from a boehmite, titania or silica coating,
[0011] Sol-gel deposition of alumina and silica,
[0012] Anodic oxidation of aluminium,
[0013] Photolithographically etched surfaces.
[0014] All of the above processes include a pre-roughening step followed by a reaction of the fluorine containing coupling agent to impart low surface energy.
[0015] The aim of the present invention is to provide a method, apparatus and finished article which represent, respectively, improvements with respect to the repellency of the coating applied thereby and onto the substrate surface. It is also an aim to provide the coating in a manner which has the required repellency, is durable and therefore can be commercially exploited.
SUMMARY OF THE INVENTION
[0016] In a first aspect of the invention there is provided a method for applying a coating to a surface of a substrate, said method comprising the steps of applying a polymer material to the said substrate surface, fluorinating the surface of said polymer material on the substrate and/or curing at least part of the said coating.
[0017] Typically, the polymer material can be applied in any conventional manner to suit particular method requirements and, for example, can include application by spin coating, solvent casting, dipping, spraying, plasma deposition, atomisation or chemical vapour deposition.
[0018] The polymer material can comprise a number of components, including but not limited to, homopolymers and copolymers. These polymeric components may occur singly, in combination with one another, or in the presence of non-polymeric additives. The components of polymer blends may be miscible or immiscible.
[0019] In one embodiment, the polymer material includes unsaturated bonds and, as an example, two such polymers are polybutadiene or polyisoprene.
[0020] In one embodiment the cover polymer material is a blend where only one component of the blend is crosslinkable, e.g. for a two component blend system (e.g. polybutadiene+polystyrene), fluorination and curing is followed by solvent washing to leave behind domains of the hydrophobic crosslinkable component, in this case polybutadiene. The fluorinated polystyrene component is washed out due to it not being capable of undergoing crosslinking.
[0021] Typically, the polymer coating forms at least the outer surface of the coating applied to the substrate. In one embodiment, the polymer coating forms part of the coating applied to the substrate surface. Thus, for example, the coating applied to the substrate surface can comprise a series of layers, with the outer layer, i.e. that furthest removed from the substrate surface, being of the polymer material and more typically a polymer including unsaturated bonds. The remainder of the layers of the coating can be made up of any combination of materials such as, for example, polymer material with saturated bonds.
[0022] In a further aspect of the invention a polymer material, typically including unsaturated bonds, forms only part of the outer surface of the coating. Thus, for example, the outermost surface of the coating can comprise domains or patterns of polymer material containing unsaturated bonds, surrounded by areas consisting of a non-polymeric material or a different polymer material, (typically one including no unsaturated bonds). Examples of such multi-component surfaces are those created by sections of composites or laminates and the segregation of components within copolymers and blends of polymers and/or copolymers. In addition the coating may comprise additional layers, supplementary to the outermost surface layer, which can consist of any combination of materials.
[0023] The fluorination of the coating can be achieved by selective exposure of the same to atomic, molecular or ionic fluorine containing species.
[0024] In one embodiment, plasma is used to generate fluorinating species. The coated substrate may be disposed within the plasma, ox exposed to fluorinating species created by a remotely located plasma.
[0025] Suitable plasmas for use in the method of the invention include non-equilibrium plasmas such as those generated by radio frequency (RF), microwaves and/ox direct current. The plasma may be applied in a pulsed manner or as a continuous wave plasma. Typically the plasmas can be operated at any or any combination of low pressure, atmospheric or sub-atmospheric pressures to suit particular purposes and reference to plasma herein should be interpreted as including any of these plasma forms.
[0026] Typically, the plasma either comprises the fluorinated compound alone or in a mixture with, for example, an inert gas. In one embodiment the fluorinated compound is introduced into the plasma treatment chamber continuously or in a pulsed manner by way of, for example, a gas pulsing valve. In one embodiment, the compound used for generating the fluorine containing plasma is SF 6 or compounds of formula CH x F 4-x where x has integer values from 0 to 3.
[0027] The step of curing the fluorinated surface affects the crosslinking of the unmodified, unsaturated polymer below the fluorinated surface and the degree of fluorination and roughened surface morphology imparted by the fluorination are largely unaffected by this process so that the coating retains its repellent characteristics whilst improving in terms of mechanical durability.
[0028] Typically, the method of curing used can be any or any combination of, heating, VUV radiation, UV radiation, electron beam irradiation or exposure to any other ionising radiations.
[0029] In one embodiment the fluorination and/or curing step can be achieved by the control or ramping of the temperature of the polymer film during the fluorination procedure, in which case the fluorination occurs at the lower temperature range and, as the temperature increases, curing occurs.
[0030] In a further aspect of the invention there is provided a method for applying a coating having liquid repellent characteristics to a surface of a substrate, said method comprising the steps of applying a coating to the substrate surface, said coating having at least an outer layer of a polymer including unsaturated bonds, said polymer being fluorinated and cured and wherein the fluorination and/or curing is performed on the polymer material in a selected pattern so as to provide selectively fluorinated and/or cured portions and selectively unfluorinated and/or uncured portions of said coating.
[0031] In one embodiment the selection can be to completely fluorinate and cure the polymer material of the coating.
[0032] Alternatively, in one embodiment, the selected pattern of fluorination and/or curing on the substrate surface coating is achieved with the use of a spatially resolved means of curing or fluorination such as an ion beam, electron beam, or laser or via masking which matches and assists the selective pattern of fluorination or curing required.
[0033] In one embodiment the mask includes a series of apertures, said apertures, when said mask is placed over the said substrate surface coating, defining the areas of said coating which are to be fluorinated and/or cured.
[0034] It should therefore be appreciated that the method can comprise the steps of applying the coating, selectively fluorinating parts of the coating and curing all of the coating thereafter or alternatively applying the coating, fluorinating the entire coating and then selectively curing said coating.
[0035] In one embodiment, UV irradiative curing is effected in a selected pattern through use of a photo mask. The pattern of transmitting an opaque material upon the mask thereby being transferred to the fluorinated coating as a pattern of cured and uncured areas. As curing is accompanied by densification, the cured areas of the fluorinated coating are lower in height than the uncured areas and this height contrast allows the formation of surface structures such as channels and pockets for the movement and containment of liquids and aerosol particles, such as and including polymer solutions, salts dissolved in liquid, and other liquid based systems whereupon removal of the liquid leaves solid behind.
[0036] In a further aspect of the invention there is provided apparatus for the generation of a coating for a substrate surface, said apparatus comprising means for application of a coating to a surface of a substrate, said means including means for applying a polymer containing unsaturated bonds to form at least the outer surface of the coating, fluorination means for fluorinating the said outer surface of said coating and curing means for curing said outer surface of the coating.
[0037] In one embodiment, the apparatus includes at least one masking means for placement with respect to the coating prior to fluorination and during the fluorination, said mask is formed so as to allow the selective fluorination of exposed portions of said coating.
[0038] In a further embodiment, there is provided a masking means for placement with respect to the coating during the curing of the coating to allow selected curing of portions of said coating.
[0039] In one embodiment, the pattern of fluorination achieved by the masking means is matched with the pattern of curing by the curing masking means to allow the provision of selected portions of the coating which are fluorinated and cured.
[0040] In a further aspect of the invention there is provided a substrate having at least one surface to which a coating is applied, said coating having at least an outer layer of polymer material and at least a portion of said polymer material is fluorinated and cured to provide the same with improved liquid repellent and durability characteristics.
[0041] In one embodiment selective portions of the polymer material have said liquid repellent characteristics, said portions defining areas which are not fluorinated and/or cured and which can act as collecting areas for liquid. In one embodiment said coating has defined therein a number of spaced liquid collection areas, each separated by areas of increased liquid repellence. In one embodiment the substrate can be used as a liquid sample collection means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Specific embodiments of the invention axe now described with reference to the accompanying drawings; wherein.
[0043] FIG. 1 is a graph showing the surface elemental composition of 4.5 μm thick polybutadiene films which have been plasma fluorinated for 5 minutes at various RF power levels;
[0044] FIG. 2 is a graph showing the RMS roughness of 4.5 μm thick polybutadiene films which have been plasma fluorinated for 5 minutes at various RF power levels;
[0045] FIG. 3 is a graph showing the water contact angle of 4.5 μm thick polybutadiene films which have been plasma fluorinated for 5 minutes at various RF power levels;
[0046] FIG. 4 illustrates a further embodiment of the invention and an infra red spectra of plasma fluorinated polybutadiene (60 W, 10 min) as a function of UV exposure time of a nonpatterned surface;
[0047] FIG. 5 illustrates the embodiment of FIG. 4 showing a series of AFM height images of a UV patterned surface;
[0048] FIG. 6 illustrates the embodiment of FIG. 4 showing a series of optical microscope images showing microfluidic self organisation of water droplets on patterned 236 nm thick polybutadiene film;
[0049] FIG. 7 illustrates the embodiment of FIG. 4 showing optical microscope images of crystals grown on patterned polybutadiene film as a function of exposure time to nebulized mist;
[0050] FIG. 8 illustrates further optical microscope images of polystyrene beads deposited into patterned polybutadiene;
[0051] and FIG. 9 illustrates the embodiment of FIG. 4 with a patterned surface showing the Raman analysis of the patterned polybutadiene film.
DETAILED DESCRIPTION OF THE INVENTION
[0052] In a first illustrative example, Polybutadiene (Aldrich, M w =420,000, 36% cis 1.4 addition, 55% trans 1.4 addition, 9% 1.2 addition) is dissolved in toluene (BDH, +99.5% purity) and spin coated onto silicon wafers using a photoresist spinner (Cammax Precima) operating at speeds between 1500-4500 rpm. The applied coatings axe subsequently annealed at 90° C. under vacuum for 1 hour in order to remove entrapped solvent.
[0053] In accordance with the method of the invention, fluorination of the coating is, in this example, performed in a cylindrical glass, plasma reactor of 5 cm diameter, 470 cm 3 volume, base pressure of 4×10 −3 mbar, and with a leak rate of better than 6×10 −9 mol s −1 .
[0054] The reactor vessel is connected by way of a needle valve to a cylinder of carbon tetrafluoride (CF 4 ) (Air Products, 99.7% purity).
[0055] A thermocouple pressure gauge is connected by way of a Young's tap to the reactor vessel. A further Young's tap is connected with an air supply and a third leads to an E2M2 two stage Edwards rotary pump by way of a liquid nitrogen cold trap. All connections are grease free.
[0056] An L-C matching unit and a power meter are used to minimise the standing wave ratio (SWR) of the power transmitted from a 13.56 MHz R.F. generator to a copper coil wound around the reactor vessel wall.
[0057] In order to carry out the fluorination of the unsaturated, polybutadiene coating the reactor vessel is scrubbed with detergent, rinsed with propan-2-ol, oven dried and then further cleaned with a 50 W air plasma for 30 min. Next, the reactor is vented to air and a polybutadiene coated silicon wafer placed into the centre of the chamber defined by the reactor vessel on a glass plate. The chamber is then evacuated back down to base pressure (4×10 −3 mbar).
[0058] Carbon tetrafluoride gas is admitted into the reaction chamber via a needle valve at a constant pressure of 0.2 mbar and allowed to purge the plasma reactor followed by ignition of the radiofrequency glow discharge. Typically 5-10 minutes is found to be sufficient to give complete surface fluorination of the polybutadiene coating. After this the RF power generator is switched off and carbon tetrafluoride gas allowed to pass over the sample for a further 5 minutes before evacuating the chamber back down to base pressure, and finally venting to air.
[0059] Curing of the fluorinated polybutadiene films is carried out by placing them in an oven, in an atmosphere of air, at 150° C.
[0060] Analysis of the coatings is achieved by using several complementary techniques. X-ray photoelectron spectroscopy (XPS) is used to obtain the elemental composition of the surfaces, and to identify various fluorinated species by means of deconvoluting the C(1s) spectra. In addition to XPS, FT-IR is used to obtain information on chemical groups present within the coating (Perkin Elmer, Spectrum One).
[0061] The thickness of the polybutadiene films is measured using a spectrophotometer (Aquila Instruments, nkd-6000).
[0062] The coatings are imaged by Atomic Force Microscopy (AFM) (Digital Instruments, Nanoscope III). RMS roughness values are calculated over 50 nm×50 nm scan areas.
[0063] The super-hydrophobicity and oleophobicity of the coatings axe investigated by sessile drop contact-angle measurements carried out at 20° C. with a video capture apparatus (A.S.T. Products VCA2500XE). The probe liquids used are high purity water (B.S. 3978 Grade 1) to determine hydrophobicity and a variety of linear chain alkanes (hexadecane, tetradecane, dodecane, decane, and octane, +99% purity, Aldrich) to evaluate oleophobicity. In the case of super-hydrophobic surfaces, the water droplets are kept stationary by the dispensing syringe. Advancing and receding contact angle values are obtained by increasing or decreasing the liquid drop volume at the surface.
[0064] The increase in coating durability after curing is ascertained by Nanoindentation hardness testing, before and after crosslinking, with a Nano instruments Nano II machine equipped with a Berkovich indenter.
[0065] The experiments carried out use average RF powers in the range of from 5 to 80 W. The results of the XPS analysis of 4.5 μm thick polybutadiene films plasma fluorinated for 5 minutes at various powers are shown in FIG. 1 .
[0066] In FIG. 1 it can be seen that plasma fluorination caused the incorporation of a large amount of fluorine into the surface of the polybutadiene coating. Deconvolution of the C(1s) spectra shows that CF, CF 2 and CF 3 environments are present.
[0067] FIG. 2 shows the RMS roughness, measured using AFM, of 4.5 μm thick polybutadiene films which have been plasma fluorinated for 5 minutes at various power levels.
[0068] It can be seen that the plasma fluorination results in an overall increase in the roughness of the polybutadiene coating. RF power levels below 30 W result in large undulating features. An increase in the RF power results in a diminishment of these features and their replacement with finer scale roughness. The transition between the two different morphologies is responsible for the decrease in RMS roughness at RF powers of approximately 30 W.
[0069] The effect of the incorporation of fluorine and the simultaneous increase in RMS roughness upon the water repellency of 4.5 μm thick polybutadiene films which are plasma fluorinated for 5 minutes at various powers is shown in FIG. 3 .
[0070] Plasma fluorination is therefore shown to cause a large increase in the hydrophobicity of the coating. Water contact angles exceed 157° for RF powers of above 40 W. More accurate measurement is not possible as the droplets quickly rolled off the coating, that is the surfaces displayed super-hydrophobic behaviour.
[0071] The oleophobicity of the fluorinated coatings is shown by contact angle measurements with droplets of linear chain alkanes given in Table 1. The 4.5 μm thick polybutadiene coating illustrated has been plasma fluorinated at an RF power of 60 W for 10 minutes.
[0000]
TABLE 1
PROBE
CONTACT ANGLE/°
LIQUID
Equilibrium
Advancing
Receding
Hysteresis
Water
174.9 ± 0.4
173.1 ± 0.4
172.7 ± 0.5
0.4 ± 0.4
Hexadecane
118.7 ± 0.8
119.1 ± 1.0
30.1 ± 1.7
89 ± 2.0
Tetradecane
109 ± 0.9
110.8 ± 1.2
29.8 ± 1.3
81 ± 1.8
Dodecane
98.4 ± 0.9
100.2 ± 1.1
29.5 ± 1.9
70.7 ± 2.2
Decane
89.8 ± 1.5
92.9 ± 1.1
29.7 ± 1.0
63.2 ± 1.5
Octane
65.2 ± 0.8
67.4 ± 0.9
28.5 ± 1.0 i
38.9 ± 1.3
[0072] The low hysteresis observed when using water as a probe liquid confirms that the coating is super-hydrophobic. In addition it can be seen that the coating is oleophobic towards a range of oils. However the large hysteresis observed with alkane probe liquids, attributable to their lower surface tensions' enabling them to wick into surface pores, shows that the coating is not super-oleophobic.
[0073] After fluorination the coatings are thermally cured at 155° C. The effect of curing for 1 hour upon the repellency, roughness and surface composition of a 4.5 μm thick polybutadiene coating plasma fluorinated at a RF power of 60 W for 10 minutes is shown in Table 2.
[0000]
TABLE 2
Measurement
Uncured
Cured
Water contact angle
174.9
± 0.4°
173.8
± 0.5°
Decane contact angle
89.8
± 1.5°
76.4
± 2°
XPS % F
70
± 2
69
± 2
XPS % C
30
± 2
29
± 2
XPS % O
0
± 0
2
± 2
AFM roughness
193
± 5 nm
191
± 5 nm
ARMS
[0074] It can be seen that curing does not significantly affect the superhydrophobicity and RMS roughness of the coating. The slight decrease in oleophobicity is attributed to the incorporation of a small amount of oxygen.
[0075] The affect of curing upon surface durability is shown in Table 3. A 4.5 μm thick polybutadiene coating plasma fluorinated at a RF power of 60 W for 10 minutes was cured for 48 hours at 155° C.
[0000]
TABLE 3
Material
Hardness/Mpa
Uncured fluorinated of butadiene
8 ± 1
Cured fluorinated polybutadiene
64 ± 8
[0076] It can be seen that curing results in an eight-fold increase in coating hardness over the uncured fluorinated material.
[0077] The results of this illustrative example therefore illustrate the advantageous benefits which can be obtained by the method and utilisation of apparatus of the present invention. The results relate to the fluorination and curing over the entire surface of a substrate for ease of testing.
[0078] However as previously discussed a further aspect of the invention is the provision of the fluorination and/or curing over selected portions of any given surface. The ability to selectively fluorinate and cure particular surfaces provides the ability to design articles for specific uses and for the surfaces to have the required characteristics in required areas. One possible use is to define portions of the surface which are not fluorinated or cured and which act as collection areas for liquids applied to the surface and which liquid is repelled from those portions which are fluorinated and cured and which typically surround and define the liquid collection areas. Thus, in use, the liquid held in each liquid collection area can define a sample to be tested. The said treated and non-treated portions are typically defined during the treatment process by the provision of masking means and/or selective printing which can be positioned relative to the surface.
[0079] A specific embodiment of this selective or patterned treatment method is now described with reference to FIGS. 4-9 . In this example, there is described a two-step approach for fabricating spatially ordered arrays of micron size particles and also metal salts by exposing patterned super-hydrophobic surfaces to a nebulized mist of the desired species. This entails plasmachemical fluorination of polybutadiene thin film surfaces followed by spatially localised UV curing by crosslinking and oxygenation.
[0080] CF 4 plasma fluorination of coating is carried out in a cylindrical glass reactor (5 cm diameter, 470 cm 3 volume) connected to a two stage rotary pump via a liquid nitrogen cold trap (base pressure of 4×10 −3 mbar, and a leak rate of better than 6×10 −9 mol s −1 ). An L-C matching unit is used to minimise the standing wave ratio (SWR) of the power transmitted from a 13.56 MHz R.F. generator to a copper coil externally wound around the glass reactor. Prior to each plasma treatment, the chamber is scrubbed with detergent, rinsed in propan-2-ol, and then further cleaned using a 0.2 mbar air plasma operating at 50 W for 30 min. A piece of polybutadiene coated substrate is then placed into the centre of the reactor, followed by evacuation to base pressure. Nex CF 4 gas (99.7% purity, Air Products) is admitted into the system via a needle valve at a pressure of 0.2 mbar, and after 5 min of purging, the electrical discharge is ignited. Upon completion of plasma exposure, the system is evacuated, and then vented to atmosphere.
[0081] Patterning of the fluorinated polybutadiene film surfaces entails UV irradiation (Oriel low pressure Hg—Xe arc lamp operating at 50 W, emitting a strong line spectrum in the 240-600 nm wavelength region) through a copper grid photomask (1-000 mesh, Agar Scientific') positioned just above the polymer surface.
[0082] These micro-patterned films are exposed to a nebulized aqueous mist (Inspiron nebulizer operating with a nitrogen gas flow of 3 dm 3 min −1 ) of either Cu 2 SO 4 salt solution (0.00125 M, Aldrich) or polystyrene beads (1×10 9 beads per ml). In the case of gold (III) chloride (Aldrich 99%), the patterned film is dipped into a 10% w/v ethyl acetate (Fisher 99%) solution for 10 min followed by rinsing in methanol to dislodge extraneous AuCl 3 species.
[0083] XPS surface analysis is undertaken on a VG ESCALAB MkII spectrometer equipped with an unmonochromatised Mg K α X-ray source (1253.6 eV) and a hemispherical analyser. Photoemitted core level electrons are collected at a fixed takeoff angle (75° away from the sample surface) with electron detection in constant analyser energy (CAE) mode operating at 20 eV pass energy. Elemental sensitivity (multiplication) factors are taken as being C(1s) F(1s): O(1s) equals 1.00:0.35:0.45. No spectral deterioration due to X-ray radiation damage was observed during the time scale associated with data acquisition.
[0084] Infrared analysis of polybutadiene films coated onto polished potassium bromide disks is carried out on a Perkin Elmer Spectrum One FTIR instrument operating in transmission mode at 4 cm −1 resolution in conjunction with a DTGS detector.
[0085] Sessile drop contact angle measurements are undertaken at 20° C. with a video capture apparatus (A.S.T, Products VCA2500XE) using high purity water as the probe liquid (B.S.3978 Grade 1). In the case of super-hydrophobic surfaces, the water droplets are kept stationary by the dispensing syringe. Advancing and receding contact angle measurements are made by increasing or decreasing the liquid drop volume whilst on the surface.
[0086] AFM images of the patterned surfaces are acquired using a Digital Instruments Nanoscope III scanning probe microscope. Damage to the tip and substrate was minimised by operating in Tapping Mode ARM. Corresponding optical images are captured with an Olympus BX40 microscope.
[0087] Raman spectroscopy and spatial mapping is performed on a Dilor Labram microscope equipped with a 1800 lines mm −1 diffraction grating and a helium-neon laser excitation source (632.8 nm line operating at 11 mW).
(a) UV Irradiation of Fluorinated Polybutadiene Films
[0088] XPS analysis detected a small amount of oxygen incorporation (2%) at the surface following UV irradiation of the whole plasma fluorinated polymer film (no mask), Table 4.
[0000]
TABLE 4
XPS analysis of CF 4 plasma fluorinated 236 nm thick polybutadiene
film (60 W, 10 min) prior to and following UV exposure.
Substrate
% C
% O
% F
Fluorinated
29 ± 2
0
71 ± 2
UV Exposure
31 ± 2
2 ± 2
67 ± 2
[0089] Infrared band assignments for polybutadiene are summarised in Table 5.
[0000]
TABLE 5
Infrared assignments for polybutadiene film and new absorbencies
observed following UV irradiation of plasma fluorinated polybutadiene. (No changes were
observed upon CF 4 plasma fluorination).
Frequency cm-1
Intensity*
Assignment
3300-3600
A†
m, br
—OH stretch
3075
M
CH 2 asymmetric stretch in —CH═CH 2 ; 1,2-addition
3005
B
Sh
CH stretch in cis-CH═CH— ; 1 4-addition
2988
w, sh
CH stretch in —CH═CH 2 ; 1,2-addition
2975
Sh
CH 2 symmetric stretch in —CH— CH 2 ; 1,2-addition
2917
Vs
—CH 2 symmetric stretch plus —CH— stretch
2845
S
—CH 2 symmetric stretch
1790
C†
w, sh
cyclic ester
1730
C†
M
aliphatic ester
1652
Sh
—C═C— stretch, 1,4-addition
1640
M
—C═C-stretch in —C=CH 2 ; 1,2 addition
1453
M
—CH 2 — deformation; 1,2 addition
1438
Sh
—CH 2 — deformation; 1,4 addition
1419
M
—CH 2 — in plane deformation; 1,2-addition
1406
vw, sh
—CH— in plane deformation in cis-CH═CH— ; 1,4-
addition
1325-1350
W
—CH2— wag
1294-1320
W
—CH 2 — in plane rock
1238
vw, br
—CH 2 — twist
1180
D†
M
O—H bend, principally primary alcohol
1080
W, br
—CH 2 — in plane rock of —CH=CH 2 ; 1,2 addition
995
S
CH out of plane bending in —CH═CHz, 1,2 addition
967
5
CH out of plane bending in trans —CH═CH— ; 1,4-
addition
911
Vs
CH out of plane bending in —CH═CH 2
727
W, br
CH out of plane bending in cis —CH═CH— ; 1,4-
addition
681
W
Unknown; 1,2-addition°
*s = strong; m = medium; w = weak; v = very; sh = shoulder; br = broad
†These features only appear upon UV exposure
[0090] No new infrared absorption features were observed following CF 4 plasma fluorination of polybutadiene. This can be explained in terms of the surface sensitivity of this analytical technique being poor in transmission mode of analysis (since only the outer most layer of polybutadiene has undergone plasma fluorination—as exemplified by XPS analysis). Bulk oxidative crosslinking of these films during UV irradiation is evident on the basis of the observed attenuation of the CH stretch feature associated with the polybutadiene alkene bonds (B) and also the emergence of oxygenated groups (A, C, and D), FIG. 4 and Table 5. Corresponding water sessile drop contact angle measurements confirms the super-hydrophobic nature of plasma fluorinated polybutadiene surface, Table 6.
[0000]
TABLE 6
Water contact angle measurements following UV irradiation of CF 4
plasma fluorinated (60 W, 10 min)/236 nm thick polybutadiene film.
UV
Contact Angle/°
Exposure/mins
Equilibrium
Advancing
Receding
0
174.9 ± 0.4
173.1 ± 0.4
172.7 ± 0.5
20
173 ± 1.0
171.6 ± 0.5
170.8 ± 0.4
40
172 ± 1.2
171.4 ± 0.5
170.0 ± 1.0
60
170.3 ± 1.0
171.0 ± 0.7
169.0 ± 0.7
[0091] The improvement in surface wettability observed following UV irradiation of the fluorinated surface can be correlated to oxygen incorporation into the film, Tables 4 and 6.
(b) UV Patterning of Fluorinated Polybutadiene Films
[0092] In the case of UV photopatterning of the CF 4 plasma fluorinated polybutadiene film, AFM indicates a drop in height for exposed square regions, FIG. 5 . Immersion of these patterned films in toluene or tetrahydrofuran causes an exacerbation of the observed topography. This can be due to either solvent swelling in the unexposed (non-crosslinked) regions or improved AFM tip-surface interactions.
(c) Copper Sulfate Salt and Polystyrene Microsphere Patterning
[0093] It is found that during exposure to steam, water droplets undergo selective condensation onto the UV irradiated square regions of the fluorinated polybutadiene film surface, FIG. 6 . Analogous behaviour is also observed in the case of a nebulized mist of aqueous Cu 2 SO 4 solution, giving rise to selective growth of salt crystals within the patterned squares, FIG. 7 . It is found that the actual crystal size can be tailored by varying the mist exposure time.
[0094] In a similar fashion, exposure to a nebulized aqueous mist of polystyrene microspheres (either 0.61 μm or 9.1 μm diameter) produces arrays of agglomerated 0.61 μm beads, or isolated 9.1 μm beads in each square (since for the latter, only one bead can physically occupy an individual 14 μm i diameter square), FIG. 8 .
(d) Gold Patterning
[0095] No strong Raman absorbances are measured for the polybutadiene film. Raman spectroscopy of CF 4 plasma treated and UV cured polybutadiene film followed by soaking in AuCl 3 /ethylacetate (10 w/v %) solution and then rinsing in methanol gives a distinct band structure between 24G-370 cm −1 , attributable to AuCl 3 salt species, FIG. 9 . Raman spectral mapping based on this spectral region confirmed selective deposition of AuCl 3 into the UV irradiated squares, FIG. 9 . XPS analysis of AuCl 3 soaked films, before and after UV irradiation (no patterning), shows very little gold or chlorine content on either of the films. Raman images taken of UV exposed fluorinated films without the photomask indicated the absence of AuCl 3 . This confirms the preference for surface energy gradients to allow entrapment of the metal salt species.
[0096] Thus, from this example, CF 4 plasma modification of polybutadiene film leads to fluorination in the outer surface region (i.e. the electrical discharge penetration depth) whilst the underlying polybutadiene can be subsequently crosslinked. There are several different ways in which the latter step can be undertaken: e.g. heat, UV or γ irradiation. In the case of UV irradiation, oxygen incorporation into the film is consistent with an oxidative cross-linking mechanism, which leads to a corresponding drop in water contact angle, FIG. 4 and Table 6. The corresponding surface roughness is not found to change markedly upon UV exposure (as also seen previously with thermal curing), thereby ruling out any observed change in water contact angle being just a manifestation of enhanced roughening. UV irradiation through a micron-scale copper grid produces a drop in height for the exposed regions, which is consistent with shrinkage of the sub-surface elastomer during cross-linking. Soaking of these films in toluene and THF (solvents for polybutadiene) exacerbates the observed height difference, due to enhanced swelling of the underlying regions of uncured polybutadiene (although a perturbation in AF1VI tip-surface interactions cannot be ruled out). The possibility of polymer removal during solvent immersion is considered to be unlikely due to the thin cross-linked top layer formed by VUV and ion bombardment during CF 4 plasma treatment.
[0097] Thus, the present invention allows many advantages to be obtained, firstly in the provision of surfaces which have improved liquid repellence in comparison to conventional coatings, but still achieves desirable durability characteristics. Furthermore the provision of these improved characteristics can be selectively applied to the surface to allow the substrate with said coating to be treated in a manner to improve and/or define the usage of the same.
|
The invention relates to the application of a coating to a substrate in which the coating includes a polymer material and the coating is selectively fluorinated and/or cured to improve the liquid repellance of the same. The invention also provides for the selective fluorination and/or curing of selected areas of the coating thus, when completed, providing a coating which has regions of improved liquid repellance with respect to the remaining regions and which remaining regions may be utilized as liquid collection areas.
| 8
|
CROSS-REFERENCES TO RELATED APPLICATIONS
NONE
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
NOT APPLICABLE
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to hydraulic coupling members. More particularly, it relates to male and female hydraulic coupling members having internal, spring-loaded poppet valves for controlling the flow of hydraulic fluid.
2. Description of the Related Art Including Information Disclosed under 37 CFR 1.97 and 1.98
A wide variety of hydraulic couplings include internal poppet valves for preventing the loss of hydraulic fluid when the coupling is disconnected. Hydraulic couplings designed for subsea use also commonly employ poppet valves for preventing seawater from entering the hydraulic system when the coupling members are de-mated. In many designs, the poppet valves include mechanical valve actuators which cause valves that are spring-loaded to the closed position to open upon coupling make-up.
U.S. Pat. Nos. 4,900,071 and 5,052,439 disclose an undersea hydraulic coupling which includes a male member and female member, and a two-piece retainer for restraining radial movement of a wedge-shaped annular seal into the central bore of the female member. The two-piece retainer includes a cylindrical retainer sleeve member that slides within the female member bore, and a threaded retainer-locking member which engages threads in the wall of the central bore. The retainer-locking member holds the retainer sleeve member in place within the female member bore. The annular seal is restrained from radial movement by a dovetail interfit with a mating shoulder on at least one of the retainer sleeve and the retainer-locking members.
U.S. Pat. No. 5,360,035 discloses an undersea hydraulic coupling having a poppet valve movable between an open and a closed position. The poppet valve is pressure balanced—i.e., it operates without substantial fluid pressure exerted axially against the face of the poppet valve. When the poppet valve is opened, radial passages are interconnected through an annular cavity between the poppet valve body and the valve bore.
U.S. Pat. No. 5,692,538 discloses an undersea hydraulic coupling member having angled flow ports to prevent ingress of debris into the hydraulic lines and having a bleed passage to allow trapped hydraulic fluid to bleed off when the coupling members are disconnected. The poppet valve in combination with the angled flow ports helps keep the hydraulic system clear of debris when the members are disconnected.
U.S. Pat. No. 6,085,785 discloses an undersea hydraulic coupling having an extended probe section. The male member of the coupling houses a valve spring having a larger diameter than the diameter of the valve body. The valve spring is configured to close the valve to prevent ingress of sea water or leakage of hydraulic fluid from the system. One or more seals engage the extended probe section.
U.S. Pat. No. 6,095,191 discloses an undersea hydraulic coupling having a male member with a tapered, frusta-conical surface and a female member with a tapered, frusta-conical bore. Before radial seals engage the frusta-conical surfaces, trapped seawater is expelled or displaced from the bore through the space between the coupling members, thereby preventing seawater from entering hydraulic lines.
U.S. Pat. No. 6,474,359 discloses an undersea hydraulic coupling member having a bleed valve which opens to allow hydraulic fluid trapped in the coupling member to escape until the pressure is below a predetermined level. The coupling member employs a poppet valve within a sleeve.
U.S. Pat. No. 6,375,153 discloses an undersea hydraulic coupling having a stepped internal bore dimensioned to increase the flow rate through the coupling. The coupling allows an increased flow rate without increasing the size or weight of the coupling by positioning the poppet valve in the body section, rather than in the probe section, of the male coupling member.
U.S. Pat. No. 6,237,632 discloses an undersea hydraulic coupling member having a primary poppet valve and a secondary poppet valve to improve reliability against leakage when the coupling members are separated. A spring extends between the first poppet valve and the actuator for the second poppet valve. The secondary poppet valve remains closed unless the first poppet valve is fully opened, so that debris or other material that could prevent sealing of the first poppet valve will not cause leakage of hydraulic fluid through the second poppet valve.
U.S. Pat. No. 6,357,722 discloses an undersea hydraulic coupling having a poppet valve with an actuator extending from the valve and a guide between the actuator and bore. The guide is a sleeve-shaped member around the actuator with flow passages which ensure a smooth flow of hydraulic fluid through the annulus between the coupling bore and actuator. The guide also helps prevent damage to the actuator, and aligns the actuator during connections, disconnections and use.
U.S. Pat. No. 6,283,444 discloses an undersea hydraulic coupling member having a valve actuator which extends through the probe section and the leading face, and has angled flow ports in the probe section which help keep the hydraulic system clear of debris when the coupling members are disconnected subsea.
U.S. Pat. No. 6,227,245 discloses an undersea hydraulic coupling member which has angled flow ports to prevent ingress of debris into the hydraulic lines. A port guard attached to the valve actuator closes the flow ports unless the poppet valve is opened by mutual engagement with an opposing coupling member.
U.S. Pat. No. 6,626,207 discloses an undersea hydraulic coupling with interlocking poppet valve actuators. The actuators extend from the poppet valves of each coupling member and interlock to resist bending and/or other lateral displacement caused by hydraulic fluid flow and turbulence in the coupling member bores and at the junction between the coupling members.
U.S. Pat. No. 6,631,734 discloses a dummy undersea hydraulic coupling member for protecting an opposing undersea hydraulic coupling member when the hydraulic lines are not operating. The dummy undersea hydraulic coupling member has a water displacement expansion chamber with a piston therein that allows trapped water and/or air to move from the receiving chamber to the water displacement expansion chamber during connection of the dummy coupling member to the opposing coupling member. The dummy coupling member may include a normally-closed poppet valve in the water displacement expansion chamber which blocks water and/or air from moving between the receiving chamber and the water displacement expansion chamber in the closed position. The poppet valve opens in response to water and/or air pressure acting upon it.
U.S. Pat. No. 7,159,616 discloses a dual-path hydraulic coupling. A female hydraulic coupling member comprises a first flow port; a second flow port; a third flow port in fluid communication with both the first flow port and the second flow port; a first poppet valve for opening and closing the first flow port; and a second poppet valve for opening and closing the second flow port, the second poppet valve being connected to the first poppet valve such that the second poppet valve moves to the closed position when the first poppet valve is open and moves to the open position when the first poppet valve is closed.
BRIEF SUMMARY OF THE INVENTION
A spring-loaded poppet valve within a hydraulic coupling member has a helical, flat wire spring that, when compressed, forms a smooth bore cylinder for the passage of hydraulic fluid and may act as a mechanical stop for the poppet valve travel.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
FIG. 1 is a cross-sectional view of a hydraulic coupling whose members are equipped with poppet valves of the prior art.
FIG. 2 is a cross-sectional view of a female hydraulic coupling member equipped with a poppet valve according to the invention shown in the closed position.
FIG. 3 is a cross-sectional view of a female hydraulic coupling member installed in a mounting plate and equipped with a poppet valve according to the invention shown in the open position.
FIG. 4 is a cross-sectional view of a male hydraulic coupling member equipped with a poppet valve according to the invention shown in the closed position.
FIG. 5 is a cross-sectional view of a male hydraulic coupling member equipped with a poppet valve according to the invention shown in the open position.
FIG. 6 is a cross-sectional view of connected male and female hydraulic coupling members each of which is equipped with a poppet valve according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1 , in a coupling of the prior art, female member 20 comprises body 21 , handle 48 which may be threaded to a manifold plate, and central bore 32 which has several variations in its diameter as it extends through the female member. The first end of the bore may be internally threaded for connection to a hydraulic line. Other connection means known in the art may be utilized including welding, swaging, compression fittings, and the like. A cylindrical passageway extends longitudinally within the female member body and terminates at valve seat 27 . Adjacent valve seat 27 is shoulder 33 which forms one end of receiving chamber 34 .
In the coupling illustrated in FIG. 1 , the receiving chamber which receives the probe of the male member has a stepped internal diameter with internal shoulders 33 , 35 and 63 . The receiving chamber has a first smaller diameter 43 and a second larger diameter 47 .
The female member 20 may include optional poppet valve 28 which is sized to slide within the cylindrical passageway. The poppet valve may be conical in shape and is urged by valve spring 41 into a seated position against valve seat 27 . When the poppet valve is in a closed position against the valve seat, it seals fluid from flowing between the male member and the female member. Hollow spring seat 42 anchors the valve spring 41 and is held in place by clip 45 . Actuator 44 extends from the apex of the poppet valve.
Ring shaped seal 50 is positioned in the receiving chamber of the female member. The ring shaped seal may be an elastomer or other polymer seal that is flexible and resilient. In other couplings of the prior art, seal 50 is fabricated from an engineering plastic such as polyetheretherketone (PEEK). Seal 50 has a first inclined shoulder surface 52 and a second inclined shoulder surface 51 . The axial thickness of the elastomeric seal at its outer circumference (adjacent element 69 in FIG. 1 ) is greater than the axial thickness of the seal at inner circumference 67 . The seal thus has a generally wedge-shaped cross section. Seal 50 may have one or more radial sealing surfaces 55 , 56 extending inwardly from the seal's inner circumference 67 . Each of the radial sealing surfaces extends inwardly from the inner circumference so as to engage the probe of the male member when the probe is inserted through the seal. The radial sealing surfaces may be elastically deformed by the probe when it is inserted through the seal. The radial sealing surfaces 55 and 56 provide guide points to help align and guide the probe of the male member when it is inserted through the seal and into the receiving chamber 34 .
In the prior art female coupling member illustrated in FIG. 1 , probe seal 50 has grooves in its outer circumference 66 . O-rings 57 , 58 or similar seals may be positioned in each of the grooves. Alternatively, seal 50 may have a plurality of integral sealing projections which extend from its outer circumference.
In the female coupling member shown in FIG. 1 , implosion of the seal into the receiving chamber due to low pressure or vacuum is resisted because the seal has an interlocking fit with reverse inclined shoulder surface 62 of seal retainer 29 and reverse inclined shoulder surface 61 of locking member 30 . The seal retainer may be a cylindrical sleeve that slides into the second diameter 47 of the receiving chamber. Alternatively, the seal retainer may be threaded to the female member or engaged to the female member by other means. In the illustrated coupling, when the seal retainer is fully engaged with the female member, first end 46 of the seal retainer abuts shoulder 63 . The seal retainer holds hollow radial metal seal 31 on internal shoulder 35 .
In the illustrated female coupling member, the seal retainer has a first internal circumferential surface 59 adjacent the first end thereof and a second internal circumferential surface 69 adjacent the second end thereof. The internal diameter of the first inner circumferential surface is smaller than the internal diameter of the second internal circumferential surface. Reverse inclined shoulder 62 is situated between the first and second internal circumferential surfaces. The reverse inclined shoulder has an interlocking fit with seal 50 to restrain the seal from moving inwardly in a radial direction. O-ring 49 is positioned in a groove at the first end 46 of the seal retainer to provide a face-type seal between the seal retainer and shoulder 63 .
In the illustrated prior art coupling, locking member 30 engages the female coupling member with threads 53 . Other engaging means known in the art may be used. When the locking member is fully secured to the female coupling member, first end 64 abuts seal retainer 29 and holds the seal retainer in place. The locking member 30 has a central opening with an internal diameter 54 that allows insertion of the probe of the male member. Reverse inclined shoulder surface 61 holds seal 50 in place and restrains the seal from moving inward in a radial direction.
The present invention provides an alternative poppet valve design and may best be understood by reference to the exemplary embodiment shown in the drawing figures.
FIG. 2 depicts a female hydraulic coupling member 100 equipped with a poppet valve according to the present invention. The probe seals 150 and 131 and receiving chamber 134 of female coupling member 100 are similar to those of the prior art coupling illustrated in FIG. 1 . Coupling 100 , however, has a seal cartridge comprised of seal retainer 129 and locking shell 130 . A seal cartridge of this type is disclosed in U.S. Pat. No. 7,163,190 to Robert E. Smith, III. The seal cartridge retains probe seal 150 with a dovetail interlocking fit and optional O-rings 157 and 158 ensure a fluid-tight seal between probe seal 150 and seal retainer 129 . The seal cartridge is held within the body of the female member 100 by threaded portion 153 which engages corresponding threads on the interior distal portion of receiving chamber 134 . Spanner holes 136 in locking member 130 receive a tool for facilitating the installation and removal of the seal cartridge. As in the coupling of FIG. 1 , seal retainer 129 also retains metal seal 131 on an internal shoulder of receiving chamber 134 and O-ring 149 (housed in a groove in a second shoulder within receiving chamber 134 ) provides a seal between retainer 129 and the body of female coupling 100 .
Female coupling member 100 has a generally cylindrical body 120 with a central bore 132 having sections of various internal diameter. The portion of body 120 distal from the end having receiving chamber 134 forms handle 148 which may be used to secure coupling 100 in a manifold plate or other such holding device. Clip 139 may engage an external groove on handle 148 to secure thrust washer 141 . As shown in FIG. 3 , coupling 100 may be mounted in a manifold plate P with shoulder 160 bearing against a first surface thereof and thrust washer 141 bearing against an opposing surface. One end of bore 132 has connector 138 for connecting the coupling to a hydraulic line. Connector 138 may be internally or externally threaded, or the connection may be made by welding, swaging, compression fittings or other means well known in the art.
A portion of bore 132 may have beveled portion 127 to serve as a seat for poppet valve 128 . In the illustrated embodiment, poppet valve 128 is comprised of valve actuator 144 , spring contactor 180 , poppet seal 170 , radial flow passages 174 , valve spring 140 and valve seat 142 .
Valve seal 170 , which may be an elastomer or other suitable material, is held between frustum portion 176 of actuator 144 and poppet body 180 . In the illustrated embodiment, one end of actuator 144 is held within body 180 by flaring at cavity 165 . When poppet valve 128 is in the closed position, seal 170 is pressed against beveled surface 127 by the action of compression spring 140 . The flow of hydraulic fluid out of the coupling and seawater into the coupling is thereby prevented when the coupling is disconnected.
Helical compression spring 140 is formed of flat wire and preferably has an outside diameter slightly smaller than inner diameter 137 of bore 132 to permit spring 140 to compress without binding against the walls of bore 132 . The ends of spring 140 may be closed & ground or open & ground.
Spring 140 may be formed of any suitable material. Examples of suitable materials include, but are not limited to: spring steel, stainless steel, silicon-chrome, high carbon steel, beryllium-copper, INCONEL® alloys, galvanized wire, mild steel, phosphor bronze and brass.
At one end, spring 140 acts against spring seat 142 which is retained in bore 132 by retainer clip 145 which may engage a groove in the wall of bore 132 . The internal diameter of spring seat 142 is preferably the same as internal diameter of spring bore 178 when spring 140 is fully compressed. Likewise, the internal diameter 172 of spring contactor 180 is preferably the same as the i.d. of spring bore 178 .
FIG. 3 shows female coupling member 100 with its poppet valve in the open position. The action of poppet valve 128 is as follows: when coupling 100 is connected to a corresponding male coupling member ( 200 ), valve actuator 144 contacts a corresponding actuator in the male member compressing spring 140 and opening poppet valve 128 by moving seal 170 off of seat 127 . Hydraulic fluid may then flow from receiving chamber 134 past seat 127 and into annular flow passage 182 . From thence the flow is through radial flow ports 174 and into the hollow central cavity of poppet body 128 . When spring 140 is fully compressed, its helical coils contact one another thereby forming a substantially smooth bore tube. This facilitates the flow of hydraulic fluid through the coupling member. In couplings of the prior art such as those illustrated in FIG. 1 , the round wire valve spring 40 provides a rough inner surface which may hinder the flow of hydraulic fluid.
It will also be appreciated that when fully compressed flat wire spring 140 provides a load path extending from actuator 144 through poppet body 128 to spring seat 142 which is fixed by retainer clip 145 . This feature enables spring seat 142 to be smaller than those of the prior art since flat wire spring 140 is less susceptible to buckling out of column when fully compressed than a round wire spring. As shown in FIG. 1 , spring seat 42 of the prior art is equipped with an extension for ensuring positive contact with poppet valve body 28 when spring 40 is compressed. This is unnecessary in a coupling according to the present invention and enables a coupling of a fixed size to have larger internal flow passage for hydraulic fluid.
FIG. 4 depicts a male hydraulic coupling member 200 equipped with a poppet valve according to the present invention. Male coupling member 200 has a generally cylindrical body 221 with a central bore 232 having sections of various internal diameter. At one end of body 221 is male probe 234 for insertion into the receiving chamber of a corresponding female member ( 100 ). The portion of body 220 distal from probe 234 forms handle 248 which may be used to secure coupling 200 in a manifold plate or other such holding device. One end of bore 232 has connector 238 for connecting the coupling to a hydraulic line. Connector 238 may be internally or externally threaded, or the connection may be made by welding, swaging, compression fittings or other means well known in the art.
A portion of bore 232 may have beveled portion 227 to serve as a seat for poppet valve 228 . In the illustrated embodiment, poppet valve 228 is comprised of valve actuator 244 , spring contactor 280 , poppet seal 270 , radial flow passages 274 , valve spring 240 and valve seat 242 .
Valve seal 270 which may be an elastomer or other suitable material is held between frustum portion 276 of actuator 244 and poppet body 280 . When poppet valve 228 is in the closed position, seal 270 is pressed against beveled surface 227 by the action of compression spring 240 . The flow of hydraulic fluid out of the coupling and seawater into the coupling is thereby prevented when the coupling is disconnected.
Helical compression spring 240 is formed of flat wire and preferably has an outside diameter slightly smaller than inner diameter 237 of bore 232 to permit spring 240 to compress without binding against the walls of bore 232 . The ends of spring 240 may be closed & ground or open & ground.
Spring 240 may be formed of any suitable material. Examples of suitable materials include, but are not limited to: spring steel, stainless steel, silicon-chrome, high carbon steel, beryllium-copper, INCONEL® alloys, galvanized wire, mild steel, phosphor bronze and brass.
At one end, spring 240 acts against spring seat 242 which is retained in bore 232 by retainer clip 245 which may engage a groove in the wall of bore 232 . The internal diameter of spring seat 242 is preferably the same as internal diameter of spring bore 278 when spring 240 is fully compressed. Likewise, the internal diameter 272 of spring contactor 280 is preferably the same as the i.d. of spring bore 278 .
FIG. 5 shows male coupling member 200 with its poppet valve in the open position. The action of poppet valve 228 is as follows: when coupling 200 is connected to a corresponding female coupling member ( 100 ), valve actuator 244 contacts a corresponding actuator in the male member compressing spring 240 and opening poppet valve 228 by moving seal 270 off of seat 227 . Hydraulic fluid may then flow from the receiving chamber of the female member ( 100 ) into opening 286 on the leading face of probe 234 and into annular probe flow passage 284 past seat 227 and into annular flow passage 282 . From thence the flow is through angled flow ports 275 and into the hollow central cavity of poppet body 228 . When spring 240 is fully compressed, its helical coils contact one another thereby forming a substantially smooth bore tube. This facilitates the flow of hydraulic fluid through the coupling member. In couplings of the prior art such as those illustrated in FIG. 1 , the round wire valve spring 40 provides a rough inner surface which may hinder the flow of hydraulic fluid.
It will also be appreciated that when fully compressed flat wire spring 240 provides a load path extending from actuator 244 through poppet body 228 to spring seat 242 which is fixed by retainer clip 245 . This feature enables spring seat 242 to be smaller than those of the prior art since flat wire spring 240 is less susceptible to buckling out of column when fully compressed than a round wire spring. As shown in FIG. 1 , spring seat 42 of the prior art is equipped with an extension for ensuring positive contact with poppet valve body 28 when spring 40 is compressed. This is unnecessary in a coupling according to the present invention and enables a coupling of a fixed size to have larger internal flow passage for hydraulic fluid.
Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of the invention as described and defined in the following claims.
|
Male and/or female members of a hydraulic coupling have an internal poppet valve that is held in the closed position by a flat wire, helical compression spring. The spring is configured such that when the poppet valve is moved to its fully open position, the coils of the spring are completely compressed thereby forming a substantially smooth bore tube for the flow of hydraulic fluid. The flat wire, helical compression spring may also act as a valve stop, limiting movement of the poppet valve and providing the necessary resistance to move the valve actuator of a corresponding valve in a mating member.
| 4
|
CROSS REFERENCE TO RELATED APPLICATION
This application is based upon and claims benefit of U.S. Provisional Patent Application Ser. No. 62/026,249 entitled “WELDED ROOF FOR MODULAR BUILDING UNITS,” filed with the U.S. Patent and Trademark Office on Jul. 18, 2014 by the inventor herein, the specification of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
This invention relates generally to modular building construction, and more particularly to a welded roof assembly for a modular building unit configured to receive various gutter system configurations.
BACKGROUND OF THE INVENTION
Roofing members for modular buildings are typically attached by way of screws or other fasteners, and are supplied in sheets arranged in a tile configuration with a portion of one roofing sheet overlapping a portion of an adjacent roofing sheet. In order to channel rainwater and water from snow and ice melt away from the modular building, gutters may be provided along the edges of the modular building unit. However, the type of gutter assembly, and in fact whether a gutter system is required at all, can vary from location to location based upon annual weather patterns, and particularly rain, snow, and ice amounts received in a given area. Different weather patterns may call for different gutter configurations, and at times even no gutter. Moreover, even with water diversion and drainage, conditions may result in water collecting on the roof and leaking into the modular building unit, such as through gaps between adjacent roofing sheets, gaps between the roofing sheets and the frame of the modular building unit, openings around fasteners, and the like. While silicone or other fillers may be provided, they are temporary and subject to failure and leakage over time. While differing gutter configurations may be provided to address different rain, snow, and ice conditions, they will require varied adaptations of the roof structure as well in order to accommodate the varied environmental conditions.
Thus, there remains a need in the art for a roofing configuration for a modular building unit that is able to accept gutters of varied configurations without requiring adaptation or modification of the building unit structure, and that protects against water leakage through the roof in all such gutter configurations, and in the case of no gutter.
SUMMARY OF THE INVENTION
Disclosed is a roof assembly for a modular building unit that comprises a roofing sheet that is welded to the frame of the modular building unit so as to form a unitary, continuous sealed weld between the roofing sheet and the structural frame of the modular building unit, and that is pitched to downwardly direct water on the roofing sheet toward one end of the modular building unit. The welded roof assembly prevents water infiltration into the modular building unit, and such watertight structure may then receive any gutter configuration the user wishes to implement without risking water infiltration into the building unit. Further, the welded roof assembly allows the modular building unit to carry a heavy snow load, as the welds attaching the roofing sheet can easily carry heavy loads. The welded roofing sheet avoids the use of screws, and the associated possibility of water leakage around the screws and into the building unit. The welded roof also permits attachment, e.g. via welding, of safety rings or other accessories directly on the roof sheet without need for specialized holes or other configurations or specific location requirements. The welded roof also is able to employ a single slope all of the way through the full span of the roof, thus avoiding the need for a centrally pitched roof assembly, and its unitary construction avoids the tiling effect that results from the use of multiple, overlapping roofing sheets. The welded roof also avoids the need for silicon or other filler agents between the unitary roofing sheet and the frame of the modular building unit. Still further, the recessed roofing panel within the exterior frame formed by the upper rails of the building unit, along with the horizontal top surfaces of such rails, provided for easy vertical stacking of modular building units atop one another.
In accordance with certain aspects of an embodiment of the invention, a roof assembly is provided for a modular building unit, comprising: a first long rail having a top wall, an exterior wall, and an interior wall; a second long rail parallel to the first long rail and having a top wall, an exterior wall, and an interior wall; a first short rail extending between the first and second long rails and having a top wall, an exterior wall, and an interior wall; a second short rail extending between the first and second long rails and having a top wall and an exterior wall, wherein the first and second long rails and the first and second short rails are joined to form a rectangular exterior roof frame of a modular building unit; and a roofing sheet, wherein the roofing sheet is joined to the first short rail at a first elevation below the top wall of the first short rail, the roofing sheet is joined to each of the first and second long rails at a point below the top wall of each of the first and second long rails and extending in a downward slope from the first elevation, and the roofing sheet is joined to the top surface of the second short rail at a lowest elevation of the roofing sheet; and wherein the roofing sheet is joined to the first short rail, each of the first and second long rails, and the top surface of the second short rail by a continuous weld.
In accordance with further aspects of an embodiment of the invention, a method of forming a roof assembly for a modular building unit is provided, comprising the steps of: providing a roof frame comprising a first long rail having a top wall, an exterior wall, and an interior wall; a second long rail parallel to the first long rail and having a top wall, an exterior wall, and an interior wall; a first short rail extending between the first and second long rails and having a top wall, an exterior wall, and an interior wall; and a second short rail extending between the first and second long rails and having a top wall and an exterior wall, wherein the first and second long rails and the first and second short rails are joined to form a rectangular exterior roof frame of a modular building unit; joining a roofing sheet to the first short rail at a first elevation below the top wall of the first short rail; joining the roofing sheet to each of the first and second long rails at a point below the top wall of each of the first and second long rails and extending in a downward slope from the first elevation; and joining the roofing sheet to the top surface of the second short rail at a lowest elevation of the roofing sheet; wherein the steps of joining the roofing sheet to the first short rail, each of the first and second long rails, and the top surface of the second short rail is performed by making a continuous weld.
BRIEF DESCRIPTION OF THE DRAWINGS
The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a modular building unit in accordance with certain aspects of an embodiment of the invention.
FIG. 2 is a perspective view of a skeletal frame of the modular building unit of FIG. 1 .
FIG. 3 is a cross-sectional view of the skeletal frame of FIG. 2 .
FIGS. 4 a through 4 d are close-up, cross-sectional views of the lower roof edge of the frame of FIG. 3 with varying gutter configurations.
FIG. 5 is a top view of a roof portion of the modular building unit of FIG. 1 .
FIG. 6 is a perspective view of the roof portion of FIG. 5 .
FIG. 7 is a close-up, detail cross-sectional view of the frame of FIG. 3 .
FIG. 8 is a cross-sectional view of a first, higher elevation top short rail of the frame of FIG. 7 .
FIG. 9 is a perspective view showing connection of the first top short rail and one of the top long rails of the frame of FIG. 7 .
FIG. 10 is a cross-sectional view of a roofing sheet short side mounting bracket of the frame of FIG. 7 .
FIG. 11 is a perspective view of the roofing sheet short side mounting bracket of FIG. 10 .
FIG. 12 is a close-up, detail cross-sectional view of the frame of FIG. 3 along an axis parallel to the first top short rail (showing the long rails in cross-section).
FIG. 13 is a perspective view of a roofing sheet long side bracket 146 for a first long side of the frame of FIG. 7 .
FIG. 14 is a rear view of the roofing sheet long side bracket of FIG. 15 .
FIG. 15 is a cross-sectional view of the roofing sheet long side bracket of FIG. 14 along section line A-A.
FIG. 16 is a cross-sectional view of the roofing sheet long side bracket of FIG. 14 along section line B-B.
FIG. 17 is a cross-sectional view of a second, lower elevation top short rail of the frame of FIG. 7 .
FIG. 18 is a perspective view showing connection of the second top short rail and one of the top long rails of the frame of FIG. 17 .
FIG. 19 shows an external gutter and drain pipe for use with the roof portion of FIG. 6 .
FIG. 20 is a cross-sectional view of the gutter and drain pipe of FIG. 19 attached to second top short rail of the frame of FIG. 7 .
FIG. 21 shows an external water deflector for use with the roof portion of FIG. 6 .
FIG. 22 is a cross-sectional view of the water deflector of FIG. 21 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is of a particular embodiment of the invention, set out to enable one to practice an implementation of the invention, and is not intended to limit the preferred embodiment, but to serve as a particular example thereof. Those skilled in the art should appreciate that they may readily use the conception and specific embodiments disclosed as a basis for modifying or designing other methods and systems for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent assemblies do not depart from the spirit and scope of the invention in its broadest form.
FIG. 1 provides a perspective view of a modular building unit 100 in accordance with certain aspects of an embodiment of the invention. Modular building unit 100 includes a skeletal frame formed by corner support posts 112 , bottom rails 114 , top long rails 115 , a first top short rail 116 (shown in FIG. 2 ), and a second top short rail 117 . This skeletal frame provides the key structural integrity for the modular building unit. Positioned between corner support posts 112 , bottom rails 114 , and top rails 115 , 116 and 117 are wall panels 118 that form the wall structures spanning each side of the modular building unit. Other standard building features, such as doors 120 and windows 122 , may be provided and integrated with individual wall panels 118 .
FIG. 2 is a perspective view of the skeletal frame forming the modular building unit of FIG. 1 . As shown in FIG. 2 , the skeletal frame comprises four corner posts 112 extending upward from bottom rails 114 and supporting the roof portion of the modular building unit 100 . The roof portion includes top long rails 115 extending lengthwise between adjacent corner support posts 112 , a first top short rail 116 extending between adjacent corner supports posts 112 and generally perpendicular to top long rails 115 , and a second top short rail 117 extending between adjacent corner support posts 112 and generally perpendicular to top long rails 115 . A roofing sheet 140 forms the exterior roof of the modular building unit, and sits within the interior of the frame defined by top long rails 115 , first top short rail 116 , and second top short rail 117 . Roofing sheet 140 may have a thickness of preferably 1 to 3 mm, and more preferably 2 mm, and may either comprise a flat sheet or a corrugated sheet comprised of continuous or segmented ribs as shown in FIG. 2 . If corrugated (which may be desirable depending upon typical roof rain and snow loads in the locale where the modular building unit is to be installed), ribs from the corrugated sheet may help with drainage of water. The roofing sheet 140 is welded around its entire perimeter to top long rails 115 , first top short rail 116 , and second top short rail 117 , all as discussed in greater detail below, to ensure complete water tightness, particularly in the case of snow and ice. Roofing sheet 140 is also welded, such as by spot welding, to purlins 124 spanning the width of the roof portion and extending between parallel top long rails 115 , again as discussed in greater detail below.
Moreover, and as better shown in the cross-sectional view of the skeletal frame of FIG. 3 , roofing sheet 140 slopes downward from first top short rail 116 to second top short rail 117 so as to direct all water to the lowest elevation of the roof portion of the modular building unit. In order to provide such downward slope, purlins 124 are positioned at progressively lower elevations, with each end of each purlin being rigidly affixed (e.g., welded) to an interior face of each top long rail 115 . Such configuration results in roofing sheet 140 realizing a downward slope of preferably between 0.5% and 5% from one end of the module to the other. In certain configurations, roofing sheet 140 may have two, opposite sloping sections (not shown), each having a downward slope of 0.5% to 5% from the middle of the modular building unit to the end of the modular building unit.
Because the modular building unit is configured with a fully welded roof, the modular building unit may be configured with varied gutter options, including no gutter. Those varying gutter options are shown in the exemplary configurations reflected in FIGS. 4 a through 4 d . FIG. 4 a shows the lowest roof edge of modular building unit 100 , including roofing sheet 140 welded directly to the top face of second top short rail 117 , which in turn is mounted above wall panel 118 . In this configuration, no gutter is provided, in which case water from the room will directly flow off of the roof, while the weld around the perimeter of roofing sheet 140 prevents infiltration of water into the modular building unit. Next, FIG. 4 b shows the same roof edge of modular building unit 100 , with a water deflector 200 attached to the exterior face of second top short rail 117 , which deflector 200 may aid in directing water flowing from the roof away from the side wall panels 118 of modular building unit 100 . Likewise, FIG. 4 c shows the same roof edge of modular building unit 100 , with gutter 190 attached to the exterior face of second top short rail 117 , which gutter 190 may receive water flowing from the roof and direct such water to a downspout (not shown) as discussed further below. Similarly, FIG. 4 d shows the same roof edge of modular building unit 100 , with an alternative gutter 119 a attached to the exterior face of second top short rail 117 , which alternative gutter 119 a is attached in the same manner as gutter 119 but embodies a decorative design to improve the overall aesthetic appearance of the modular building unit 100 . Those of ordinary skill in the art will recognize that gutter assemblies of other varying configurations may likewise be provided without departing from the spirit and scope of the invention.
FIG. 5 provides a top view, and FIG. 6 provides a perspective view, of the roof portion of modular building unit 100 . Roofing sheets 140 are shown spanning the full length of the roof, and as mentioned above, may optionally include ribs 142 that may aid in directing water toward the lowest elevation point on the roof (i.e., toward second top short rail 117 ). Optionally, roofing sheets 140 may be provided in separate sections, in which each of the sections are preferably welded together to form the same waterproof, welded seam that is provided along the perimeter of roofing sheet 140 . Mounting brackets are provided at the interior faces of each of first top short rail 116 and the two top long rails 115 . More specifically, roofing sheet short side mounting bracket 144 is affixed to and runs parallel to first top short rail 116 , and roofing sheet long side brackets 146 are affixed to and run parallel to each top long rail 115 . Roofing sheet short side mounting bracket 144 provides a horizontal mounting and welding surface for the highest elevation portion of roofing sheet 140 , while roofing sheet long side brackets 146 provide a downwardly angled mounting and welding surface for the long edges of roofing sheet 140 , resulting in the roofing sheet 140 following a downward slope from first top short rail 116 to second top short rail 117 . The lowest elevation point of roofing sheet 140 is welded directly to the top surface of second top short rail 117 , again allowing water on roofing sheet 140 to flow directly onto and over second top short rail 117 .
Corner boxes 119 may be provided at each corner of the roof portion of modular building unit 100 , which corner boxes 119 principally serve as corner elements for joining each perpendicular pair of rails and one of corner support posts 112 . Corner boxes 119 may also be provided features, such as openings, in the top and side walls of each corner box 119 to receive a crane hook or other device to aid in lifting the entire modular building unit when necessary for transport or installation.
FIG. 7 provides a close-up, detailed cross-sectional view of the skeletal frame of modular building unit 100 . First top short rail 116 is shown at the left most portion of FIG. 7 , with roofing sheet short side mounting bracket 144 extending from the interior face of first top short rail 116 and supporting roofing sheet 140 . The underside of roofing sheet 140 overlaps a portion of roofing sheet short side mounting bracket 144 and is welded to short side mounting bracket 144 . Likewise, as roofing sheet 140 extends toward second top short rail 117 , it rests on and is preferably welded to purlins 124 . At the opposite end from first top short rail 116 (i.e., the right edge as viewed in FIG. 7 ), roofing sheet 140 overlaps a portion of second top short rail 117 and is welded to the top of second top short rail 117 .
Other features, including sealed joints attaching the overall roof portion to wall panels 112 , interior ceiling trays, and subfloor construction details, are shown in FIG. 7 but are not critical to the roofing structure of the instant invention, and thus are not described further here.
FIG. 8 is a cross-sectional view of first top short rail 116 , and FIG. 9 is a perspective view of first top short rail 116 connecting to one of top long rails 115 through a connecting corner box 119 . As shown in FIGS. 8 and 9 , first top short rail 116 has a planar top face 150 , a planar outer face 152 that forms a portion of the exterior side wall of modular building unit 100 , interior bracket flange 154 , and bottom profile 156 to fit with a modular wall panel as shown in FIG. 7 . Interior bracket flange 154 extends downward from the interior edge of planar top face 150 , and provides an attachment surface for roofing sheet short side mounting bracket 144 .
FIG. 10 provides a cross-sectional view of roofing sheet short side mounting bracket 144 , and FIG. 11 provides a perspective view of such roofing sheet short side mounting bracket 144 . Bracket 144 comprises a back wall 170 configured for attachment, such as by welding, to interior bracket flange 154 of first top short rail 116 . Bracket 144 also has a short side roofing sheet support surface 172 which, when bracket 144 is mounted on first top short rail 116 , extends generally horizontally and parallel to planar top face 150 of first top short rail 116 . Support surface 172 supports the highest elevation end of roofing sheet 140 , with the underside of roofing sheet 140 resting on the top side of support surface 172 and the two being joined by a continuous weld. Bracket 144 may also include a top lip 174 extending generally parallel to short side roofing sheet support surface 172 , which top lip 174 limits the opportunity for wind to blow water onto top short rail 116 , so that water remains contained on roof sheet 140 . Further, corner notches 176 are provided at opposite ends of support surface 172 to allow contact with edges of roofing sheet long side brackets 146 , in order to provide a continuous surface to receive a continuous weld around the entire perimeter of roofing sheet 140 .
Next, FIG. 12 provides a cross-sectional view of the skeletal frame of modular building unit 100 along an axis parallel to first top short rail 116 (showing the top long rails 115 in cross section). Top long rails 115 are of generally the same cross-sectional configuration as first top short rail 116 (although obviously with a longer overall length dimension). Roofing sheet long side mounting brackets 146 are affixed (e.g., welded) to interior bracket flange 154 of long rails 115 and support roofing sheet 140 along its long edge. The underside of the long edge of roofing sheet 140 overlaps a portion of roofing sheet long side mounting brackets 146 and is welded to long side mounting brackets 146 . Likewise and as mentioned above, roofing sheet 140 is supported by and is preferably welded to purlins 124 for additional support.
FIG. 13 is a perspective view of a roofing sheet long side bracket 146 for attachment to a first one of top long rails 115 . Those of ordinary skill in the art will appreciate that the opposite top long rail 115 will receive a similarly configured long side bracket 146 that is the mirror image of the bracket shown in FIG. 13 . Likewise, FIG. 14 is a rear view of roofing sheet long side bracket 146 . Further, FIG. 15 provides a cross-sectional view of bracket 146 along section line A-A of FIG. 14 , and FIG. 16 provides a cross-sectional view of bracket 146 along section line B-B of FIG. 14 . As shown in FIGS. 13 through 16 , bracket 146 includes a back wall 180 providing an attachment surface for attaching (e.g., welding) bracket 146 to interior bracket flange 154 of top long rails 115 . Back wall 180 has a generally horizontal top edge and a downwardly sloping bottom edge. Likewise, bracket 146 has a long side roofing sheet support surface 182 which, when each bracket 146 is mounted on its respective top long rail 115 , extends outward from back wall 180 and provides a downwardly sloping support surface for the long edge of roofing sheet 140 , with the underside of such long edge of roofing sheet 140 resting on the top side of support surface 182 and the two being joined by a continuous weld. Such continuous weld seamlessly extends from the weld joining the highest elevation portion of roofing sheet 140 to short side roofing sheet support surface 172 . Bracket 146 may also include a top lip 184 extending generally parallel to top long rails 115 , again serving to keep water from being blown off of roofing sheet 140 .
FIG. 17 shows a cross-sectional view of second top short rail 117 , and FIG. 18 is a perspective view of second top short rail 117 connecting to one of top long rails 115 through a connecting corner box 119 . As shown in FIGS. 17 and 18 , second top short rail 117 has a planar top face 160 configured to directly receive an overlapping portion of the lowest elevation section of roofing sheet 140 . As noted above, roofing sheet 140 is welded directly to such planar top face 160 of second top short rail 117 , and such weld seamlessly continues from the weld attaching roofing sheet 140 to each of roofing sheet short side mounting bracket 144 and roofing sheet long side brackets 146 . Second top short rail 117 also has a planar outer face 162 which is configured to directly receive various gutter configurations as discussed in greater detail below, or alternatively to form a portion of the exterior side wall of modular building unit 100 (in cases where no gutter system is to be used). Second top short rail 117 further includes planar interior face 164 and a bottom profile 166 to fit with a modular wall panel as shown in FIG. 7 .
FIG. 19 shows an external gutter 190 for use with the welded roof described above. External gutter 190 may include a plurality of overflow openings 192 provided on the outermost wall of gutter 190 , and a spigot 194 at one end of gutter 190 . Spigot 194 is shaped to fit within a drain pipe 196 , which drain pipe may be joined to modular building unit 100 with, by way of non-limiting example, an angle bracket 198 , such as to one of corner support posts 112 that is adjacent to second top short rail 117 . Likewise, FIG. 20 shows a cross-sectional view along section line C-C of FIG. 19 of the gutter 190 and drain pipe 196 , with external gutter 190 attached to second top short rail 117 with one or more fasteners 199 , such as a screw.
Similarly, FIG. 21 shows an external water deflector 200 for use with the welded roof described above, and FIG. 22 provides a cross-sectional view of such water deflector 200 . With reference to both FIGS. 21 and 22 , water deflector 200 has a back wall 202 that is configured for facing attachment to planar outer face 162 of second top short rail 117 , a plurality of openings 204 for receiving connectors (e.g., screws) for such attachment, and an upper angle 206 configured to direct water outward and away from the edge of the roof of modular building unit 100 as it flows off of the roof.
The foregoing configuration results in a modular building unit having a roof structure that may readily receive a variety of gutter configurations, and that is simultaneously effective with no gutter, in an assembly that protects against water infiltration into the modular building unit regardless of the gutter configuration. Thus, a single modular building unit configuration may be provided in geographies having widely varied rain and snow conditions, with gutters being added (or not) depending upon the specific precipitation conditions of that particular environment, saving the user from having to maintain multiple configurations for differing environements.
Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with said underlying concept. It should be understood, therefore, that the invention may be practiced otherwise than as specifically set forth herein.
|
Disclosed is a roof assembly for a modular building unit that comprises a roofing sheet that is welded to the frame of the modular building unit to form a unitary, continuous sealed weld between the roofing sheet and the generally horizontal structural frame of the modular building unit, and that is pitched to downwardly direct water toward one end of the modular building unit. The welded roof assembly prevents water infiltration into the modular building unit, and such watertight structure may then receive any gutter configuration the user wishes to implement without risking water infiltration into the building unit. The welded roofing sheet avoids the use of screws or other fasteners, and the associated possibility of water leakage around the screws and into the building unit. The welded roof also is able to employ a single slope all of the way through the full span of the roof, thus avoiding the need for a centrally pitched roof assembly, and its unitary construction avoids the tiling effect that results from the use of multiple, overlapping roofing sheets. The welded roof also avoids the need for silicon or other filler agents between the unitary roofing sheet and the frame of the modular building unit.
| 4
|
FIELD OF THE INVENTION
[0001] The present invention concerns improvements in and relating to insect/fly screens for mounting over door and window openings.
BACKGROUND TO THE INVENTION
[0002] Whereas there are currently commercially available a number of different designs of insectffly screens that are adapted to mount over door and window openings, many of these are hinged to the surround of the opening and are not optimally convenient in use.
[0003] More sophisticated fly screen systems have become available in recent years and which are designed to slide on tracks across a door or window opening. As a generality, however, these are formed with a bulky, rigid frame defining the tracks as well as a comparatively bulky and rigid frame of the flyscreen itself.
[0004] It is a general object of the present invention to provide a comparatively slim, compact and economical flyscreen installation and which is reliably effective and may be adapted to suit a number of different types of door and window configuration.
SUMMARY OF THE INVENTION
[0005] According to a first aspect of the present invention there is provided an improved flyscreen to be slidingly deployed across an opening of window or door, the window or door having a static glazing pane or panel and an opening pane or panel, the flyscreen comprising a frame dimensioned to correspond to the dimensions of the window or door opening to be covered by the flyscreen and having a mesh screen therein extending thereacross, the frame having a brush or filamentous pad strip extending substantially the full height of an upright of the frame and which when the screen is slidingly mounted adjacent to a window or door to be slidingly moved back and forth across the opening of the window or door, is substantially able to brush over the surface of the static pane or panel of the window or door.
[0006] Advantageously the flyscreen is installed to a window or door and wherein the upright/jamb of the window or door which defines one side of the opening of the window or door against which the trailing edge upright of the flyscreen frame comes to rest when the screen is drawn to overlie the opening has a mating brush or filamentous pad strip thereon extending at least substantially the length thereof to cooperatively engage/abutt against the brush or filamentous pad strip of the frame to substantially seal the edge of that frame against ingress by any insects.
[0007] Preferably the fly screen is adapted to mount to a sliding window or door having a handle that projects substantially from the plane of the window or door, wherein the brush or filamentous pad strip on the frame is provided on a projecting limb of the frame that projects from the frame toward the plane of the door or window static pane, allowing the mesh screen to clear the door or window handle but ensure that the brush or filamentous pad strip remains closed or brushes over the surface of the door or window static pane as the frame is slid back and forth.
[0008] Preferably the projecting limb is adapted to be demountable from the frame.
[0009] Advantageously a plurality of interchangeable projecting limbs are provided of differing projection extents to suit different extents of projection of the door or window handles.
[0010] Suitably a brush or filamentous pad strip is provided extending along substantially the full length of the top edge of the frame.
[0011] Preferably a brush or filamentous pad strip is provided extending along substantially the full length of the bottom edge of the frame.
[0012] Suitably a brush or filamentous pad strip is provided extending along the top edge and/or bottom edge of the projecting limb of the frame.
[0013] According to a second aspect of the present invention there is provided an improved flyscreen to be slidingly deployed across the opening of a window or door and being of horizontal roller screen type having a mesh flyscreen on a roller that is mounted, in use, to a top, bottom or side of a door or window opening to be drawn across the opening, the flyscreen assembly further comprising a pair of guide rails extending in use opposite to each other to guide the opposing side edges of the screen as it is extended, wherein at least one and suitably both of the guide rails has a brush extending therealong substantially the length thereof and is/are provided with an adjustable stabiliser/gripping bar extending therealong substantially the length thereof to grip and stabilise the screen against the brush(es) to counter sag and/or disturbance by the wind or other disruptive forces.
[0014] Preferably the stabilising/gripping bars are provided with Velcro™ or other fastening means to fasten to the edge of the mesh screen, gripping the screen in place.
[0015] Advantageously the roller blind is arranged to extend in a substantially vertical direction and the screen is extended or retracted by a drawstring.
[0016] Preferably the screen is arranged vertically and the leading edge of the screen has a bar extending thereacross which is weighted to facilitate stable deployment of the screen.
[0017] Advantageously the roll of the roller blind is held in a roller cassette and wherein the cassette is provided with two rows of brush means, one inward of the other relative to the opening of the roller cassette from which the screen is drawn, whereby the second row of brush means acts as a secondary barrier against ingress of flies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] A preferred embodiment of the present invention will now be more particularly described by way of example with reference to the accompanying drawings, wherein
[0019] [0019]FIGS. 1 a and 1 b are, respectively, front and rear elevation views of a first embodiment of flyscreen, to be mounted on tracks to slide across a door opening in a set of French windows;
[0020] [0020]FIG. 2 is a plan view of the flyscreen of the first embodiment from above,
[0021] [0021]FIG. 3 is an end elevation view of the leading end of the flyscreen; and
[0022] [0022]FIG. 4 is an enlarged fragmentary view of the same;
[0023] [0023]FIGS. 5 and 6 are, respectively, an enlarged fragmentary plan view of the screen as seen in FIG. 2, and a horizontal sectional view of the same;
[0024] [0024]FIGS. 7 a and 7 b are, respectively, front and rear elevation views of the second preferred embodiment of the present invention suitable for use with sliding windows;
[0025] [0025]FIG. 8 is an end elevation view of the second preferred embodiment of fly screen;
[0026] [0026]FIG. 9 is a plan view of the second preferred embodiment from above;
[0027] [0027]FIG. 9 a is a fragmentary view of the dovetail mounting of the projecting limb to the fly screen frame of the FIG. 9 embodiment;
[0028] [0028]FIG. 10 is a front elevation view of a third preferred embodiment of the invention, comprising a flyscreen of roller screen type;
[0029] [0029]FIG. 11 is an end elevation view of the FIG. 10 embodiment;
[0030] [0030]FIG. 12 is a fragmentary view of a track and stabilising/gripping bar as viewed from the left hand side at detail A in FIG. 10;
[0031] [0031]FIGS. 13A and 13B are, respectively, fragmentary plan views from above of the details shown in FIG. 12 and showing the stabilising/gripping bar partially released and in locking engaged state, respectively; and
[0032] [0032]FIGS. 14A and 14B are, respectively, a transverse sectional view through the roller screen top casing/roller cassette and a frontal view of the secondary brush component thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] As illustrated in FIGS. 1 to 6 , the first embodiment of the insect screen is suitable for use with French windows (glazed sliding doors) and may also be used as a sun screen. It comprises a mesh sheet 1 held substantially taut within a rectangular frame 2 a - d. This is of a size and shape that corresponds to the size and shape of the French windows or other sliding door installation against which it is adapted to sit. The frame 2 a - d mounts within an additional channel retro-fitted to or integral with the track of the sliding French window in order to be able to slide across the door opening when the French window/door is slid back to its opened state.
[0034] The mesh of the mesh sheet 1 is suitably sufficiently fine to exclude the smallest of flying insects such as midges, gnats and mosquitoes. It is suitably of a plastics polymer such as nylon—in which case horizontal strengthening bars 3 are suitably provided at intervals which are suitably equal intervals, of the height of the screen extending across the width of the screen. However, where the mesh is formed of a substantially rigid material such as aluminium or other metal or metal alloy, such additional strengthening is generally unnecessary other than, if desired, to act as a clear visual warning that the screen is drawn across the door opening to prevent individuals from failing to notice the fine unobtrusive screen and walking into it.
[0035] As can be seen from the side elevation, the insect screen has an extremely slim profile which in practice suitably of the order of 20 mm or less and generally of the order of 15 mm.
[0036] The rectangular frame 2 a - d is suitably formed of a pair of uprights/stiles 2 a, 2 b and top and bottom opposing cross-bars 2 c, 2 d all of aluminium, hard, hardened or strengthened plastics, wood or other suitable material that is lightweight but reasonably rigid.
[0037] The trailing edge stile 2 a of the frame has a vertically extending brush 4 (preferably bristle brush) which is adapted to ride smoothly over the surface of the underlying static glazing pane of the French windows without damage to the glass if the screen should be pressed against the glass. It co-operatively engages with a corresponding vertically extending brush 5 that is mounted on the static stile 6 of the French windows that borders the door opening opposite the jamb 6 . Abutment of the vertical brush 4 on the trailing edge stile 2 a of the screen frame against the vertical brush on the static stile 6 gives a firm and insect tight closure of the door opening when the screen is drawn across the opening.
[0038] The leading edge of the leading stile 2 b of the screen has a lip 7 which sits closely against the rail 8 b on the door jamb to close that other side of the door opening, There is generally no need for a further brush or other sealing element at that end.
[0039] Each of the top and bottom cross-bars 2 c, 2 d has their own respective brush 9 , 10 extending horizontally the length thereof to seal the screen respectively from top and bottom.
[0040] The illustrated configuration of fly screen has a pair of small handle knobs 10 provided on one of the transverse strengthening bars 3 , one knob 10 at each end. A small handle (not shown) is suitably provided on the alternate face of the screen for handling the screen from the outside. This is suitably provided on the transverse bar 3 or on the leading edge stile 2 b that is particularly suitably pivotable to collapse substantially flat against the screen so that when the screen is fully retracted back against the static pane of the French windows the screen lies very closely against the static pane of the French windows.
[0041] By way of further detail apparent in the figures, the screen is provided with triangular corner pieces at each corner of the frame to better hold the mesh of the screen in place within the frame.
[0042] A second embodiment of the invention, comprising a fly screen for sliding windows, is illustrated in FIGS. 7 to 9 and has a rigid rectangular frame construction in common with the first aspect The materials and construction are suitably generally the same. However, the trailing edge stile 2 a ′ of the fly screen frame 2 a ′- 2 d ′ is provided with an extension profile 20 that carries the brush 4 ′ of the trailing end of the frame and which is dimensioned to enable the brush 4 ′ to maintain continuous contact with the underlying window while giving the fly screen clearance of the window handle. The depth of the extension 20 is adapted to suit the required clearance.
[0043] In a particularly preferred embodiment the extension profile 20 is demountable from the fly screen trailing edge stile 2 a ′ to enable selection of the appropriate depth of extension 20 from amongst alternatives. The extension profile suitably keys to the frame by a sliding dovetail arrangement 21 or other keying arrangement.
[0044] Brushes are suitably provided not only along the top and bottom bars and the profile extension of the trailing edge but optionally also at the leading edge. Where a brush is provided down the leading edge 2 b ′ this is suitably a felt brush rather than a bristle brush in contrast to the others.
[0045] As in the embodiment of FIGS. 1 to 6 , the brush 4 ′ will abut/engage with a corresponding brush 6 ′ on an upright of the sliding window when the screen 1 ′ is fully extended across the window opening.
[0046] Turning now to FIGS. 10 to 13 , these illustrate a roller blind-like insect screen which has a mesh sheet 1 ″ on a roll that may be pulled downwardly with its opposing lateral edges running in a pair of upright U-shaped channel tracks 30 .
[0047] It may optionally also have a corresponding bottom track (not shown). It is preferably cord adjustable for deployment, since a spring-loaded gravity drop mechanism is unreliable.
[0048] The bottom bar 31 of the screen is suitably weighted with lead weights or the like to give stability and provide balance from front to back of the bar 31 . A handle knob 46 is provided mid-way along the bar 31 to facilitate manual manipulation into place.
[0049] The strength of the screen 1 and support for the weighted bottom bar 31 is enhanced through provision of thickened solid 1 cm edging to the screen 1 .
[0050] The top casing/roller cassette 40 has a removable front cover 43 and along the back thereof, a brush 44 extending the length thereof to exclude flies.
[0051] A removable secondary fly trap is suitably positioned in the top casing/roller cassette 40 of the roller comprising a plastic moulding 41 that hangs from the roof of the cassette 40 and extends the length of the roller the moulding 41 having a brush 42 running along its length that rests on the screen roll 1 ″ and accordingly remains continuously in contact with the screen roll 1 ″ as the screen is extended or retracted and as the roll 1 ″ correspondingly decreases or increases in diameter.
[0052] The upright tracks 30 on either side of the roller screen 1 ″ each have a bristle brush 32 along one longitudinal edge and a stabiliser panel/wing 33 along the opposing longitudinal edge. Each of the wings 33 is adjustably mounted to its track 30 on hinges 34 . The hinges 34 take the form of bent pins being elongate and mounting in slots 35 in the wings 33 so that the wings 33 may be deployed by pulling laterally across and pivoting outwardly to release the edges of the roller blind screen 1 ″ to allow it to be pulled down. The wings 33 are then pivoted back and pushed back into the tracks 30 so that their curved rear faces push into and thereby to grip the fly screen against the brushes 32 in the tracks 30 once the screen is fully drawn down and deployed.
[0053] A strip of Velcro™ or similar is suitably provided on the rear face of each wing 33 preferably extending substantially along its length to enhance its grip. This gripping of the fly screen once the screen is deployed holds it firmly in place against any gusts of wind.
[0054] In the absence of a bottom track or not, the bottom edge/leading edge of the screen is suitably provided with a short felt brush 45 therealong and which effectively seals against the windowsill.
|
An improved flyscreen to be slidingly deployed across an opening of window or door, the window or door having a static glazing pane or panel and an opening pane or panel, the flyscreen comprising a frame dimensioned to correspond to the dimensions of the window or door opening to be covered by the flyscreen and having a mesh screen therein extending thereacross, the frame having a brush or filamentous pad strip extending substantially the full height of an upright of the frame and which when the screen is slidingly mounted adjacent to a window or door to be slidingly moved back and forth across the opening of the window or door, is substantially able to brush over the surface of the static pane or panel of the window or door.
| 4
|
FIELD OF THE INVENTION
[0001] The present invention relates to an adsorbent composition which is suitable for desulfurizing cracking gasoline or diesel fuel.
BACKGROUND OF THE INVENTION
[0002] With increasing recognition of environmental protection, environmental regulations are gradually becoming stricter. It is believed that decreasing the sulfur content in gasoline or diesel fuel is one of the most important measures to improve the air quality because the sulfur contained in the fuel adversely affects the performance of the catalytic converter of automobiles and vehicles. The sulfur oxides present in the exhaust gas from automobile engines inhibit the activity of the noble metal catalyst in the converter and poisons the catalyst irreversibly. Gases released from an ineffective or poisoned converter comprise uncombusted non-methane hydrocarbons, nitrogen oxide and carbon monoxide, all of which easily form photochemical smogs when catalyzed by sunlight.
[0003] In China, most sulfur contained in gasolines comes from heat processed gasoline, which is mainly catalytic cracking gasoline. Therefore, decreasing the sulfur content in the cracking gasoline would facilitate reducing sulfur content of these gasolines. The current standard for gasoline product is GB 17930-2006 “Motor Vehicle Gasoline,” which further restricts the sulfur content of gasoline and requires that by Dec. 31, 2009 the sulfur content of gasoline be lowered to 50 ppm. This circumstance means that catalytic cracking gasoline must be desulfurized to a great degree in order to meet the environmental requirement.
[0004] When lowering the sulfur content of motor vehicle fuel, changes in olefin content which leads to a reduction of octane number (including Research Octane Number, ROM and Motor Octane Number, MON) should be avoided so to retain the combustion characteristics of the motor vehicle fuel. Generally, the negative change on the olefin content is caused by the hydrogenation reaction induced upon removal of thiophene compounds (including thiophene, benzothiophene, alkylthiophene, alkylbenzothiophene and alkyldibenzothiophene). Further, the loss of aromatic hydrocarbons in the cracking gasoline due to saturation under hydrogenation condition should also be avoided. Therefore, the most desirable approach is to desulfurize the gasoline while retaining its octane number.
[0005] On the other hand, both hydrodesulfurization and hydrogenation of unsaturated hydrocarbons consume hydrogen, which increases the operational cost of the desulfurization. Accordingly, there is a need for a method of desulfurization without consuming large volumes of hydrogen, thereby providing a more economical method for treatment of cracking gasoline or diesel fuel.
[0006] Traditionally, a fixed-bed process has been used for desulfurization in a liquid phase. However, this process is disadvantageous in the homogeneity of reaction and the regeneration of the material. Compared with the fixed-bed process, a fluidized-bed process is advantageous given wider applications prospects in the future because of better heat transfer and pressure drop. In this context, a fluidized-bed reactor is usually provided with granular reactants. However, for most reactions, the granular reactants do not have sufficient abrasion-resistance. Accordingly, it is of great significance to find a granular reactant, or adsorbent, with both excellent abrasion-resistance and desulfurization performance.
[0007] Chinese Patents CN 1110931A and CN 1151333A describe a new absorbing composition comprising zinc oxide, silicon dioxide, colloidal oxide and an accelerant and a process for making the same. In the process, fluidizable particles are produced by a pressure forming technique, and the particle pore volumes are increased by adding to the colloid a pore-forming agent which becomes flammable when heated. The particles prepared by this process are comparatively big, and the particle size is within the range of about 100 to about 300 micron, which is not most favorable for the fluidization process.
[0008] U.S. Pat. No. 6,150,300, Chinese Patents CN 1355727A and CN 1258396 disclose a granular adsorbent composition comprising a mixture of zinc oxide, silica, alumina, nickel or cobalt in a reduced state. The adsorbent is made by first mixing silica, alumina and zinc oxide under a shearing force, preparing the solid particle through a granulating machine, and impregnating nickel after drying and calcinating the particle. These patents do not disclose the physical-chemical properties, particularly the abrasion-resistance of the adsorbent, although the adsorbent disclosed in these patents reportedly show good desulfurization performance.
[0009] Chinese Patent CN 1422177A describes a process for making an adsorbent for removal of the sulfide contained in cracking gasoline. The process comprises the steps of impregnating an adsorbent carrier comprising zinc oxide, expanded perlite and alumina with accelerant metal such as cobalt and nickel, and subsequently reducing the accelerant at an appropriate temperature. The abrasion-resistance of the adsorbent can be improved by adjusting the level of zinc oxide and binder (particularly alumina from Disperal and Vista Dispal, Condea) in the adsorbent. Chinese Patent CN 1627988A further discusses in detail the major compounds produced under the reaction conditions. Chinese Patents CN 1856359 and CN 1871063 disclose that the physical-chemical properties of particles prepared by spray drying method in this patent are more suitable for fluidized-bed, as well as the particulars of adsorbents with similar constituents and a process of making the same.
[0010] In preparing these adsorbents, the strength of adsorbents is improved by adding clay. However, because the clay has no pores, the pore volume of the adsorbents tends to be smaller and thus the activity of the adsorbent decreases. Therefore, it is most desirable to have an adsorbent with high pore volume and high strength.
[0011] In view of the above, it is desirable to provide a new adsorbent composition for removing sulfur from cracking gasoline or diesel fuel and a process of making the adsorbent.
SUMMARY OF THE INVENTION
[0012] The present invention provides an adsorbent for removing sulfur from cracking gasoline or diesel fuel. The adsorbent has excellent abrasion-resistance and desulfurization activity.
[0013] The present invention also provides a process for making an adsorbent having such characteristics.
[0014] The present invention further provides a use of the subject adsorbent.
[0015] The adsorbent according to the invention comprises, based on the total weight of the adsorbent:
1) from about 5 to about 40 wt % of pillared clay, 2) from about 3 to about 35 wt % of inorganic oxide binder, 3) from about 10 to about 80 wt % of oxides of one or more metals selected from Groups IIB, VB and VIB, and 4) from about 5 to about 30 wt % of at least one metal accelerant selected from cobalt, nickel, iron and manganese.
[0020] Preferably, the pillared clay content is in the range of from about 15 to about 25 wt %, and the inorganic oxide binder content is in the range of from about 10 to about 15 wt %, and the metal oxide content is in the range of from about 40 to about 60 wt %, and the metal accelerant content is in the range of about 12 to about 20 wt %.
[0021] Preferably, the pillared clay is characterized by inter-layered mineral crystals composed of two single-layered mineral clay components arranged in an alternate manner, wherein the layer distance is no less than 1.7 nm and there is a strong peak at 3.4° in the XRD spectrum. Examples of such pillared clay include but are not limited to: rectorite, Yunmeng clay, bentonite, montmorillonite and smectite; rectorite is preferred. Rectorite belongs to layered clay with regularly inter-layered mineral structure. It is a crystalline mineral clay which is formed by arranging a non-expandable mica layer and an expandable smectite layer which sharing the adjacent 2:1 clay layer in an alternate and ordered manner. The composition is characterized in the strong peak at 3.4° in the XRD spectrum.
[0022] Preferably, the binder is one or more of heat resistant inorganic oxides, such as one or more inorganic oxides selected from alumina, silica, and amorphous silica-alumina, preferably alumina.
[0023] Preferably, the metal oxides can be oxides of one or more metals of Group IIB, VB and VIB metals or any other metal oxide having sulfur storage properties; oxides of vanadium, zinc or molybdenum are preferred; most preferably zinc oxide.
[0024] Preferably, the metal accelerant can be comprised of any metal capable of reducing oxidized sulfur to hydrogen sulfide. By way of example and without limitation, the metal accelerant at least comprises one or more metals selected from cobalt, nickel, iron, and manganese; preferably the metal accelerant contains nickel.
[0025] It must be noted that, as used in the specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise.
[0026] The term “cracking gasoline” as used herein means hydrocarbons having a boiling range of 40° C. to 210° C., or any fractions thereof produced by thermal cracking, or by catalytic cracking higher hydrocarbon molecules into smaller molecules. Suitable thermal cracking processes include but are not limited to pyrolysis, thermal cracking, visbreaking thermal and combinations thereof. Examples of suitable catalytic cracking process include but are not limited to fluidized-bed catalytic cracking and heavy oil catalytic cracking and combinations thereof. Particularly suitable catalytic cracking gasolines include but are not limited to coked gasoline, thermal cracking gasoline, visbreaking gasoline, fluidized-bed catalytic cracking gasoline, heavy oil cracking gasoline and combinations thereof. According to the process of the invention, it is possible in some cases to fractionate and/or hydrogenate the cracking gasoline prior to desulfurization when used as hydrocarbon-containing fluid.
[0027] The term “diesel fuel” as used herein means any hydrocarbon mixture or any fractions thereof with boiling range of 170° C. to 450° C. Such hydrocarbon containing fluids include but are not limited to light cycle oil, kerosene, straight-run diesel oil, hydrogenated diesel oil and the combination thereof.
[0028] The term “sulfur” as used herein means the element sulfur in any form, such as organic sulfide existing in hydrocarbon containing liquids, including as cracking gasoline or diesel fuel. Sulfur contained in the hydrocarbon-containing liquid according to the present invention includes but is not limited to carbonyl sulfide (COS), carbon disulfide (CS 2 ), mercaptans or other thiophene compounds and the combination thereof, particularly thiophene, benzothiophene, alkylthiophene, alkylbenzothiophene, and alkyldibenzothiophene, and thiophene compounds having higher molecular weight which are usually contained in diesel fuel.
[0029] The present invention also provides a process for preparing an adsorbent, comprising the steps of:
(1) contacting pillared clay, an inorganic oxide binder precursor and an acidic solution to form a slurry; (2) adding an oxide of one or more metals selected from Groups IIB, VB and VIB to the slurry to form a carrier mixture; (3) molding, drying and calcinating the carrier mixture to form a carrier; (4) introducing a compound component comprising at least one metal accelerant selected from one or more of cobalt, nickel, iron and manganese to the carrier, and drying and calcinating the carrier to form an adsorbent precursor; and (5) obtaining the absorbent by reducing the adsorbent precursor in hydrogen containing atmosphere so that the accelerant metal is substantially present in a reduced state.
[0035] According to a preferred method of preparing the adsorbent according to the invention, the pillared clay of step (1) includes but is not limited to rectorite, Yunmeng clay, bentonite, montmorillonite and smectite; with rectorite preferred.
[0036] The inorganic oxide binder precursor preferably represents a material which can form a heat-resistant inorganic oxide during the process of making the adsorbent. For example, the precursor of alumina can be selected from hydrated alumina and/or aluminum sol; the hydrated alumina is selected from one or more of boehmite, pseudo-boehmite, alumina trihydrate, amorphous aluminum hydroxide. The precursor of silica can be selected from one or more of silica sol, silica gel and water glass. The precursor of amorphous silica-alumina can be selected from one or more of silica-alumina gol, mixture of silica sol and alumina sol, and silica-alumina gel. These precursors of heat-resistant inorganic oxides are known to the ordinary person skilled in the art.
[0037] The acidic solution that is used in contacting the pillared clay and the inorganic oxide binder component is selected from one or more of water-soluble inorganic acid and/or organic acid, preferably one or more of hydrochloric acid, nitric acid, phosphoric acid and acetic acid. The amount of acid used is such that the pH of the slurry is between about 1 to about 5, preferably between about 1.5 to about 4. In step (2), an oxide of one or more metals selected from Groups IIB, VB and VIB, preferably an oxide of vanadium, zinc or molybdenum etc. are added to the slurry of step (1). The oxide can be added directly as powder or a pre-formed oxide slurry may be added. Those methods are known to the ordinary person skilled in the art. The carrier mixture thus obtained can be in the form of wet mixture, dough, paste, or slurry. The mixture is subsequently molded into an extrudate, sheet, pellet, sphere, or microspheric particle. For example, the mixture can be molded (preferably extruded) into particles, or preferably be molded into a cylindrical extrudate with a diameter of about 1.0 to about 8.0 mm and a length of about 2.0 to about 5.0 mm when it is a dough or paste mixture. The extrudate thus obtained is subsequently dried and calcinated. The carrier mixture produced can be thickened, dried and molded when it is in a form of wet mixture. More preferably, the carrier mixture can be molded by spray drying into microspheres with a particle size of about 20 to about 200 microns when it is in the form of a slurry. To facilitate spray drying, the slurry has a solids content of about 10 to about 50 wt. %, preferably about 20 to about 50 wt. % before drying.
[0038] The methods and conditions for drying the carrier mixture are known to the ordinary person skilled in the art. The drying methods include without limitation airing, baking, and blow drying. The drying temperature can be in the range of from about room temperature to about 400° C., preferably between about 100° C. to about 350° C.
[0039] The calcinating conditions for the carrier mixture are also known to the ordinary person skilled in the art. Generally, the calcinating temperature is between about 400° C. to about 700° C., preferably about 450° to about 650° C., and the calcinating time is at least about 0.5 hour, preferably about 0.5 to about 100 hours, more preferably about 0.5 to about 10 hours.
[0040] In the process according to the present invention, the metal accelerant can be introduced into the carrier by impregnation or precipitation techniques well known in the art. The impregnation can be performed by impregnating the calcinated carrier with a solution or suspension of a compound component containing the metal accelerant. The precipitation can be performed by first mixing the solution or suspension containing the compound component with the carrier, and then adding ammonia to precipitate the metal accelerant onto the carrier. The metal accelerant can be transformed into a metal oxide when calcined. The compound component comprising the metal accelerant is preferably selected from acetates, carbonates, nitrates, sulfates, sulfocyanides and oxides of accelerant metals, e.g. cobalt, nickel, iron, and/or manganese, and mixtures of any of the foregoing. The metal accelerant preferably contains nickel.
[0041] The composition that results from the introduction of the metal accelerant is preferably dried at between about 50° C. to about 300° C., preferably between about 100° C. to about 250° C., for a time between about 0.5 to about 8 hours, preferably about 1 to about 5 hours. Thereafter, the composition is preferably calcinated at between about 300° C. to about 800° C., preferably between about 450° C. to about 750° C. in the presence of oxygen or an oxygen-containing atmosphere for a time between about 0.5 to about 4 hours, preferably between about 1 to about 3 hours. The adsorbent precursor is obtained once volatile materials are removed and the accelerant metals are transformed into metal oxide.
[0042] The adsorbent precursor is reduced at between about 300° C. to about 600° C. under a hydrogen or a hydrogen-containing atmosphere; the adsorbent of the invention is obtained when the accelerant metals are in a substantially reduced state. Preferably, the reduction temperature is between about 400° C. to about 500° C., and the hydrogen content of the atmosphere is between about 10 to about 60 vol. %, and the reduction time is between about 0.5 to about 6 hours, more preferably between about Ito about 3 hours.
[0043] The present invention further provides a method for desulfurizing cracking gasoline or diesel fuel, comprising fully contacting the sulfur containing material to be desulfurized, with the adsorbent according to the invention, at a between about 350° C. to about 500° C., preferably between about 400° C. to about 450° C., during which the sulfur contained in the material is adsorbed in the adsorbent and thus a product having low sulfur content is obtained. The adsorbent can be recycled after going through oxidation-reduction regeneration process.
[0044] The adsorbent prepared from pillared clay according to the present invention has very high abrasion-resistance and large pore volume. It is suitable for use in the desulfurization process and can greatly increase the life of the adsorbent.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] FIG. 1 is a schematic structure of rectorite used herein, wherein A is non-expandable mica layer, B is expandable smectite layer, C is clay layer, D is exchangeable cation in smectite layer, and E is stationary cation in mica layer. The layer distance (d 001 ) of the rectorite is 1.9-2.9 nm,
[0046] the chemical formula of the rectorite is as follows:
[0000] {(Na 0.72 K 0.02 Ca 0.05 )(Ca 0.24 Na 0.07 )}(Al 4.00 Mg 0.02 )[Si 6.58 Al 1.62 ]O 22
[0047] Wherein (Na 0.72 K 0.02 Ca 0.05 ) represents stationary interlayer cation; (Ca 0.24 Na 0.7 ) represents exchangeable interlayer cation; (Al 4.00 Mg 0.02 ) represents hexacoordinated ion; [Si 6.58 Al 1.62 ] represents tetracoordinated ion.
[0048] FIG. 2 is an x-ray diffraction pattern of rectorite. The rectorite is characterized in a strong peak at 3.4° (characteristic peak), which is related to the pillar height. The XRD is measured on D5005 X-ray diffractometer from Siemens, with Cu target, K α radiation, solid detector, tube voltage of 40 kV, and tube current of 40 mA.
DETAILED DESCRIPTION OF THE INVENTION
[0049] While embodiments of the present disclosure are described in connection with the above embodiments and the corresponding text and figures, there is no intent to limit the claims to the embodiments in these descriptions. On the contrary, the intent is to cover all alternatives, modifications, and equivalents included within the spirit and scope of embodiments of the present disclosure.
[0050] The present invention will be further illustrated with reference to the following examples, but not limited thereby.
[0051] The desulfurization effect is measured based on the sulfur content in the product which is analyzed by offline chromatography.
Example 1
[0052] The adsorbent was prepared as follows: 3.36 kg of powder zinc oxide (from Beijing Chemical Works) and 4.57 kg of deionized water were mixed, and subsequently stirred for 30 minutes to obtain zinc oxide slurry.
[0053] 1.56 kg of alumina (from Shandong Aluminum Corporation, having a dry basis of 1.14 kg) and 2.13 kg of rectorite (having a dry basis of 1.70 kg, available from Qilu Petrochemical Catalyst Company) were mixed under stirring, and then added with 3.6 kg of deionized water for uniform mixing, subsequently added with 300 ml 30% HCl (chemically pure, available from Beijing Chemical Works) under stirring for acidifying for 1 hour, and finally heated to 80° C. for aging for 2 hours. A zinc oxide slurry was added and mixed under stirring for 1 hour to obtain the carrier slurry, which was spray dried using a Niro Bowen Nozzle Tower™ spray drier, with a pressure of 8.5-9.5 MPa, an inlet temperature of less than 500° C., and an outlet temperature of about 150° C. The microspheres thus produced were dried at 180° C. for 1 hour, and then calcinated at 635° C. for 1 hour to obtain the adsorbent carrier.
[0054] 6.4 kg of the adsorbent carrier was spray impregnated with 7.56 kg of nickel nitrate hexahydrate and 1.10 kg of deionized water twice, and the resultant mixture was dried at 180° C. for 4 hours and calcinated at 635° C. for 1 hour to produce the adsorbent precursor which was composed of 42 wt. % of zinc oxide, 14.3 wt. % of alumina binder, 21.2 wt. % of rectorite, and 22.5 wt. % of nickel oxide. The precursor was reduced under hydrogen atmosphere at 425° C. for 2 hours to produce an adsorbent, which is reported as A1 in Table 1.
Example 2
[0055] The adsorbent was prepared as follows: 4.56 kg of powder zinc oxide (from Beijing Chemical Works) and 5.57 kg of deionized water were mixed, and subsequently stirred for 30 minutes to obtain zinc oxide slurry.
[0056] 1.10 kg of alumina (from Shandong Aluminum Corporation, having a dry basis of 0.8 kg) and 1.50 kg of rectorite (having a dry basis of 1.20 kg, available from Qilu Petrochemical Catalyst Company) were mixed under stirring, and then added with 2.8 kg of deionized water for uniform mixing, subsequently added with 275 ml 30% HCl (chemically pure, available from Beijing Chemical Works) under stirring for acidifing for 1 hour, and finally heated to 80° C. for aging for 2 hours. A zinc oxide slurry was added and mixed under stirring for 1 hour to obtain the carrier slurry, which was spray dried using a Niro Bowen Nozzle Tower™ spray drier, with a pressure of 8.5-9.5 MPa, an inlet temperature of less than 500° C., and an outlet temperature of about 150° C. The microspheres thus produced were dried at 180° C. for 1 hour, and then calcinated at 635° C. for 1 hour to obtain the adsorbent carrier.
[0057] The active ingredient nickel was introduced as shown in Example 1 to produce the adsorbent precursor which was composed of 57 wt. % of zinc oxide, 10.0 wt. % of alumina binder, 15.0 wt. % of rectorite, and 18.0 wt. % of nickel oxide. The reduced adsorbent is reported as A2.
Comparative Example 1
[0058] The adsorbent was prepared according to the method of Example 1 except that diatomite was used instead of pillared rectorite. The precursor was composed of 49 wt. % of zinc oxide, 11.5 wt. % of alumina binder, 19.0 wt. % of diatomite, and 20.5 wt. % of nickel oxide. The reduced adsorbent is reported as B1.
Comparative Example 2
[0059] The adsorbent was prepared according to the method of Example 1 except that expanded perlite was used instead of pillared rectorite. The precursor was composed of 54 wt. % of zinc oxide, 10.5 wt. % of alumina binder, 16.6 wt. % of expanded perlite, and 18.9 wt. % of nickel oxide. The reduced adsorbent is reported as B2.
Example 3
[0060] Both abrasion-resistant strength and desulfurization performance of the adsorbents prepared by as above were measured. The strength of the adsorbent was measured by straight tube abrasion in accordance with the method of RIPP 29-90 described in “Petrochemical Analysis Method (RIPP experimentation).” The following methods were employed to evaluate the desulfurization performance of these adsorbents. A fixed-bed micro-reaction system was used to evaluate the desulfurization performance of the adsorbents. The material for the adsorbing reaction was catalytic cracking gasoline having a sulfur content of 800 ppm. The adsorbing test was performed under hydrogen atmosphere at the temperature of 410° C. and weight space velocity of 4 h −1 . The sulfur contents of the gasoline as well as the adsorbents after desulfurization were analyzed, and the results are reported in Table 1.
[0000] TABLE 1 Abrasion-resistant strength and desulfurization performance of different adsorbents Adsorbent A1 A2 B1 B2 B3 Abrasion-resistance 4.7 5.7 11.3 10.5. 5.8 Sulfur content of gasoline/ 28 16 25 22 53 ppm Sulfur content of 11.1 12.3 11.9 12.1 8.9 adsorbent/wt. %
As shown by the results in Table 1, adsorbents A1 and A2 according to the present invention had superior abrasion-resistant strength and significantly lower sulfur content in the adsorbed products.
Comparative Example 3
[0061] The adsorbent was prepared according to the method applied in Example 2 except that kaolin was used instead of pillared rectorite. The precursor was composed of 52 wt. % of zinc oxide, 11.5 wt. % of alumina binder, 17.6 wt. % of kaolin, and 18.9 wt. % of nickel oxide. The reduced adsorbent is reported as B3.
[0062] Many variations and modifications may be made to the above-described embodiments. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.
|
An adsorbent for desulfurizing cracking gasoline or diesel fuel comprising 1) pillared clay, (2) inorganic oxide binder, (3) an oxide of one or more metals selected from Groups IIB, VB and VIB, and (4) at least one metal accelerant selected from cobalt, nickel, iron and manganese. The adsorbent exhibits excellent abrasion-resistant strength and desulfurization performance.
| 2
|
RELATED APPLICATIONS
The present application is a Continuation application of U.S. patent application Ser. No. 14/325,436, which was filed on Jul. 8, 2014, which is a Continuation application of U.S. patent application Ser. No. 13/872,553 (Now U.S. Pat. No. 8,839,161) which is a Continuation application of U.S. patent application Ser. No. 12/923,800 (Now U.S. Pat. No. 8,584,061), which claims priority from Japanese Patent Application No. 2009-235488, filed on Oct. 9, 2009, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor device, and more particularly relates to a semiconductor device including a plurality of semiconductor chips electrically connected by through silicon vias.
2. Description of Related Art
A memory capacity required in semiconductor memory devices such as DRAM (Dynamic Random Access Memory) is increasing every year. In recent years, there has been proposed a method to meet this requirement. In this method, a plurality of memory chips are stacked and electrically connected via through silicon vias arranged on a silicon substrate (see Japanese Patent Application Laid-open No. 2007-158237).
Specifically, in a semiconductor memory device in which an interface chip having front end units such as interface circuits incorporated thereon and a core chip having back end units such as memory cores incorporated thereon are stacked, because read data that is read in parallel from the memory cores is supplied as it is to the interface chip without performing serial conversion, a large number of through silicon vias (approximately 4000 units in some cases) are required. However, the entire chip becomes defective when even one of the through silicon vias becomes defective, and if a plurality of the chips are stacked, all the chips become defective. Thus, to prevent the entire chip from becoming defective due to a defective through silicon via, auxiliary through silicon vias are sometimes provided in such semiconductor memory devices.
In the semiconductor device disclosed in Japanese Patent Application Laid-open No. 2007-158237, one auxiliary through silicon via is allocated to a group of through silicon vias constituted by a plurality of through silicon vias (for example, eight through silicon vias).
However, when a defective through silicon via is simply replaced with an auxiliary through silicon via, an unignorable difference in wiring lengths can occur between signal paths before and after replacement of the through silicon vias depending on a location of the defective through silicon via. That is, for example, when a defect occurs to a through silicon via that is located near the auxiliary through silicon via, a difference in wiring lengths between signal paths before and after replacement of the through silicon vias is very small. However, when a defect occurs to a through silicon via that is located away from the auxiliary through silicon via, a signal path after replacement of the through silicon vias is longer by an amount equivalent to detouring of a signal path up to the auxiliary through silicon via. Such a difference in the wiring lengths can generate skew in a signal input into and/or output from the through silicon via. The skew can degrade the signal quality.
This problem is not limited to semiconductor memory devices such as DRAMs, but can occur to all semiconductor devices that include a plurality of semiconductor chips that are electrically connected to each other via through silicon vias.
SUMMARY
In one embodiment, there is provided a semiconductor device comprising: a first semiconductor chip that includes 1 st to n th driver circuits and an output switching circuit; a second semiconductor chip that includes 1 st to n th receiver circuits and an input switching circuit; and 1 st to n+m th through silicon vias provided on at least one of the first and second semiconductor chips, wherein the output switching circuit selectively connects each of the 1 st to n th driver circuits to different ones of the 1 st to n+m th through silicon vias by connecting an i th driver circuit to one of i th to i+m th through silicon vias, where i is an integer among 1 to n, and the input switching circuit selectively connects each of the 1 st to n th receiver circuits to different ones of the 1 st to n+m th through silicon vias by connecting an i th receiver circuit to one of i th to i+m th through silicon vias.
According to the present invention, a defective through silicon via is not simply replaced by an auxiliary through silicon via, but the defective through silicon via is bypassed by shifting a connection relation between driver circuits and the through silicon vias and a connection relation between receiver circuits and the through silicon vias can be flexibly switched. Therefore, almost no difference in wiring lengths occurs between signal paths before and after replacement of the through silicon vias. Thus, because almost no skew is generated, the signal quality can be enhanced.
BRIEF DESCRIPTION OF THE DRAWINGS
The above features and advantages of the present invention will be more apparent from the following description of certain preferred embodiments taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic cross-sectional view for explaining the structure of a semiconductor memory device 10 according to the preferred embodiment of the present invention;
FIGS. 2A to 2C are diagram showing the various types of through silicon via TSV provided in a core chip;
FIG. 3 is a cross-sectional view showing the structure of the through silicon via TSV 1 of the type shown in FIG. 2A ;
FIG. 4 is a schematic circuit diagram showing a first embodiment of the present invention, and shows a state where none of the through silicon vias is defective;
FIG. 5 is showing a first embodiment of the present invention, and shows a state where a defect is generated in the through silicon via 306 ;
FIG. 6 is a circuit diagram showing in further detail a portion of the output switching circuit 120 ;
FIG. 7 is a schematic diagram showing a connection relation between the interface chip IF and the core chips CC 0 to CC 7 ;
FIG. 8 is a schematic circuit diagram showing a second embodiment of the present invention, and shows a case where the through silicon vias 302 and 304 are defective;
FIG. 9 is a circuit diagram showing in further detail a portion of the output switching circuits 130 and 140 ; and
FIG. 10 is a block diagram showing the circuit configuration of the semiconductor memory device 10 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
Preferred embodiments of the present invention will be explained below in detail with reference to the accompanying drawings.
FIG. 1 is a schematic cross-sectional view provided to explain the structure of a semiconductor memory device 10 according to the preferred embodiment of the present invention.
As shown in FIG. 1 , the semiconductor memory device 10 according to this embodiment has the structure where 8 core chips CC 0 to CC 7 that have the same function and structure and are manufactured using the same manufacture mask, an interface chip IF that is manufactured using a manufacture mask different from that of the core chips and an interposer IP are laminated. The core chips CC 0 to CC 7 and the interface chip IF are semiconductor chips using a silicon substrate and are electrically connected to adjacent chips in a vertical direction through plural through silicon vias TSV penetrating the silicon substrate. Meanwhile, the interposer IP is a circuit board that is made of a resin, and plural external terminals (solder balls) SB are formed in a back surface IPb of the interposer IP.
Each of the core chips CC 0 to CC 7 is a semiconductor chip which consists of circuit blocks other than a so-called front end unit (front end function) performing a function of an interface with an external device through an external terminal among circuit blocks included in a 1 Gb DDR3 (Double Data Rate 3)-type SDRAM (Synchronous Dynamic Random Access Memory). The SDRAM is a well-known and common memory chip that includes the front end unit and a so-called back end unit having a plural memory cells and accessing to the memory cells. The SDRAM operates even as a single chip and is capable to communicate directly with a memory controller. That is, each of the core chips CC 0 to CC 7 is a semiconductor chip where only the circuit blocks belonging to the back end unit are integrated in principle. As the circuit blocks that are included in the front end unit, a parallel-serial converting circuit (data latch circuit) that performs parallel/serial conversion on input/output data between a memory cell array and a data input/output terminal and a DLL (Delay Locked Loop) circuit that controls input/output timing of data are exemplified, which will be described in detail below. The interface chip IF is a semiconductor chip in which only the front end unit is integrated. Accordingly, an operation frequency of the interface chip is higher than an operation frequency of the core chip. Since the circuits that belong to the front end unit are not included in the core chips CC 0 to CC 7 , the core chips CC 0 to CC 7 cannot be operated as the single chips, except for when the core chips are operated in a wafer state for a test operation in the course of manufacturing the core chips. The interface chip IF is needed to operate the core chips CC 0 to CC 7 . Accordingly, the memory integration of the core chips is denser than the memory integration of a general single chip. In the semiconductor memory device 10 according to this embodiment, the interface chip has a front end function for communicating with the external device at a first operation frequency, and the plural core chips have a back end function for communicating with only the interface chip at a second operation frequency lower than the first operation frequency. Accordingly, each of the plural core chips includes a memory cell array that stores plural information, and a bit number of plural read data for each I/O (DQ) that are supplied from the plural core chips to the interface chip in parallel is plural and associated with a one-time read command provided from the interface chip to the core chips. In this case, the plural bit number corresponds to a prefetch data number to be well-known.
The interface chip IF functions as a common front end unit for the eight core chips CC 0 to CC 7 . Accordingly, all external accesses are performed through the interface chip IF and inputs/outputs of data are also performed through the interface chip IF. In this embodiment, the interface chip IF is disposed between the interposer IP and the core chips CC 0 to CC 7 . However, the position of the interface chip IF is not restricted in particular, and the interface chip IF may be disposed on the core chips CC 0 to CC 7 and may be disposed on the back surface IPb of the interposer IP. When the interface chip IF is disposed on the core chips CC 0 to CC 7 in a face-down manner or is disposed on the back surface IPb of the interposer IP in a face-up manner, the through silicon via TSV does not need to be provided in the interface chip IF. The interface chip IF may be disposed to be interposed between the two interposers IP.
The interposer IP functions as a rewiring substrate to increase an electrode pitch and secures mechanical strength of the semiconductor memory device 10 . That is, an electrode 91 that is formed on a top surface IPa of the interposer IP is drawn to the back surface IPb via a through-hole electrode 92 and the pitch of the external terminals SB is enlarged by the rewiring layer 93 provided on the back surface IPb. In FIG. 1 , only the two external terminals SB are shown. In actuality, however, three or more external terminals are provided. The layout of the external terminals SB is the same as that of the DDR3-type SDRAM that is determined by the regulation. Accordingly, the semiconductor memory device can be treated as one DDR3-type SDRAM from the external controller.
As shown in FIG. 1 , a top surface of the uppermost core chip CC 0 is covered by an NCF (Non-Conductive Film) 94 and a lead frame 95 . Gaps between the core chips CC 0 to CC 7 and the interface chip IF are filled with an underfill 96 and surrounding portions of the gaps are covered by a sealing resin 97 . Thereby, the individual chips are physically protected.
When most of the through silicon vias TSV provided in the core chips CC 0 to CC 7 are two-dimensionally viewed from a lamination direction, that is, viewed from an arrow A shown in FIG. 1 , the through silicon vias TSV are short-circuited from the through silicon vias TSV of other layers provided at the same position. That is, as shown in FIG. 2A , the vertically disposed through silicon vias TSV 1 that are provided at the same position in plain view are short-circuited, and one wiring line is configured by the through silicon via TSV 1 . The through silicon via TSV 1 that are provided in the core chips CC 0 to CC 7 are connected to internal circuits 4 in the core chips, respectively. Accordingly, input signals (command signal, address signal, etc.) that are supplied from the interface chip IF to the through silicon vias TSV 1 shown in FIG. 2A are commonly input to the internal circuits 4 of the core chips CC 0 to CC 7 . Output signals (data etc.) that are supplied from the core chips CC 0 to CC 7 to the through silicon via TSV 1 are wired-ORed and input to the interface chip IF.
Meanwhile, as shown in FIG. 2B , the a part of through silicon vias TSV are not directly connected to the through silicon via TSV 2 of other layers provided at the same position in plain view but are connected to the through silicon via TSV 2 of other layers through the internal circuits 5 provided in the core chips CC 0 to CC 7 . That is, the internal circuits 5 that are provided in the core chips CC 0 to CC 7 are cascade-connected through the through silicon via TSV 2 . This kind of through silicon via TSV 2 is used to sequentially transmit predetermined information to the internal circuits 5 provided in the core chips CC 0 to CC 7 . As this information, layer address information to be described below is exemplified.
Another group of through silicon vias TSV is short-circuited from the TSVs of other layer provided at the different position in plan view, as shown in FIG. 2C . With respect to this kind of group of through silicon via TSV 3 , internal circuits 6 of the core chips CC 0 to CC 7 are connected to the through silicon via TSV 3 a provided at the predetermined position P in plain view. Thereby, information can be selectively input to the internal circuits 6 provided in the core chips. As this information, defective chip information to be described below is exemplified.
As such, as types of the through silicon vias TSV provided in the core chips CC 0 to CC 7 , three types (TSV 1 to TSV 3 ) shown in FIGS. 2A to 2C exist. As described above, most of the through silicon vias TSV are of a type shown in FIG. 2A , and an address signal, a command signal, and a clock signal are supplied from the interface chip IF to the core chips CC 0 to CC 7 , through the through silicon via TSV 1 of the type shown in FIG. 2A . Read data and write data are input to and output from the interface chip IF through the through silicon via TSV 1 of the type shown in FIG. 2A . Meanwhile, the through silicon vias TSV 2 and TSV 3 of the types shown in FIGS. 2B and 2C are used to provide individual information to the core chips CC 0 to CC 7 having the same structure.
FIG. 3 is a cross-sectional view showing the structure of the through silicon via TSV 1 of the type shown in FIG. 2A .
As shown in FIG. 3 , the through silicon via TSV 1 is provided to penetrate a silicon substrate 80 and an interlayer insulating film 81 provided on a surface of the silicon substrate 80 . Around the through silicon via TSV 1 , an insulating ring 82 is provided. Thereby, the through silicon via TSV 1 and a transistor region are insulated from each other. In an example shown in FIG. 3 , the insulating ring 82 is provided double. Thereby, capacitance between the through silicon via TSV 1 and the silicon substrate 80 is reduced.
An end 83 of the through silicon via TSV 1 at the back surface of the silicon substrate 80 is covered by a back surface bump 84 . The back surface bump 84 is an electrode that contacts a surface bump 85 provided in a core chip of a lower layer. The surface bump 85 is connected to an end 86 of the through silicon via TSV 1 , through plural pads P 0 to P 3 provided in wiring layers L 0 to L 3 and plural through-hole electrodes TH 1 to TH 3 connecting the pads to each other. Thereby, the surface bump 85 and the back surface bump 84 that are provided at the same position in plain view are short-circuited. Connection with internal circuits (not shown in the drawings) is performed through internal wiring lines (not shown in the drawings) drawn from the pads PO to P 3 provided in the wiring layers L 0 to L 3 .
A relief method that is used when a defect occurs to a through silicon via is explained below. The relief method explained below can be applied to any type of the through silicon vias TSV 1 to TSV 3 explained above.
FIG. 4 is a schematic circuit diagram for explaining a connection relation between the interface chip IF and the core chips CC 0 to CC 7 according to a first embodiment of the present invention. FIG. 4 shows a state where none of the through silicon vias is defective.
In FIG. 4 , as an example, there is shown a portion where 8-bit data D 1 to D 8 is supplied from the interface chip IF to each of the core chips CC 0 to CC 7 . The data D 1 to D 8 are signals that need to be simultaneously output from the interface chip IF and simultaneously input into each of the core chips CC 0 to CC 7 . Address signals and write data are examples of such data.
As shown in FIG. 4 , the interface chip IF includes eight driver circuits 101 to 108 corresponding to the data D 1 to D 8 , and each of the core chips CC 0 to CC 7 includes eight receiver circuits 201 to 208 corresponding to the data D 1 to D 8 . Meanwhile, in the first embodiment, nine (8+1) through silicon vias 301 to 309 are prepared to connect the driver circuits 101 to 108 to the receiver circuits 201 to 208 . Among the through silicon vias 301 to 309 , the through silicon via 309 is an auxiliary through silicon via, and the through silicon via 309 is not used unless any of the other through silicon vias 301 to 308 is defective.
To explain specifically, the interface chip IF includes an output switching circuit 120 that connects an output terminal of each of the driver circuits 101 to 108 to one of the two corresponding through silicon vias via driver circuits 111 to 119 . “Two corresponding through silicon vias” means an i-th through silicon via and an (i+1)-th through silicon via when a last digit of a reference number of the driver circuits 101 to 108 is taken as i (i is a value among 1 to 8). For example, a first through silicon via 301 and a second through silicon via 302 correspond to the driver circuit 101 , and the through silicon via 302 and a third through silicon via 303 correspond to the driver circuit 102 . Thus, some of the through silicon vias, that is, the through silicon vias 302 to 308 , correspond to two driver circuits. However, two driver circuits are never connected to the same through silicon via. Thus, a connection to each through silicon via is performed exclusively. Which one of the two corresponding through silicon vias is to be selected is decided by relief signals R 1 to R 8 .
The relief signals R 1 to R 8 are allocated to the through silicon vias 301 to 308 , respectively. One of the relief signals R 1 to R 8 is activated when a corresponding through silicon via is defective. Assuming that a relief signal Rx is activated, an i-th through silicon via is selected for a driver circuit whose last digit of a reference number is 1 to x−1, and an (i+1)-th through silicon via is selected for a driver circuit whose last digit of a reference number is x to 8. In the example shown in FIG. 4 , none of the relief signals R 1 to R 8 is active, and thus the output switching circuit 120 connects the output terminals of the driver circuits 101 to 108 to the through silicon vias 301 to 308 via the driver circuits 111 to 118 , respectively.
The same connection relation holds true on a core chips CC 0 to CC 7 side. Specifically, each of the core chips CC 0 to CC 7 includes an input switching circuit 220 , and as shown in the example of FIG. 4 , when none of the relief signals R 1 to R 8 is active, the input switching circuit 220 connects input terminals of the receiver circuits 201 to 208 to the through silicon vias 301 to 308 via receiver circuits 211 to 218 , respectively.
In this manner, when none of the through silicon vias 301 to 308 is defective, each of the driver circuits is connected to corresponding one of the receiver circuits via a path PA, and the auxiliary through silicon via 309 is not used.
On the other hand, when one of the through silicon vias 301 to 308 becomes defective, the through silicon via 309 is used. The defective through silicon via is not simply replaced by the through silicon via 309 ; however, a connection relation among the through silicon vias 301 to 308 and the driver circuits 101 to 108 and a connection relation among the through silicon vias 301 to 308 and the receiver circuits 201 to 208 are shifted with the defective through silicon via as a boundary.
FIG. 5 is a schematic circuit diagram of a state where a defect is generated in the through silicon via 306 .
As shown in FIG. 5 , the relief signal R 6 is activated when a defect is generated in the through silicon via 306 . As a result, the output switching circuit 120 connects the output terminals of the driver circuits 101 to 105 to the through silicon vias 301 to 305 via the driver circuits 111 to 115 , respectively, and connects the output terminals of the driver circuits 106 to 108 to the through silicon vias 307 to 309 via the driver circuits 117 to 119 , respectively. In this manner, a connection relation among the through silicon vias 301 to 309 and the driver circuits 101 to 108 is shifted with the defective through silicon via as a boundary.
The same connection relation holds true even on the core chips CC 0 to CC 7 side. That is, the input switching circuit 220 connects, in response to activation of the relief signal R 6 , the input terminals of the receiver circuits 201 to 205 to the through silicon vias 301 to 305 via the receiver circuits 211 to 215 , respectively, and connects the input terminals of the receiver circuits 206 to 208 to the through silicon vias 307 to 309 via the receiver circuits 217 to 219 , respectively. In this manner, even on the input side, a connection relation among the through silicon vias 301 to 309 and the receiver circuits 201 to 208 is shifted with the defective through silicon via as a boundary.
In this manner, when the through silicon via 306 is defective, the driver circuits 101 to 105 are connected to the receiver circuits 201 to 205 , respectively, via the path PA; however, the driver circuits 106 to 108 are connected to the receiver circuits 206 to 208 , respectively, via a path PB. That is, when a through silicon via 30 x is defective, the driver circuits 101 to 10 ( x −1) are connected to the receiver circuits 201 to 20 ( x −1), respectively, via the path PA, and the driver circuits 10 x to 108 are connected to the receiver circuits 20 x to 208 , respectively, via the path PB.
That is, the defective through silicon via (the through silicon via 306 shown in FIG. 5 ) is not simply replaced by the auxiliary through silicon via (the through silicon via 309 shown in FIG. 5 ); however, the connection relation among the through silicon vias 301 to 308 and the driver circuits 101 to 108 , and the connection relation among the through silicon vias 301 to 308 and the receiver circuits 201 to 208 are shifted with the defective through silicon via as a boundary. In this manner, even after replacement of through silicon vias, an output terminal of a driver circuit having a relatively larger reference number is connected to a through silicon via having a relatively larger reference number, and an input terminal of a receiver circuit having a relatively larger reference number is connected to the through silicon via having the relatively larger reference number. Therefore, when the through silicon vias 301 to 309 are arranged in this order, as far as the i-th through silicon via and the (i+1)-th through silicon via are arranged adjacent to each other, a difference in wiring lengths almost does not occur between signal paths before and after replacement of the through silicon vias. Because almost no skew is generated due to replacement of through silicon vias, the signal quality can be enhanced.
FIG. 6 is a circuit diagram showing in further detail a portion of the output switching circuit 120 shown in FIGS. 4 and 5 .
As shown in FIG. 6 , the output switching circuit 120 includes control circuit units 121 a to 128 a and switch circuit units 121 b to 128 b corresponding to the driver circuits 101 to 108 , respectively. The control circuit units 121 a to 128 a are exclusive OR (EOR) circuits that receive a relief signal Ri and a shift signal SHIFT (i−1). The switch circuit units 121 b to 128 b are controlled by selection signals SEL 1 to SEL 8 output from the control circuit units 121 a to 128 a , respectively.
This is specifically explained below. The control circuit units 121 a to 128 a output high level selection signals SELi when logical levels of the relief signal Ri and the shift signal SHIFT (i−1) differ, and they output low level selection signals SELi when logical levels of the relief signal Ri and the shift signal SHIFT (i−1) are the same. The relief signals R 1 to R 8 are activated to the low level when corresponding one of the through silicon vias is defective, and they are activated to the high level when corresponding one of the through silicon vias is normal. The relief signals R 1 to R 8 are held in replacement control circuits 121 c to 128 c , respectively. The relief signals R 1 to R 8 are held until power is turned off. Ingenious attempts need to be made to reduce the number of wirings or the number of through silicon vias through which a relief signal is transmitted. Such attempts include coding the relief signal before transmitting, transmitting the relief signal in a time multiplexing manner. When the relief signal is processed in this manner, the replacement control circuits 121 c to 128 c have to decode the relief signal. This is why the replacement control circuits 121 c to 128 c are provided.
Meanwhile, shift signals SHIFT 1 to SHIFT 7 are inverted signals of the selection signals SEL 1 to SEL 7 , respectively, that are output from a previous stage control circuit unit (that is, a control circuit unit having one reduced reference number) among the control circuit units 121 a to 127 a . A logical level of a shift signal SHIFT 0 that is supplied to the control circuit unit 121 a , which is a first stage control circuit unit, is fixed to the low level (VSS).
Each of the switch circuit units 121 b to 128 b includes two transfer gates that become exclusively conductive. A transfer gate on an i-th through silicon via side is selected when a corresponding selection signal SELi has the high level, and a transfer gate on an (i+1)-th through silicon via side is selected when a corresponding selection signal SELi has the low level.
In this configuration, when all of the relief signals R 1 to R 8 have the high level, that is, when all the through silicon vias 301 to 308 are normal, all the selection signals SEL 1 to SEL 8 have the high level, and each of the switch circuit units 121 b to 128 b selects the i-th through silicon via. Therefore, the output terminals of the driver circuits 101 to 108 are connected to the through silicon vias 301 to 308 via the driver circuits 111 to 118 , respectively.
On the other hand, when one of the relief signals R 1 to R 8 has the low level, that is, when one of the through silicon vias 301 to 308 is defective, a selection signal SELx corresponding to the defective through silicon via has the low level, and corresponding one of the switch circuit unit 12 xb selects the (i+1)-th through silicon via. Moreover, when the selection signal SELx has the low level, because a shift signal SHIFTx has the high level, each of the switch circuit units 12 (x+1)b to 128 b provided at a next stage selects the (i+1)-th through silicon via. In this manner, a shifting operation is realized with the defective through silicon via as a boundary.
A combination of signals in which the shift signal is high level and the relief signal is low level is not permitted to be input. Such a combination of signals is a pattern that occurs when the number of the defective through silicon vias exceeds the number of the auxiliary through silicon vias. If such a combination of signals occurs, the relief based on the auxiliary through silicon via fails.
While the circuit configuration and operations of the output switching circuit 120 have been explained above, the circuit configuration and operations of the input switching circuit 220 are identical to those, and thus explanations thereof will be omitted.
FIG. 7 is a schematic diagram showing a connection relation between the interface chip IF and the core chips CC 0 to CC 7 .
FIG. 7 shows a case where the through silicon via 306 in the core chip CC 0 among the core chips CC 0 to CC 7 is defective. As shown in FIG. 7 , among the through silicon vias in the core chips CC 0 to CC 7 , the corresponding through silicon vias, that is, the through silicon vias that have been allocated with the same reference number, are all short-circuited. That is, when a through silicon via in one of the core chips CC 0 to CC 7 is defective, the corresponding through silicon vias in the other core chips are all invalidated. In the example shown in FIG. 7 , because the through silicon via 306 in the core chip CC 0 is defective, the through silicon vias 306 in the other core chips CC 1 to CC 7 are invalidated irrespective of whether they are defective. That is, the connection relation between the through silicon vias and the driver circuits, and the connection relation between the through silicon vias and the receiver circuits are the same in the interface chip IF and the core chips CC 0 to CC 7 .
FIG. 8 is a schematic circuit diagram for explaining a connection relation between the interface chip IF and the core chips CC 0 to CC 7 according to a second embodiment of the present invention, and shows a case where the through silicon vias 302 and 304 are defective.
As shown in FIG. 8 , in the second embodiment, two auxiliary through silicon vias 309 and 310 are allocated with respect to eight through silicon vias 301 to 308 . That is, the total number of the through silicon vias is ten.
In the second embodiment, two output switching circuits 130 and 140 are arranged on an interface chip IF side, and two input switching circuits 230 and 240 are arranged on the core chips CC 0 to CC 7 side. Relief signals R 11 to R 18 are supplied to the output switching circuit 130 and the input switching circuit 230 , and switching of output paths and input paths is performed based on these relief signals. Similarly, relief signals R 21 to R 29 are supplied to the output switching circuit 140 and the input switching circuit 240 , and switching of output paths and input paths is performed based on these relief signals. By providing the two output switching circuits 130 and 140 and the two input switching circuits 230 and 240 , the connection relation between the through silicon vias 301 to 310 and the driver circuits 101 to 108 , and the connection relation between the through silicon vias 301 to 310 and the receiver circuits 201 to 208 can be shifted by maximum two units.
Only one bit of the relief signals R 11 to R 18 is activated when one or two of the eight through silicon vias 301 to 308 are defective. When one through silicon via 30 x is defective, a corresponding relief signal Rx is activated, and when two through silicon vias 30 x and 30 y (x<y) are defective, a relief signal Rx corresponding to a through silicon via having a relatively smaller reference number is activated. The relief based on the auxiliary through silicon vias according to the present embodiment fails if three or more through silicon vias among the through silicon vias 301 to 308 are defective. Only one bit of the relief signals R 21 to R 29 is activated when there are two defective through silicon vias among the eight through silicon vias 301 to 309 . Specifically, when two through silicon vias 30 x and 30 y (x<y) are defective, a relief signal Ry corresponding to a through silicon via having a relatively larger reference number is activated. In this condition, the relief signal R 21 is never activated. Therefore, a logical level of the relief signal R 21 can be fixed to a non-activation logical level. However, because it is desirable that the number of logical steps between each of the driver circuits and each of the through silicon vias are equal to the number of logical steps between each of the through silicon vias and each of the receiver circuits, as shown in FIG. 8 , it is preferable not to omit a logical gate using the relief signal R 21 .
With the above configuration, when one of the eight through silicon vias 301 to 308 is defective, in the same manner as the first embodiment, the problem is solved by shifting the connection relation by one through silicon via with the defective through silicon via as a boundary. Further, when two through silicon vias among nine through silicon vias 301 to 309 are defective, the problem is solved by, between the two defective through silicon vias, first shifting the connection relation by one through silicon via with a defective through silicon via having a relatively smaller reference number as a boundary, and then further shifting the connection relation by one through silicon via with a defective through silicon via having a relatively larger reference number as a boundary.
In the example shown in FIG. 8 , two through silicon vias 302 and 304 are defective, and thus relief signals R 12 and R 24 are activated. In this manner, a shifting operation is performed first by the output switching circuit 130 with the through silicon via 302 as a boundary. Therefore, the output terminal of the driver circuit 102 is connected to the through silicon via 303 . Moreover, a shifting operation is performed by the output switching circuit 140 with the through silicon via 304 as a boundary, and therefore the output terminal of the driver circuit 103 is connected to the through silicon via 305 . The same holds true on the input side.
FIG. 9 is a circuit diagram showing in further detail a portion of the output switching circuits 130 and 140 shown in FIG. 8 .
As shown in FIG. 9 , the output switching circuit 130 has the same circuit configuration as the output switching circuit 120 except that it receives the relief signals R 11 to R 18 instead of the relief signals R 1 to R 8 . Further, the output switching circuit 140 has the same circuit configuration as the output switching circuit 130 except that it is provided at a next stage of the output switching circuit 130 and it receives the relief signals R 22 to R 29 . Specific circuit configurations and operations of the output switching circuits 130 and 140 are identical to those of the output switching circuit 120 , and therefore explanations thereof will be omitted. Moreover, the same holds true for circuit configurations and operations of the input switching circuits 230 and 240 .
As described above, in the second embodiment, the problem can be solved even when two through silicon vias are defective. Although not shown, a problem caused by three or more defective through silicon vias can be solved by providing three or more auxiliary through silicon vias.
The semiconductor memory device 10 according to the preferred embodiment of the present invention will be explained below in detail.
FIG. 10 is a block diagram showing the circuit configuration of the semiconductor memory device 10 .
As shown in FIG. 10 , the external terminals that are provided in the interposer IP include clock terminals 11 a and 11 b , an clock enable terminal 11 c , command terminals 12 a to 12 e , an address terminal 13 , a data input/output terminal 14 , data strobe terminals 15 a and 15 b , a calibration terminal 16 , and power supply terminals 17 a and 17 b . All of the external terminals are connected to the interface chip IF and are not directly connected to the core chips CC 0 to CC 7 , except for the power supply terminals 17 a and 17 b.
First, a connection relationship between the external terminals and the interface chip IF performing the front end function and the circuit configuration of the interface chip IF will be described.
The clock terminals 11 a and 11 b are supplied with external clock signals CK and /CK, respectively, and the clock enable terminal 11 c is supplied with a clock enable signal CKE. The external clock signals CK and /CK and the clock enable signal CKE are supplied to a clock generating circuit 21 provided in the interface chip IF. A signal where “/” is added to a head of a signal name in this specification indicates an inversion signal of a corresponding signal or a low-active signal. Accordingly, the external clock signals CK and /CK are complementary signals. The clock generating circuit 21 generates an internal clock signal ICLK, and the generated internal clock signal ICLK is supplied to various circuit blocks in the interface chip IF and is commonly supplied to the core chips CC 0 to CC 7 through the through silicon vias TSV.
A DLL circuit 22 is included in the interface chip IF and an input/output clock signal LCLK is generated by the DLL circuit 22 . The input/output clock signal LCLK is supplied to an input/output buffer circuit 23 included in the interface chip IF. A DLL function is used to control the front end unit by using the signal LCLK synchronized with a signal of the external device, when the semiconductor memory device 10 communicates with the external device. Accordingly, DLL function is not needed for the core chips CC 0 to CC 7 as the back end.
The command terminals 12 a to 12 e are supplied with a row-address strobe signal /RAS, a column address strobe signal /CAS, a write enable signal /WE, a chip select signal /CS, and an on-die termination signal ODT. These command signals are supplied to a command input buffer 31 that is provided in the interface chip IF. The command signals supplied to the command input buffer 31 are further supplied to a command decoder 32 . The command decoder 32 is a circuit that holds, decodes, and counts the command signals in synchronization with the internal clock ICLK and generates various internal commands ICMD. The generated internal command ICMD is supplied to the various circuit blocks in the interface chip IF and is commonly supplied to the core chips CC 0 to CC 7 through the through silicon vias TSV.
The address terminal 13 is a terminal to which address signals A 0 to A 15 and BA 0 to BA 2 are supplied, and the supplied address signals A 0 to A 15 and BA 0 to BA 2 are supplied to an address input buffer 41 provided in the interface chip IF. An output of the address input buffer 41 is commonly supplied to the core chips CC 0 to CC 7 through the through silicon vias TSV. The address signals A 0 to A 15 are supplied to a mode register 42 provided in the interface chip IF, when the semiconductor memory device 10 enters a mode register set. The address signals BA 0 to BA 2 (bank addresses) are decoded by an address decoder (not shown in the drawings) provided in the interface chip IF, and a bank selection signal B that is obtained by the decoding is supplied to a data latch circuit 25 . This is because bank selection of the write data is performed in the interface chip IF.
The data input/output terminal 14 is used to input/output read data or write data DQ 0 to DQ 15 . The data strobe terminals 15 a and 15 b are terminals that are used to input/output strobe signals DQS and /DQS. The data input/output terminal 14 and the data strobe terminals 15 a and 15 b are connected to the input/output buffer circuit 23 provided in the interface chip IF. The input/output buffer circuit 23 includes an input buffer IB and an output buffer OB, and inputs/outputs the read data or the write data DQ 0 to DQ 15 and the strobe signals DQS and /DQS in synchronization with the input/output clock signal LCLK supplied from the DLL circuit 22 . If an internal on-die termination signal IODT is supplied from the command decoder 32 , the input/output buffer circuit 23 causes the output buffer OB to function as a termination resistor. An impedance code DRZQ is supplied from the calibration circuit 24 to the input/output buffer circuit 23 . Thereby, impedance of the output buffer OB is designated. The input/output buffer circuit 23 includes a well-known FIFO circuit.
The calibration circuit 24 includes a replica buffer RB that has the same circuit configuration as the output buffer OB. If the calibration signal ZQ is supplied from the command decoder 32 , the calibration circuit 24 refers to a resistance value of an external resistor (not shown in the drawings) connected to the calibration terminal 16 and performs a calibration operation. The calibration operation is an operation for matching the impedance of the replica buffer RB with the resistance value of the external resistor, and the obtained impedance code DRZQ is supplied to the input/output buffer circuit 23 . Thereby, the impedance of the output buffer OB is adjusted to a desired value.
The input/output buffer circuit 23 is connected to a data latch circuit 25 . The data latch circuit 25 includes a FIFO circuit (not shown in the drawings) that realizes a FIFO function which operates by latency control realizing the well-known DDR function and a multiplexer MUX (not shown in the drawings). The input/output buffer circuit 23 converts parallel read data, which is supplied from the core chips CC 0 to CC 7 , into serial read data, and converts serial write data, which is supplied from the input/output buffer, into parallel write data. Accordingly, the data latch circuit 25 and the input/output buffer circuit 23 are connected in serial and the data latch circuit 25 and the core chips CC 0 to CC 7 are connected in parallel. In this embodiment, each of the core chips CC 0 to CC 7 is the back end unit of the DDR3-type SDRAM and a prefetch number is 8 bits. The data latch circuit 25 and each banks of the core chips CC 0 to CC 7 are connected respectively, and the number of banks that are included in each of the core chips CC 0 to CC 7 is 8. Accordingly, connection of the data latch circuit 25 and the core chips CC 0 to CC 7 becomes 64 bits (8 bits×8 banks) for each DQ.
Parallel data, not converted into serial data, is basically transferred between the data latch circuit 25 and the core chips CC 0 to CC 7 . That is, in a common SDRAM (in the SDRAM, a front end unit and a back end unit are constructed in one chip), between the outside of the chip and the SDRAM, data is input/output in serial (that is, the number of data input/output terminals is one for each DQ). However, in the core chips CC 0 to CC 7 , an input/output of data between the interface chip IF and the core chips is performed in parallel. This point is the important difference between the common SDRAM and the core chips CC 0 to CC 7 . However, all of the prefetched parallel data do not need to be input/output using the different through silicon vias TSV, and partial parallel/serial conversion may be performed in the core chips CC 0 to CC 7 and the number of through silicon vias TSV that are needed for each DQ may be reduced. For example, all of data of 64 bits for each DQ do not need to be input/output using the different through silicon vias TSV, and 2-bit parallel/serial conversion may be performed in the core chips CC 0 to CC 7 and the number of through silicon vias TSV that are needed for each DQ may be reduced to ½ (32).
To the data latch circuit 25 , a function for enabling a test in an interface chip unit is added. The interface chip does not have the back end unit. For this reason, the interface chip cannot be operated as a single chip in principle. However, if the interface chip never operates as the single chip, an operation test of the interface chip in a wafer state may not be performed. This means that the semiconductor memory device 10 cannot be tested in case an assembly process of the interface chip and the plural core chips is not executed, and the interface chip is tested by testing the semiconductor memory device 10 . In this case, when a defect that cannot be recovered exists in the interface chip, the entire semiconductor memory device 10 is not available. In consideration of this point, in this embodiment, a portion of a pseudo back end unit for a test is provided in the data latch circuit 25 , and a simple memory function is enabled at the time of a test.
The power supply terminals 17 a and 17 b are terminals to which power supply potentials VDD and VSS are supplied, respectively. The power supply terminals 17 a and 17 b are connected to a power-on detecting circuit 43 provided in the interface chip IF and are also connected to the core chips CC 0 to CC 7 through the through silicon vias TSV. The power-on detecting circuit 43 detects the supply of power. On detecting the supply of power, the power-on detecting circuit activates a layer address control circuit 45 on the interface chip IF.
The layer address control circuit 45 changes a layer address due to the I/O configuration of the semiconductor device 10 according to the present embodiment. As described above, the semiconductor memory device 10 includes 16 data input/output terminals 14 . Thereby, a maximum I/O number can be set to 16 bits (DQ 0 to DQ 15 ). However, the I/O number is not fixed to 16 bits and may be set to 8 bits (DQ 0 to DQ 7 ) or 4 bits (DQ 0 to DQ 3 ). The address allocation is changed according to the I/O number and the layer address is also changed. The layer address control circuit 45 changes the address allocation according to the I/O number and is commonly connected to the core chips CC 0 to CC 7 through the through silicon vias TSV.
The interface chip IF is also provided with a layer address setting circuit 44 . The layer address setting circuit 44 is connected to the core chips CC 0 to CC 7 through the through silicon vias TSV. The layer address setting circuit 44 is cascade-connected to the layer address generating circuit 46 of the core chips CC 0 to CC 7 using the through silicon via TSV 2 of the type shown in FIG. 2B , and reads out the layer addresses set to the core chips CC 0 to CC 7 at testing.
The interface chip IF is also provided with a defective chip information holding circuit 33 . When a defective core chip that does not normally operates is discovered after an assembly, the defective chip information holding circuit 33 holds its chip number. The defective chip information holding circuit 33 is connected to the core chips CC 0 to CC 7 through the through silicon vias TSV. The defective chip information holding circuit 33 is connected to the core chips CC 0 to CC 7 while being shifted, by using the through silicon via TSV 3 of the type shown in FIG. 2C .
The interface chip IF is also provided with a relief information holding circuit 400 . The relief information holding circuit 400 stores the relief signal described above by anti-fuse elements and the like. When a defective through silicon via is discovered by an operation test after the assembly, the relief signal is written in the relief information holding circuit 400 by a tester. The relief signal held in the relief information holding circuit 400 is readout when the power is turned on, and the read relief signal is transmitted to the replacement control circuits 121 c to 128 c in the interface chip IF and is also transmitted to the replacement control circuits in the core chips CC 0 to CC 7 by using the through silicon via TSV 1 of the type shown in FIG. 2A .
The above description is the outline of the connection relationship between the external terminals and the interface chip IF and the circuit configuration of the interface chip IF. Next, the circuit configuration of the core chips CC 0 to CC 7 will be described.
As shown in FIG. 10 , memory cell arrays 50 that are included in the core chips CC 0 to CC 7 performing the back end function are divided into eight banks. A bank is a unit that can individually receive a command. That is, the individual banks can be independently and nonexclusively controlled. From the outside of the semiconductor memory device 10 , each back can be independently accessed. For example, a part of the memory cell array 50 belonging to the bank 1 and another part of the memory cell array 50 belonging to the bank 2 are controlled nonexclusively. That is, word lines WL and bit lines BL corresponding to each banks respectively are independently accessed at same period by different commands one another. For example, while the bank 1 is maintained to be active (the word lines and the bit lines are controlled to be active), the bank 2 can be controlled to be active. However, the external terminals (for example, plural control terminals and plural I/O terminals) of the semiconductor memory device 10 are shared. In the memory cell array 50 , the plural word lines WL and the plural bit lines BL intersect each other, and memory cells MC are disposed at intersections thereof (in FIG. 10 , only one word line WL, one bit line BL, and one memory cell MC are shown). The word line WL is selected by a row decoder 51 . The bit line BL is connected to a corresponding sense amplifier SA in a sense circuit 53 . The sense amplifier SA is selected by a column decoder 52 .
The row decoder 51 is controlled by a row address supplied from a row control circuit 61 . The row control circuit 61 includes an address buffer 61 a that receives a row address supplied from the interface chip IF through the through silicon via TSV, and the row address that is buffered by the address buffer 61 a is supplied to the row decoder 51 . The address signal that is supplied through the through silicon via TSV is supplied to the row control circuit 61 through the input buffer B 1 . The row control circuit 61 also includes a refresh counter 61 b . When a refresh signal is issued by a control logic circuit 63 , a row address that is indicated by the refresh counter 61 b is supplied to the row decoder 51 .
The column decoder 52 is controlled by a column address supplied from a column control circuit 62 . The column control circuit 62 includes an address buffer 62 a that receives the column address supplied from the interface chip IF through the through silicon via TSV, and the column address that is buffered by the address buffer 62 a is supplied to the column decoder 52 . The column control circuit 62 also includes a burst counter 62 b that counts the burst length.
The sense amplifier SA selected by the column decoder 52 is connected to the data control circuit 54 through some amplifiers (sub-amplifiers or data amplifiers or the like) which are not shown in the drawings. Thereby, read data of 8 bits (=prefetch number) for each I/O (DQ) is output from the data control circuit 54 at reading, and write data of 8 bits is input to the data control circuit 54 at writing. The data control circuit 54 and the interface chip IF are connected in parallel through the through silicon via TSV.
The control logic circuit 63 receives an internal command ICMD supplied from the interface chip IF through the through silicon via TSV and controls the row control circuit 61 and the column control circuit 62 , based on the internal command ICMD. The control logic circuit 63 is connected to a layer address comparing circuit (chip information comparing circuit) 47 . The layer address comparing circuit 47 detects whether the corresponding core chip is target of access, and the detection is performed by comparing a SEL (chip selection information) which is a part of the address signal supplied from the interface chip IF through the through silicon via TSV and a layer address LID (chip identification information) set to the layer address generating circuit 46 . When the layer address comparing circuit 47 detects a match, it activates a match signal HIT.
In the layer address generating circuit 46 , unique layer addresses are set to the core chips CC 0 to CC 7 , respectively, at initialization. A method of setting the layer addresses is as follows. First, after the semiconductor memory device 10 is initialized, a minimum value (0, 0, 0) as an initial value is set to the layer address generating circuits 46 of the core chips CC 0 to CC 7 . The layer address generating circuits 46 of the core chips CC 0 to CC 7 are cascade-connected using the through silicon vias TSV of the type shown in FIG. 2B , and have increment circuits provided therein. The layer address (0, 0, 0) that is set to the layer address generating circuit 46 of the core chip CC 0 of the uppermost layer is transmitted to the layer address generating circuit 46 of the second core chip CC 1 through the through silicon via TSV and is incremented. As a result, a different layer address (0, 0, 1) is generated. Hereinafter, in the same way as the above case, the generated layer addresses are transmitted to the core chips of the lower layers and the layer address generating circuits 46 in the core chips increment the transmitted layer addresses. A maximum value (1, 1, 1) as a layer address is set to the layer address generating circuit 46 of the core chip CC 7 of the lowermost layer. Thereby, the unique layer addresses are set to the core chips CC 0 to CC 7 , respectively.
The layer address generating circuit 46 is provided with a defective chip signal DEF supplied from the defective chip information holding circuit 33 of the interface chip IF, through the through silicon via TSV. As the defective chip signal DEF is supplied to the individual core chips CC 0 to CC 7 using the through silicon via TSV 3 of the type shown in FIG. 2C , the defective chip signals DEF can be supplied to the core chips CC 0 to CC 7 , individually. The defective chip signal DEF is activated when the corresponding core chip is a defective chip. When the defective chip signal DEF is activated, the layer address generating circuit 46 transmits, to the core chip of the lower layer, a non-incremented layer address, not an incremented layer address. The defective chip signal DEF is also supplied to the control logic circuit 63 . When the defective chip signal DEF is activated, the control logic circuit 63 is completely halted. Thereby, the defective core chip performs neither read operation nor write operation, even though an address signal or a command signal is input from the interface chip IF.
An output of the control logic circuit 63 is also supplied to a mode register 64 . When an output of the control logic circuit 63 shows a mode register set, the mode register 64 is updated by an address signal. Thereby, operation modes of the core chips CC 0 to CC 7 are set.
Each of the core chips CC 0 to CC 7 has an internal voltage generating circuit 70 . The internal voltage generating circuit 70 is provided with power supply potentials VDD and VSS. The internal voltage generating circuit 70 receives these power supply potentials and generates various internal voltages. As the internal voltages that are generated by the internal voltage generating circuit 70 , an internal voltage VPERI (≈VDD) for operation power of various peripheral circuits, an internal voltage VARY (<VDD) for an array voltage of the memory cell array 50 , and an internal voltage VPP (>VDD) for an activation potential of the word line WL are included. In each of the core chips CC 0 to CC 7 , a power-on detecting circuit 71 is also provided. When the supply of power is detected, the power-on detecting circuit 71 resets various internal circuits.
The peripheral circuits in the core chips CC 0 to CC 7 operates in synchronization with the internal clock signal ICLK that is supplied form the interface chip IF through the through silicon via TSV. The internal clock signal ICLK supplied through the through silicon via TSV is supplied to the various peripheral circuits through the input buffer B 2 .
The above description is the basic circuit configuration of the core chips CC 0 to CC 7 . In the core chips CC 0 to CC 7 , the front end unit for an interface with the external device is not provided. Therefore the core chip cannot operate as a single chip in principle. However, if the core chip never operates as the single chip, an operation test of the core chip in a wafer state may not be performed. This means that the semiconductor memory device 10 cannot be tested, before the interface chip and the plural core chips are fully assembled. In other words, the individual core chips are tested when testing the semiconductor memory device 10 . When unrecoverable defect exists in the core chips, the entire semiconductor memory device 10 is led to be unavailable. In this embodiment, in the core chips CC 0 to CC 7 , a portion of a pseudo front end unit, for testing, that includes some test pads TP and a test front end unit of a test command decoder 65 is provided, and an address signal and test data or a command signal can be input from the test pads TP. It is noted that the test front end unit is provided for a simple test in a wafer test, and does not have all of the front end functions in the interface chip. For example, since an operation frequency of the core chips is lower than an operation frequency of the front end unit, the test front end unit can be simply realized with a circuit that performs a test with a low frequency.
Kinds of the test pads TP are almost the same as those of the external terminals provided in the interposer IP. Specifically, the test pads include a test pad TP 1 to which a clock signal is input, a test pad TP 2 to which an address signal is input, a test pad TP 3 to which a command signal is input, a test pad TP 4 for input/output test data, a test pad TP 5 for input/output a data strobe signal, and a test pad TP 6 for a power supply potential.
A common external command (not decoded) is input at testing. Therefore, the test command decoder 65 is also provided in each of the core chips CC 0 to CC 7 . Because serial test data is input and output at testing, a test input/output circuit 55 is also provided in each of the core chips CC 0 to CC 7 .
This is the entire configuration of the semiconductor memory device 10 . Because in the semiconductor memory device 10 , the 8 core chips of 1 Gb are laminated, the semiconductor memory device 10 has a memory capacity of 8 Gb in total. Because the chip selection signal /CS is input to one terminal (chip selection terminal), the semiconductor memory device is recognized as a single DRAM having the memory capacity of 8 Gb, in view of the controller.
In the semiconductor memory device 10 having the configuration mentioned above, the relief signal held in the relief information holding circuit 400 is read out when the power is turned on, and the read relief signal is transmitted to the replacement control circuits in the interface chip IF and the core chips CC 0 to CC 7 . As explained above, in the interface chip IF and the core chips CC 0 to CC 7 , the defective through silicon via is not simply replaced by the auxiliary through silicon via, but the defective through silicon via is bypassed by shifting the connection relation. Therefore, almost no difference in the wiring lengths occurs between signal paths before and after replacement of the through silicon vias. Thus, because almost no skew is generated, the signal quality can be enhanced.
It is apparent that the present invention is not limited to the above embodiments, but may be modified and changed without departing from the scope and spirit of the invention.
For example, in the above embodiments, a case of supplying data from the interface chip IF to the core chips CC 0 to CC 7 is explained; however, in reverse, the same holds true when supplying data from the core chips CC 0 to CC 7 to the interface chip IF. That is, it is possible to provide the driver circuit on the core chips CC 0 to CC 7 side and provide the receiver circuits on the interface chip IF side. Because the write data supplied from the interface chip IF to the core chips CC 0 to CC 7 and the read data supplied from the core chips CC 0 to CC 7 to the interface chip IF are transmitted via the same through silicon vias, for such through silicon vias, both the driver circuits and the receiver circuits are provided in each of the interface chip IF and the core chips CC 0 to CC 7 .
For example, in the above embodiments, a chip-stacked DRAM has been explained as an example. However, in the present invention, the type of semiconductor chips to be stacked is not particularly limited thereto. It can be other memory devices such as an SRAM, a PRAM, an MRAM, an RRAM, and a flash memory, or can be a logical system device such as a CPU and a DSP.
|
A method for bypassing a defective through silicon via x in a group of n adjacent through silicon vias, includes receiving a plurality of relief signals to identify the defective through silicon via x, activating x−1 switch circuits to connect x−1 data circuits to through silicon vias 1 to x−1 in the group of n adjacent through silicon vias, activating n−x switch circuits to connect n−x data circuits to through silicon vias x+1 to n in the group of n adjacent through silicon vias, and activating a switch circuit to connect a data circuit to an auxiliary through silicon via which is adjacent through silicon via n in the group of n adjacent through silicon vias.
| 7
|
BACKGROUND OF THE INVENTION
This invention relates to a shift control apparatus used in an automatic transmission for a vehicle having at least one frictional engaging element and an electromagnetic valve to control the hydraulic pressure supplied to the frictional engaging element and achieving a plurality of speed ratios including a predetermined speed ratio achieved by engaging the frictional engaging element, to reduce speed shift shocks during a down shift in association with retardation of the vehicle.
The automatic transmission for a vehicle selectively supplies hydraulic fluid to frictional engaging elements such as clutches and breaks to connect a desired rotatory element in its gear system to an input shaft of the transmission or fix the element to a transmission casing, thereby automatically changing the speed ratio according to operation conditions of the vehicle.
Such an automatic transmission for a vehicle is required to be small in speed-shift shocks to protect various parts and components and maintain comfortable drive feeling. For this purpose, an automatic transmission for a vehicle has been proposed which uses a proper electronic control over the hydraulic pressure and its supply timing to frictional engaging elements, aiming for reduced speed-shift shocks.
An example of the structure of such an automatic transmission for a vehicle is shown in FIG. 6.
Referring to FIG. 6, a crack shaft 12 of an engine 11 is integrally connected with an impeller 14 of a torque converted 13. The torque converter has the impeller 14, a turbine 15, a stator 16, and a one-way clutch 17. The stator 16 is connected to a transmission case 18 by the one-way clutch 17. By the function of the one-way clutch, the stator is allowed to rotate in the same direction as the crank shaft 12 but is not allowed to rotate in the reverse direction. The torque transmitted to the turbine 15 is transmitted to the input shaft 19 (hereinafter referred to as the "transmission input shaft") of the gear transmission apparatus to achieve four forward speeds and a single reverse speed disposed at the rear of the torque converter 13.
The gear transmission apparatus comprises three clutches 20, 21, and 22, two breaks 23 and 24, one one-way clutch 25, and one ravigneaux type planetary gear mechanism 26. The ravigneaux type planetary gear mechanism 26 comprises a ring gear 27, a long pinion gear 28, a short pinion gear 29, a front sun gear 30, a rear sun gear 31, and a carried 32. The carrier 32 rotatably supports the pinion gears 28 and 29 and is rotatably engaged with the transmission input shaft 19.
The ring gear 27 connected to a transmission output shaft 33. The front sun gear 30 is connected to the transmission input shaft 19 through a kickdown drum 34 and a front clutch 20. Furthermore, the rear sun gear 31 is connected to the transmission input shaft 19 through a rear clutch 21. The carrier 32 is connected to a transmission casing 18 through a low reverse break 24 and the one-way clutch 25 and to the transmission input shaft 19 through a 4th-speed clutch 22 disposed at the rear end of the gear transmission apparatus. The kickdown drum 34 is integrally connectable to the transmission casing 18 by a kickdown break 23. Torque passed through the ravigneaux type planetary gear mechanism 26 is transmitted from a drive gear 35 mounted to the transmission output shaft 33 to the drive shaft side of driving wheels (not shown).
The clutches 20 to 22 and the breaks 23 and 24 as frictional engaging elements individually comprises hydraulic mechanisms provided with engaging piston devices or servo mechanisms. These hydraulic mechanisms are operated through a hydraulic control unit (not shown) by hydraulic fluid generated by an oil pump 36 connected to the impeller 14 of the torque converted 13.
Detailed structure an functions of the mechanisms are already known, for example, in Japanese Patent Publication Laid-open 58-46248/1983, 58-54270/1983, or 61-31749/1986. Thus, selective engagement of various frictional engaging elements is achieved according to the position of a shift lever provided beside the driver's seat of the vehicle (not shown) selected by the driver and operation conditions of the vehicle, and various speed ratios are automatically achieved through the hydraulic control unit according to instructions from an electronic control unit to control the operation conditions of the engine 11.
The select pattern of the shift lever includes P (parking), R (reverse), N (neutral), D (automatic three forward speeds or automatic four forward speeds), 2 (automatic two forward speeds), and L (fixed to the 1st speed) positions. With the shift lever set to the D position, when an auxiliary switch (over-drive switch, not shown) is operated, the automatic three forward speeds or the automatic four forward speeds can be selected. The functions of the individual frictional engaging elements when the shift lever is set to the individual positions are shown in FIG. 7. In the figure, symbol " " indicates that the engaging is achieved only when the L position is selected.
In the past, when the making an automatic down-shift in association with retardation of a vehicle equipped with such an automatic transmission, a speed ratio according to the current vehicle speed and the throttle opening has been read from a graph which is predetermined according to the vehicle speed and the throttle opening representing the load to the engine 11. When the current speed ratio differs from a speed ratio read from the graph, a hydraulic control valve is driven at a predetermined duty ratio to supply a predetermined engaging hydraulic pressure to the engaging side frictional engaging element, in order to achieve the newly read speed ratio.
In a prior art automatic transmission for a vehicle for a vehicle shown in FIG. 6 and FIG. 7 in which a plurality of speed ratios are achieved by electronically controlling hydraulic pressures to a plurality of frictional engaging elements to selectively engage these frictional engaging elements, the hydraulic control value is driven at a predetermined duty ratio so that a predetermined hydraulic pressure is supplied to the engaging side frictional engaging element independent of the retardation rate of the vehicle.
As a result, there occurs a difference in hydraulic pressure supplied to the engaging side frictional engaging element between a rapid retardation when the break pedal is rapidly pressed down and a moderate retardation when the bake pedal is not pressed down.
For example, when control is set so that speed-shift shocks are reduced at a down-shift in association with a moderate retardation of the vehicle, the hydraulic pressure supplied to the engaging side frictional engaging element tends to become too low because the engine speed rapidly decreases at a down-shift in association with rapid braking of the vehicle. As a result, large speed-shift shocks tend to occur due to a delay in engaging the engagingr142e frictional engaging element.
On the contrary, when the control is set so that speed-shift shocks are reduced at a down-shift in association with a rapid retardation of the vehicle, a high hydraulic pressure is supplied to the engaging side frictional engaging element at a down-shift in association with a moderate retardation of the vehicle where almost no decrease occurs in the engine speed. As a result, engaging of the engaging side frictional engaging elements tends to be too early, resulting in high speed-shift shocks.
OBJECT OF THE INVENTION
With a view to eliminated the above prior art problems with automatic transmissions for a vehicle, it is a primary object of the present invention to provide a shift control apparatus for use in an automatic transmission for a vehicle having at least one frictional engaging element and an electromagnetic valve to control the hydraulic pressure supplied to the frictional engaging element and achieving a plurality of speed ratios including a predetermined speed ratio achieved by engaging the frictional engaging element, to reduce speed-shift shocks at a down shift in association with retardation of the vehicle, compared to prior art apparatus.
SUMMARY OF THE INVENTION
In accordance with the present invention, in an automatic transmission for a vehicle having at least one frictional engaging element and an electromagnetic valve to control hydraulic pressure supplied to the frictional engaging element and achieving a plurality of speed ratios including a predetermined speed ratio achieved by engaging the frictional engaging element, a shift control apparatus comprises retardation rate detection means for detecting retardation rate of the vehicle and electromagnetic valve control means for controlling the electromagnetic valve according to the value detected by the retardation rate detection means.
The electromagnetic valve control means may be one which controls the electromagnetic valve according to the value detected by the retardation rate detection means during a shift from another speed ratio to the above predetermined speed ratio. In this case, speed shift instruction means may be provided which instructs a shift operation to a predetermined speed ratio when the above other speed ratio is higher by two steps or more than the predetermined speed ratio and the present vehicle speed is higher than a predetermined value.
The retardation rate detection means may be provided with output shaft rotation speed detection means for detecting the rotation speed of the output shaft of the automatic transmission to calculate the retardation rate of the vehicle according to the rate of change in the output shaft rotation speed.
Similarly, it is also possible to provided input shaft rotation speed detection means in the retardation rate detection means for detecting the rotation speed of the input shaft of the automatic transmission to calculate the retardation rate according to the rate of change in the input shaft rotation speed.
Alternatively, the retardation rate detection means may be provided with acceleration detection means for detecting the acceleration of the vehicle to calculate the retardation rate of the vehicle according to the output value from the acceleration detection means.
Therefore, when the retardation rate detection means determines that the retardation rate of the vehicle is high, that is, a down-shift at a rapid retardation, the hydraulic pressure supplied to the engaging side frictional engaging element is set higher by the electromagnetic valve control means through the electromagnetic valve to prevent speed-shift shocks in association with a delay in engaging the engaging side frictional engaging element. This allows the engaging side frictional engaging element to engage at a proper timing, thereby achieving a down-shift with reduced speed-shift shocks.
On the contrary, when the retardation rate detection means determines that the retardation rate of the vehicle is small, that is, a down-shift at a moderate retardation of the vehicle, the hydraulic pressure supplied to the engaging side frictional engaging element is set lower by the electromagnetic valve control means through the electromagnetic valve to prevent too early engagement of the engaging side frictional engaging element. This allows the engaging side frictional engaging element to engage at a proper timing, thereby achieving a down-shift with reduced speed-shift shocks.
As described above, with the shift control apparatus for an automatic transmission for a vehicle according to the present invention, the hydraulic pressure supplied to the frictional engaging element is corrected according to the retardation rate of the vehicle. As a result, when the retardation rate of the vehicle is too high, that is, a down-shift at a rapid retardation, the hydraulic pressure supplied to the engaging side frictional engaging element is set higher to allow the engaging side frictional engaging element to engage at a proper timing. On the contrary, when the retardation rate of the vehicle is small, that is, a down-shift at a moderate retardation of the vehicle, the hydraulic pressure supplied to the engaging side frictional engaging element is set lower to engage the engaging side frictional engaging element at a proper timing. As a result, a down-shift with reduced speed-shift shocks in any case.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1, along with FIG. 2, is a flow chart showing the control flow of an embodiment according to the shift control apparatus for an automatic transmission for a vehicle according to the present invention.
FIG. 2 is a flow chart showing the control flow of an embodiment according to the shift control apparatus for an automatic transmission for a vehicle according to the present invention.
FIG. 3 is a graph showing the relationship between a retardation rate of the vehicle and a corrected duty ratio in this embodiment.
FIG. 4 is a three-dimensional graph showing the relationship between the oil temperature of the automatic transmission for a vehicle and the engine speed and a target duty ratio in this embodiment.
FIG. 5 is a graph showing an example of the relationship between the engine speed and a target duty ratio in this embodiment.
FIG. 6 is a skeletal view showing the structure of an automatic transmission for a vehicle of four forward speeds used in the present invention.
FIG. 7 is an operation element chart showing the relationship between the engaging condition of the individual frictional engaging elements and speed ratios.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment in which the shift control apparatus for an automatic transmission for a vehicle according to the present invention is applied to a vehicle equipped with an automatic transmission of four forward speeds shown in FIG. 6 and FIG. 7 will now be described.
In this embodiment, the retardation rate of the vehicle is calculated according to a rate α (rpm/sec 2 ) of change in rotation speed of a transmission output shaft 33. For this purpose, a rotation speed sensor 37 for detecting the rotation speed of the transmission output shaft 33 is provided at the rear end of a transmission casing 18. Detection signal of the rotation speed sensor 37 is outputted to an electronic control unit to control the operation condition of an engine 11, and the electronic control unit calculates the retardation rate of the vehicle.
Thus, the retardation rate of the vehicle is calculated by the electronic control unit according to the detection signal from the rotation speed sensor 37. Then, a correction duty ratio Δd to a basic duty ratio d B of a hydraulic control valve to control the engaging hydraulic pressure to the engaging side frictional engaging element is read from a graph as shown in FIG. 3 according the magnitude of retardation rate of the vehicle. And, a final target duty ratio d O for the hydraulic control valve is calculated.
In this case, the basic duty ratio d B is previously stored in the electronic control unit as a three-dimensional graph as shown in FIG. 4 using an oil temperature T O of the automatic transmission hydraulic fluid and a engine speed N E as variables. Therefore, the target duty ratio D O of the hydraulic control valve is calculated by adding the basic duty ratio d B and the correction duty ratio Δd by the following equation:
d.sub.O =d.sub.B +Δd
Specifically, when the rate α of change in rotation speed of the transmission output shaft 33 (hereinafter referred to as the "vehicle retardation rate") is smaller than a predetermined smallest threshold value α S , the correction duty ratio Δd is set to
Δd=0%
On the contrary, when the vehicle retardation rate α is greater than a largest threshold value α L , the correction duty ratio Δd is set to
Δd=-10%
Furthermore, when the vehicle retardation rate α is greater than the smallest threshold value α S and smaller than the largest threshold value α L , the correction duty ratio Δd is set to
Δd=-10·α/(α.sub.L -α.sub.S)%.
Since this embodiment uses a hydraulic control valve of a type which closes when unenergized, the higher the duty ratio, the lower hydraulic pressure tends to be supplied to the engaging side frictional engaging element. On the other hand, when a hydraulic control valve of a type which opens when unenergized is used, the higher the duty ratio, the higher hydraulic pressure tends to be supplied to the engaging side frictional engaging element.
FIG. 5 shows the relationship between changes in the engine speed N E and the target duty ratio d O of the hydraulic control valve.
As can be seen from FIG. 5, when the engine speed N E slowly decreases with a small retardation rate as indicated by the solid line, the target duty ratio d O normally varies as indicated by the solid line. However, when the engine speed rapidly decreases with a large retardation rate as indicated by the two-dot-bar line, the target duty ratio d O of the hydraulic valve is set to a value lower than a normal target duty ratio d O as indicated by the two-dot-bar line. As a result, a higher pressure of hydraulic fluid is supplied to the engaging side frictional engaging element.
In the present invention, even when the engine speed N E decreases with irregular retardation rate as indicated by the broken line, the target duty ratio d O is always adequately set as indicated by the broken line.
Furthermore, in this embodiment, when the retardation rate α of the vehicle is large, the shift pattern from the 4th position is changed from 4-3-2 to 4-3-1 to improve the braking effect. Thus, when the retardation rate α of the vehicle is large, the shift pattern is changed from the normal case to improve the effect of engine brake, thereby improving safety of the vehicle at rapid braking.
The control flow of this embodiment is shown in FIG. 1 and FIG. 2.
Referring to FIG. 1 and FIG. 2, when a shift instruction from the 4th speed to the 3rd speed is generated in association with a decrease in the vehicle speed in step S1, the retardation rate α of the vehicle is calculated according to the detection signal from the rotation speed sensor 37 in step S2. In step S3, the retardation rate α is determined as to whether or not it is smaller than the smallest threshold value α S .
In step S3, when the retardation rate α of the vehicle is determined to be smaller than the smallest threshold value α S , that is, the retardation rate α of the vehicle is very small, in step S4 the correction duty ratio Δd is set to
Δd=0%
And a pre-stopping control from the 4th speed to the 3rd speed in association with retardation of the vehicle is performed in step S5.
When, in step S3, the retardation rate α of the vehicle is determined to be greater than the smallest threshold value α S , determination is made in step S6 as to whether or not the retardation rate α of the vehicle is between the smallest threshold value α S and the largest threshold value α L . When the retardation rate α of the vehicle is determined to be between the smallest threshold value α S and the largest threshold value α L , that is the retardation rate α of the vehicle is medium, in step S7 the correction duty ratio Δd is set to
Δd=-10·α/(α.sub.L -α.sub.S)%.
After that, the processing goes to step S5.
When, in step S6, the retardation rate α of the vehicle is determined not to be between the smallest threshold value α S and the largest threshold value α L , that is, the retardation rate α of the vehicle is greater than the largest threshold value α L and is very high, in step S8 the correction duty ratio Δd is set to
Δd=-10%
Then, the processing goes to step S5.
After the pre-stopping control in association with retardation of the vehicle from the 4th speed to the 3rd speed is performed in step S5, when a shift instruction from the 3rd speed to the 2nd speed is generated in step S9 in association with further retardation of the vehicle, the retardation rate α of the vehicle is again calculated in step S10. Then, in step S11, determination is made as to whether or not the retardation rate α of the vehicle is smaller than the smallest threshold value α S .
When, in step S11, the retardation rate α of the vehicle is determined to be smaller than the smallest threshold value α S , that is, the retardation rate α of the vehicle is very small, in step S12 the correction duty ratio Δd is set to
Δd=0%
After that, pre-stopping control from the 3rd speed to the 2nd speed in association with retardation of the vehicle is performed in step S13.
After the pre-stopping control from the 3rd speed to the 2nd speed is performed, a creep control to suppress creeping of the vehicle is performed as needed.
When, in step S11, the retardation rate α of the vehicle is determined to be greater than the smallest threshold value α S , determination is made in step S14 as to whether or not the retardation rate α of the vehicle is between the smallest threshold value α S and the largest threshold value α L . When the retardation rate α of the vehicle is determined to be between the smallest threshold value α S and the largest threshold value α L , that is the retardation rate α of the vehicle is medium, in step S15 the correction duty ratio Δd is set to
Δd=-10·α/(α.sub.L -α.sub.S)%.
After that, the processing goes to step S13.
When, in step S14, the retardation rate α of the vehicle is determined not to be between the smallest threshold value α S and the largest threshold value α L , that is, the retardation rate α of the vehicle is greater than the largest threshold value α L and is very high, a shift instruction from the 3rd speed to the 1st speed is generated in step S17. This remarkably improves the effect of engine braking in association with rapid retardation over normal cases.
In this case, the rear clutch 21 as the engaging side frictional engaging element in the 1st speed, as can be seen from FIG. 7, is engaged in the 3rd speed, and a shift from the 3rd speed to the 1st speed is achieved by the action of the one-way clutch 25 which functions after the front clutch 20 and the 4th-speed clutch 22 are released. Therefore, no setting is required for the correction duty ratio Δd and the target duty ratio d O of the hydraulic control valve.
Similarly to the above, after the pre-stopping control from the 3rd speed to the 1st speed is performed, a creep control to suppress creeping of the vehicle is performed as needed.
In this embodiment, the retardation rate of the vehicle is calculated according to the changing rate α in the rotation speed of the transmission output shaft 33 of the vehicle. However, alternatively, this may be calculated according to the rate of change in rotation speed of the transmission input shaft 19, which is integral with the turbine 15 of the torque converter 13, an acceleration sensor (G sensor) or the like.
|
In an automatic transmission for a vehicle having at least one frictional engaging element and an electromagnetic valve to control hydraulic pressure supplied to the frictional engaging element and achieving a plurality of speed ratios including a predetermined speed ratio achieved by engaging the frictional engaging element, a shift control apparatus includes retardation rate detection means for detecting retardation rate of the vehicle and electromagnetic valve control means for controlling the electromagnetic valve according to the value detected by the retardation rate detection means, and hydraulic pressure supplied to the frictional engaging element is corrected by the electromagnetic valve through electromagnetic valve control means according to the retardation rate of the vehicle detected by the retardation rate detection means, thereby reducing speed-shift shocks during a down-shift in association with retardation of the vehicle.
| 5
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional application Ser. No. 60/564,684, filed Apr. 22, 2004.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a sound emitting device which is designed to be attached to an article of clothing or the body of a wearer, to assist in maintaining a correct posture. The device may also be used to detect and warn of the nodding of the head associated with drowsiness.
[0003] Numerous studies have discussed the importance of good posture to good health. For example, the brochure entitled Posture for a Healthy Back, published by the Cleveland Clinic in 2001, lists the following benefits from proper posture:
[0004] Keeps bones and joints in the correct alignment so that muscles are being used properly.
[0005] Helps decrease the abnormal wearing of joint surfaces.
[0006] Decreases the stress on the ligaments holding the joints of the spine together.
[0007] Prevents the spine from becoming fixed in abnormal positions.
[0008] Prevents fatigue because muscles are being used more efficiently, allowing the body to use less energy.
[0009] Prevents backache and muscular pain.
[0010] Contributes to a good appearance.
[0011] It is also well recognized that many activities, such as operating machinery or driving an automobile, can become extremely dangerous when the operator or driver becomes overly tired and drowsy.
[0012] It is accordingly an object of the present invention to provide a simple device for assisting a person in the maintenance of good posture, by monitoring for both forward and rearward leaning of the body from a position of good posture and alerting a wearer of the device so that corrective positioning can be undertaken.
[0013] It is also an object of the invention to provide a device of the described type which can also be used to monitor for a forward or rearward tilt of the head which is associated with drowsiness, and which can signal the wearer that such nodding has occurred.
SUMMARY OF THE INVENTION
[0014] The above and other objects and advantages of the invention are achieved by the provision of a sound emitting device which comprises a tubular member configured to permit it to be attached to an article of clothing or the body of a wearer. The tubular member houses an internal ball or hammer for impacting the wall of the tubular member so as to emit a sound whenever the tubular member is pivoted a predetermined angle in either direction from an initial orientation. The device may thus be attached to an article of clothing or the body of the wearer so as to be disposed in the initial orientation when the wearer is in a position of correct posture, and when the wearer tilts either forwardly or rearwardly from the position of correct posture a sound is emitted which alerts the wearer to take corrective action.
[0015] In one embodiment, the tubular member has opposite end walls, and a ball is mounted within the tube so that it is free to roll between the end walls. Thus, the device may be attached to an article of clothing or the body of the wearer so that the tubular member is disposed substantially horizontally when the wearer is in a position of correct posture, and when the wearer tilts either forwardly or rearwardly from the position of correct posture the ball rolls into contact with the lower one of the end walls to emit a sound which alerts the wearer to take corrective action.
[0016] In a second embodiment, the tubular member may have closed or open ends, and a hammer is pivotally mounted within the tubular member. The hammer and the side wall of the tubular member are composed of materials which result in an audible sound being emitted whenever the hammer pivots into contact with the wall of the tubular member. Also, a spring biasing member is provided for supporting the hammer in a neutral position which is spaced from the wall of the tubular member. Thus in use, the device may be attached to an article of clothing or to the body of the wearer in a predetermined orientation when the wearer of the device is in a position of correct posture, and when the wearer tilts either forwardly or rearwardly from the position of correct posture the hammer pivots into contact with the wall of the tubular member to emit a sound which alerts the wearer to take corrective action.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Some of the objects and advantages of the present invention having been stated, others will appear from the following detailed disclosure, when considered in conjunction with the attached drawings, in which
[0018] FIG. 1 is a perspective view, partly broken away, of a first embodiment of the sound emitting device of the present invention, shown attached in an operative position to a cap of a wearer;
[0019] FIG. 2 is an exploded view of the sound emitting device shown in FIG. 1 , with the ends of the device being opened to permit the ball to be received therein;
[0020] FIG. 3 is a fragmentary perspective end view of the device shown in FIG. 1 ;
[0021] FIGS. 4A and 4B are schematic views showing the device of FIG. 1 in oppositely tilted orientations;
[0022] FIG. 5 is a schematic perspective view, partly broken away, showing a second embodiment of the device of the invention mounted within a cap of a wearer;
[0023] FIG. 6A is a fragmentary view of the device and cap of FIG. 5 in a position when the head of the wearer is tilted rearwardly;
[0024] FIG. 6B is a view similar to FIG. 6A showing the device and cap of FIG. 5 in a position when the head of the wearer is tilted forwardly;
[0025] FIG. 7 is a view similar to the upper portion of FIG. 1 , and showing a another embodiment of the device;
[0026] FIG. 8 is a view similar to FIG. 7 , and showing still another embodiment of the device;
[0027] FIG. 9 is a sectioned side elevation view of a further embodiment of a device which embodies the present invention; and
[0028] FIG. 10 is a sectional view taken along the line 10 - 10 of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] FIGS. 1-3 , 4 A, and 4 B illustrate a first embodiment of the invention, which comprises a sound emitting device 10 which comprises a cylindrical tube 15 which encloses a freely moveable ball 16 . The ball 1 may be composed of glass, metal, ceramic, or any other hard material which permits it to function in the manner described below.
[0030] The tube 15 is preferably formed of a suitable metallic material, such as brass, and it includes opposite ends which are formed by integral end flaps 17 and 18 . The flaps 17 and 18 are initially formed in an open configuration as shown in FIG. 2 to permit assembly of the ball 16 within the tube, and the flaps are then folded upwardly to enclose the ball as seen in FIGS. 1, 3 , 4 A, and 4 B.
[0031] The sound emitting device 10 is configured so that it can be attached to an article of clothing or the body of the wearer, so that the tube 15 is disposed substantially horizontally when the wearer is in a position of correct posture. Thus, for example, and as shown in FIG. 1 , the device 10 may be attached within the band 19 of a cap 20 . A suitable adhesive 21 may be used to hold the device in the correct orientation within the band 19 . Also, by mounting the device within the band of the cap, it will be possible to locate the device immediately adjacent the ear of the wearer of the cap.
[0032] When the tube 15 is horizontal as seen in FIG. 1 , the ball remains stationary, and when the level becomes inclined to a predetermined degree from horizontal in either direction, and as seen in FIGS. 4A and 4B , the ball rolls into contact with the lowermost end flap 17 or 18 so as to emit a soft sound or ping.
[0033] Viewing FIG. 3 , it will be seen that the end flaps 17 and 18 do not completely close the ends of the tube 15 , and thus the air which is in front the ball 16 as it moves along the tube is free to escape. Thus movement of the ball is not retarded by a closed air pocket in front of the ball.
[0034] FIGS. 5, 6A , 6 B, 7 , and 8 illustrate further embodiments of the invention. Specifically, and as shown FIG. 5 , the device 10 a is mounted within the upper portion of a cap 30 so that the device is in a horizontal orientation when the wearer is in a position of correct posture. Also, as seen in FIGS. 5, 6A , and 6 B, the device 10 a has ends 17 a, 18 a formed by separate members which close the ends of the tube 15 a. The tube 15 a and the ends 17 a, 18 a are preferably formed of a metal, which functions to emit a sound when the ends are struck by the ball 16 , although other materials such as a hard plastic may be used. Also, it may be desirable to form a vent hole (not shown) through the ends 17 a, 18 a to facilitate the release of the air in front of the moving ball.
[0035] It will be understood that when the wearer of the cap 20 or 30 assumes correct posture, the ball 16 may be disposed adjacent one of the ends of the tube 10 or 10 a. Thus when the wearer tilts in a direction to lower such one end, the ball may not strike such one end and no sound will be emitted. However, this occasional failure of the device to emit a sound has not been found to adversely effect the overall efficacy of the device.
[0036] In the embodiments of FIGS. 7 and 8 , the tube 10 b or 10 c is configured to releasably retain the ball 16 at a medial location along the length of the tube when the tube is in a horizontal orientation. For example, as illustrated in FIG. 7 , the tube 10 b is formed with a shallow U-shaped curvature, so that the ball 16 is retained at the bottom of the U by gravity when the tube is horizontal. Alternatively, and as shown in FIG. 8 , the ball 16 is releasably held in a small depression 25 at the medial location of the tube 10 c, in which case the tube could otherwise be a straight cylinder as in the case of the tubes 10 and 10 a. Thus in the embodiments of FIGS. 7 and 8 , the ball 16 will be assured to strike the lowered end of the tube and emit a sound whenever the wearer tilts from the correct posture in either direction.
[0037] As described above, the invention finds particular utility when the sound emitting device is attached to a hat, cap, or other headwear. For this purpose, the device 10 a, 10 b, or 10 c may include an integral safety pin or the like (not shown). The tube of the device is oriented to be horizontal when the wearer's posture is properly upright, and the wearer is thereby signaled whenever his or her posture departs from a desired upright position, thus informing the wearer to correct his or her posture. It is believed that after extended use, the senses of the human body will react to the sound almost automatically to maintain a correct posture.
[0038] The invention also provides a unique function when the sound emitting device is worn while the wearer is jogging. More particularly, when the wearer jogs while in a proper upright position, the ball will bounce against the side wall in the tube and emit a continuous series of discrete sounds. However, if the wearer should lean either forward or backward to an unacceptable degree while jogging, the ball will move to one end of the tube and not emit the same continuous discrete sounds. Thus when the sounds cease, the wearer is notified that his or her posture should be corrected.
[0039] FIGS. 9 and 10 illustrate a further embodiment wherein the sound emitting device comprises a hollow tube 15 d having either open or closed ends, and with a single or double ended hammer 32 pivotably mounted at a central location in the tube. When the tube is horizontal, the hammer is held in a neutral position by a spring biasing member 34 , and when the tube is moved in either direction from the horizontal, the hammer overcomes the spring member 34 and moves relative to the wall of the tube by reason of the inertia of the hammer, so that the hammer strikes the wall of the tube and emits a sound. Rather than using a spring biasing member, the hammer could be biased toward its neutral position by a suitable magnetic arrangement.
[0040] The embodiment of FIGS. 9 and 10 can also be mounted in an orientation other than horizontal. For example, the tube 15 d could be attached to a hat, cap or other headwear in a vertical orientation, with the hammer 32 striking the inside wall of the tube whenever the tube is displaced from the vertical.
[0041] A second use for the device of the invention is to assist in avoiding the effects of drowsiness. When the device is attached to the hat or cap of an operator of machinery, or a driver of an automobile, any nodding of the head resulting from drowsiness will result in a sound being emitted which will alert the operator or driver in time to permit corrective action.
[0042] Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains, having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
|
A device for assisting a wearer of the device to maintain correct posture or avoid the effects of drowsiness. The device comprises a tubular member which may be attached to an article of clothing or the body of a wearer, and the tubular member houses a ball, or a hammer, which impacts the wall of the tubular member so as to emit an audible sound or ping whenever the device is tilted from is initial position, to thereby warn the wearer of the tilted condition and so that corrective action can be taken.
| 0
|
BACKGROUND OF THE INVENTION
This invention relates generally to pressure-biased valves or the like, and more particularly to a valve system of such type incorporating novel and improved differential area pressure-biased valve sleeves.
PRIOR ART
Zero leakage or very low leakage valves often employ a differential area sleeve which engages the mating valve surface with a force or pressure which is a direct function of the pressure being sealed. U.S. Pat. No. 3,324,887 (assigned to the assignee of this invention) discloses one such valve system. In such valve, the case or housing is at exhaust pressure; therefore, in each instance, the sleeves provide a seal between an internal zone of higher pressure and an external zone of lower pressure. Such sleeves provide an internal, radially extending, unbalanced or differential area facing in a direction away from the valve slide, which is exposed to the higher internal pressure and produces a force on the sleeve urging it into contact with the valve slide with a force which is a direct function of the pressure being sealed. Because the differential area, or unbalanced area, is internal in each instance, all of the sleeves can be assembled into the valve body passages from the end remote from the valve slide.
In other instances, the valve case or housing is not at exhaust pressure. An example of such a device is illustrated in FIG. 3, which is also prior art. This prior art system is a pressure regulator in which the case pressure in zone 10 is the regulated pressure and is above exhaust pressure at port 11. In such a valve, differential area sleeves 12 connect between the valve member 13 and the valve exhaust port 11. and such sleeves, therefore, provide a seal between an external zone of higher pressure and an internal zone of lower pressure. Consequently, the unbalanced or differential area is located externally of the sleeve and is exposed to the zone of higher pressure in order to produce the sealing force on the sleeve, which is a direct function of the differential in the pressures between the external zone and the internal zone.
In the past, as illustrated in FIG. 3, the sleeves at the exhaust ports have been assembled into the valve body from the valve cavity end of the passage in the valve body. Therefore, in such valves, it has been necessary to move the sleeves along the valve cavity to the passages in the body and then insert them in an outward direction along the receiving passage prior to the insertion of the valve member. This is a difficult assembly procedure, and can present severe problems in some instances in which clearances are very limited.
Further, in such prior art devices, the sleeve members must extend substantially the entire length of the passage within the valve body, and it is therefore necessary to custom-manufacture sleeves for each valve body thickness.
SUMMARY OF THE INVENTION
In accordance with the present invention, a novel and improved valving system is provided in which the assembly of the valve sleeve within the valve body can be accomplished in each instance from the exterior of the valve body. Further, in accordance with this invention, adapter rings are provided so that the valve sleeves themselves can be standardized as to length and used in various valve bodies having valve passages of differing lengths. Such adapter rings are arranged to compensate for differences in the length of the valve body passages in which the sleeves are located.
Further in accordance with this invention, the springs utilized to provide an initial bias on the sleeves urging them toward engagement with the valve member are relatively low rate springs which are not as sensitive to tolerance size variations as the relatively high spring rate wave washer type springs often used in the prior art.
These and other aspects of this invention are illustrated in the accompanying drawings, and are more fully described in the following specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal section of a pressure regulator incorporating the present invention;
FIG. 2 is an enlarged, fragmentary section illustrating the structure of the inlet and exhaust seals in the regulating position; and
FIG. 3 is a fragmentary, longitudinal section of one form of prior art device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a pressure regulator incorporating this invention. Such regulator is intended for establishing and maintaining relatively high regulated pressures, e.g., in the order of 1500 psi, when supplied with pressure in the order of 3000 psi. Further, the regulator is designed to accommodate fairly high flow rates. The particular regulator illustrated finds its primary use in connection with equipment for the control of blowouts at oil wells or the like.
The regulator provides a valve body assembly 16. Such assembly includes a main body member 17 formed with a longitudinal opening 18 therethrough which defines the valve cavity 19. An upper body cap 21 is bolted to one end of the body member 17 and a lower body cap 22 is bolted to the opposite end thereof.
The particular regulator illustrated provides mechanical springs 23 and 24 to adjustably establish the regulated pressure. It should be understood, however, that other systems for controlling the pressure may be utilized. For example, a pneumatic system may be provided in which an air spring controls the regulated pressure, or a hydraulic system utilizing hydraulic pressure may be used to establish the regulated pressure of the device.
In the illustrated embodiment, the springs 23 and 24 are located within a spring housing 26 threaded onto the end of the upper cap member 21. The springs 23 and 24 apply a spring force to the valve member 27 positioned within the valve cavity 19 for longitudinal movement therein. This spring force is applied by the springs to a thrust member 28, which in turn engages a control member 29 having a cylindrical extension 29a extending through a seal 31 in the upper cap member 21 into engagement with the lower side of the thrust member 28.
The upper ends of the springs 23 and 24 engage a second thrust member 32, which is positioned by a screw 33 threaded through a cap 34 mounted on the upper end of the spring housing 26. A ball 37 is positioned between the screw 33 and the thrust member 32 to minimize friction when the screw is rotated by a handle 38.
The pressure in the valve cavity 19 acts on an unbalanced area of the extension 29a to overcome the force of the springs 23 and 24, and to move to a valve-closed position when the desired regulated pressure is reached. A piston head 30 on the control member 29 is provided with an orifice 30a (or a peripheral slot if desired) to provide damping. Roll pins 30b connect the valve member 27 and the control member 29.
The actual valving function is performed by the coaction between the valve member 27 and an opposed pair of identical inlet valve sleeves 41 and an opposed pair of identical outlet or exhaust valve sleeves 42. The valve member 27 is either rectangular or square in cross section, and is formed with a longitudinal central passage 43 communicating with a pair of lateral inlet ports or passages 44 and a pair of lateral exhaust ports or passages 46. The valve member assumes the position illustrated in FIG. 1 when the pressure within the valve cavity 19 is zero or is substantially below the pressure at which the regulator is set to operate. In such position, the lower end of the valve member 27 engages the lower end cap 22.
When the pressure within the valve cavity 19 builds up, it acts on an unbalanced area of the extension 29a of the control member 29 extending through the seal 31 to overcome the force of the springs 23 and 24, and the valve member 27 raises up until the inlet passages 44 move to a location immediately above and isolated from the inlet valve sleeves 41, as illustrated in FIG. 2. In such condition, inlet pressure supplied to the inlet port 47 is isolated from the valve cavity 19 by the engagement with the inner ends of the valve sleeves 41 and the surface of the valve member 19 spaced from the inlet passages 44. In such condition, the exhaust passages 46 are not yet open to the exhaust sleeves 42, so the cavity 19 is isolated from both the inlet port 47 and the exhaust port 48, and the cavity is at regulated pressure.
If the pressure within the cavity 19 exceeds desired regulated pressure, the valve member 27 moves still further upward, and the exhaust passages 46 move into communication with the exhaust sleeves 42 to reduce the pressure within the cavity 19 to regulated pressure. Once regulated pressure is re-established, the valve member 27 returns to the position of FIG. 2, in which both inlets and outlets are closed. Conversely, if the pressure in the cavity 19 reduces, the valve member moves downwardly under the action of the springs to again establish communication between the passages 44 and the sleeves 41 to supply additional fluid to the regulator and again re-establish the desired regulated pressure.
Three tubes 51, 52, and 53 extend across the valve member and are open to valving faces thereof to ensure that the pressures within the two opposed valve sleeves 41 are always equal, and similarly that the pressures within the two opposed valve sleeves 42 are always equal. This ensures that the valve is laterally balanced at all times.
The inlet port 47 and the exhaust port 48 are formed in a side plate 56 which is bolted onto one side of the main valve body 17, and an opposite side plate 57, which in the illustrated embodiment does not contain any ports, is bolted on the opposite side of the valve member 17 to back up the sleeves on that side of the valve. It should be understood that additional ports can be provided on the right side by an appropriate replacement of the valve plate 57. The regulated pressure within the valve cavity 19 is open to a controlled pressure port 58 in the valve body. Preferably, an elongated, lateral passage 59 is provided to the valve member to ensure full communication between the central passage 43 and the controlled pressure port 58.
Reference should now be made to FIG. 2, which is an enlarged, fragmentary section illustrating the details of structure of the inlet and exhaust sleeves 41 and 42, respectively. It should be understood that the two inlet sleeves 41 are identical and opposite, and that the associated elements which work with each inlet sleeve 41 are also identical. Similarly, the two opposed exhaust sleeves 42 are identical along with the associated elements. Therefore, this detailed description of one inlet sleeve assembly and one exhaust sleeve assembly illustrated in FIG. 2 applies equally to the opposed corresponding sleeves and associated elements.
During the operation of the regulator once regulation is achieved, the pressure within the inlet port 47 is always greater than the regulated pressure within the valve cavity 19. Similarly, during regulation, the pressure within the valve cavity 19 always exceeds the pressure in the exhaust port 48. The inlet sleeve 41 is therefore provided with an unbalanced area open to the interior of the sleeve which is exposed to the higher pressure therein and produces a force on the sleeve 41 in the direction toward the valve member 27. Such force is a direct function of the difference in pressure between the interior of the sleeve 41 and the valve cavity 19.
Since valves of this type do not provide any measurable leakage, and are considered to be zero leakage valves, the pressure drop across the forward face 61 of the inlet valve sleeve 41 occurs at the inner edge of such face at 62. A seal 63 provides a fluidtight joint between the inner surface of the passage 64 within the body member 17 and the exterior surface of the sleeve 66 on the valve sleeve 41. This seal 63 provides dynamic sealing with the surface 66, so that the effective area of the seal 63 is an area encompassed within the diameter 66. The differential or unbalanced area is the difference between the area of a circle having the diameter 66 and the area of a circle having the diameter 63. This area, being unbalanced, results in a fluid-induced force on the sleeve 41 in a direction to the right as viewed in FIG. 2, because the unbalanced or differential area is exposed to the higher internal pressure within the sleeve. Such force is considered to be substantially equal to the unbalanced differential area times the difference in pressure across the seal.
Positioned immediately behind the inlet sleeve 41 is an adapter ring 67 which is formed with a counterbore 68 providing a shoulder 69. A similar counterbore 71 in the inlet sleeve provides a shoulder 72 opposed to the shoulder 69. A light spring 73 extends between the two shoulders and provides a light, resilient force urging the inlet sleeve to the right as viewed in FIG. 2 to initiate contact. The force of this spring, however, is not intended to supply any material sealing force, but merely maintains light engagement to ensure that the pressure-induced force will be created as the pressure differential builds up.
A seal 74 provides a seal between the valve body 17 and the side plate 56. The inner end of the passage 64 is formed with an inwardly directed shoulder providing a face 76 against which a backup ring 77 seats to position the seal 63. Such shoulder joins with an inner wall 78 which closely fits the forward end of the inlet sleeve 41 and the rearward portion at 79 closely fits the main passage 64 within the body. Therefore, the sleeve 41 is installed in the body from the outer end of the passage 64 and the adapter tube or sleeve 67 is then inserted along with the spring 73 from the outer end. Because the sleeve 41, spring 43, and adapter tube 67 can be assembled from the outer end of the passage 64, it is easy to install the sleeve and its associated elements.
The exhaust sleeves 42 are also assembled from the exterior of the associated passages. The exhaust sleeves 42 are positioned within a passage 81 formed in the valve body 17 and provide a forward portion 82 which closely fits such passage. Rearwardly of the portion 82, the valve sleeve 42 is formed with a reduced diameter, rearward extension 83. An adapter sleeve 84 is positioned within the passage or bore 81 with a close fit, and extends to a forward end 86 located between the rearward extension of the sleeve and the walls of the passage 81. A seal 87 and backup ring 88 are positioned adjacent to and are located by the forward end 86 of the adapter tube 84 to provide a fluidtight joint between the wall of the bore 81 and the extension 83. Here again, the spring 89 extends between a shoulder 91 on the adapter tube 84 and the rearward end at 92 of the exhaust sleeve to ensure initial engagement between the forward end or sealing face 93 of the sleeve 42.
In this instance, the pressure within the valve cavity 19 is greater than the pressure within the sleeve 42, so an unbalanced area is located on the exterior of the sleeve to produce the fluid-induced force for sealing. Because the pressure surrounding the sleeve is greater than the internal pressure, the pressure drop occurs at the outer edge of the end face 93 at 94. The diameter of such edge at 94 is greater than the diameter of the exterior surface 95 of the extension 83. Consequently, the differential area, which is the area of the circle having a diameter 94 minus the area of the circle having the diameter of 95, is exposed to the higher pressure within the cavity 19 and produces a force on the sleeve urging it to the right as viewed in FIG. 2. This force is a direct function of the difference in pressure between the two sides of the sleeve 42 times such differential area. Since the maximum diameter of the sleeve 42 is as small as the diameter of the bore 41, the sleeve 42 can also be positioned in the valve from the outer end of the bore 81. Similarly, the spring 89 and the adapter tube 84 are positioned from the exterior or the outer end of the bore 81. Here again, a seal 96 provides a fluidtight joint between the body member 17 and the side plate 56.
In addition to providing the advantage of allowing the assembly of the exhaust sleeve from the exterior of the valve body, after the valve member 27 is installed, the adapter sleeves or tubes 67 and 84 permit the use of standard lengths of inlet and exhaust sleeves 41 and 42, respectively, and variations in the wall thickness of the valve body are accommodated by variations in the length of the adapter tubes 67 and 84. This further reduces the manufacturing cost of the completed valve because the adapter tubes need not be formed with as much precision as the sleeves. It should be understood that the forward ends of the sleeves must be accurately produced to a very good finish so that proper sealing is achieved with the surface of the valve member 27 and dimensional tolerances must be very closely held to ensure proper unbalanced areas.
Further, the structure in most instances permits the use of simple coil springs having a relatively low spring rate to back up the respective sleeves instead of the relatively high spring rate of wave springs 97 of the prior art, as illustrated in FIG. 3. This further reduces the precision required to produce a valve and permits the use of wider tolerances in the manufacture of the tubes 67 and 84.
Although the preferred embodiment of this invention has been shown and described, it should be understood that various modifications and rearrangements of the parts may be resorted to without departing from the scope of the invention as disclosed and claimed herein.
|
A valve system is disclosed in which sleeves providing an unbalanced area are arranged so that the unbalanced area is exposed to the zone of higher pressure and produces a sealing force between the sealing face of the sleeves and a mating valving surface, which force is a direct function of the difference in the pressure across the seal. Adapter rings are positioned behind each seal and a spring provides an initial light bias on the sleeve to urge it into mating engagement with the valving surface. The adapter ring and sleeve structure is arranged so that all of the sleeves, including those sleeves having an external unbalanced area, may be assembled in the valve body from the end of the sleeve receiving passage remote from the valving surface. The adapter rings also make it possible to use standard length sleeves in combination with relatively low cost adapter rings having lengths selected to provide a total sleeve adapter ring length which matches the length of the passages in the valve body.
| 8
|
BACKGROUND OF INVENTION
[0001] a. Field of Invention
[0002] The invention relates generally to the creation/production of electric energy using hydro turbine technology. More particularly, the present invention utilizes reciprocal weights and floatation devices to lift the weights by rising water and then moving water in a continuous loop via gravity, with the weights, to operate one or more hydro turbines. There may be a series of weights that operate out of phase from one another to establish a continuous output arrangement.
[0003] b. Description of Related Art
[0004] The following patents are representative of the field pertaining to the present invention:
[0005] U.S. Pat. No. 7,584,609 B2 to Welch, Jr. et al. describes a system and method for generating electricity that includes converting wave motion into mechanical power. A fluid matter is driven as a function of the mechanical power to a reservoir. The fluid matter is flowed from the reservoir. At least a portion of a kinetic energy of the flowing fluid matter is converted into electrical energy. The fluid matter may be liquid or gas.
[0006] U.S. Pat. No. 7,222,487 B1 to Hinkley describes a wheel assembly with tangentially attached fluid receptacles around the perimeter that rotates to power a gravity driven fluid electricity generating assembly. A plunger pump assembly with a drive wheel powered by the wheel assembly pumps a quantity of fluid to fill a fluid receptacle with each motion of a lever arm eccentrically attached to the drive wheel.
[0007] U.S. Pat. No. 7,003,955 B2 to Davis describes an enhanced pumped storage power system. More particularly, the invention is a regenerative power system that utilizes the gravitational forces of downward movement of large quantities of water to convert same to electrical energy. In the preferred mode of implementation, the system utilizes a man-made lake at a first level of elevation. Though higher altitudes can be effective, the lake need only be approximately twenty to thirty feet in elevation. The lake, which may exceed one hundred acres in size, may be elevated above and adjacent a natural body of water, such as seawater at a coastline. As such, sandy terrain associated with the region facilitates initial construction of the system. An underground generator is utilized for the power conversion and pumping of the water back to the upper reservoir during times of low energy demand, allowing for significant noise reduction. Importantly, the system of the present invention may be utilized to provide significant levels of power to serve relatively large geographic areas during times of peak energy demand, when other sources of power are more expensive and subject to power outages. Finally, it should be noted that the components of the system are aesthetically-pleasing in nature, allowing the system to be effectively utilized in a residential area
[0008] U.S. Pat. No. 6,996,937 B2 to Halloran describes a system for generating electrical power using hydraulic supports on which a building structure is mounted. A pump injects fluid into the supports to raise the building structure and thereby store energy in the elevated structure. A valve can be opened to deliver fluid under pressure to a turbine or hydraulic motor driven generator to generate electricity.
[0009] U.S. Pat. No. 6,817,180 B2 to Newman describes a portable hydroelectric apparatus which converts the kinetic energy of water caused by gravity into electrical energy. This conversion is accomplished without the presence of a river or stream. A new type of buoyancy motor is disclosed which is formed as a U-tube erected vertically. One leg and the curved portion at the bottom are filled with a series of separate air-filled tanks. The other leg is filled with water, with a suitable seal at the bottom of the leg through which are made to jut 11/2 tanks so the seal prevents water from leaking downward into the air space of the curved portion of the U-tube. Suitable means prevent the water column in the one leg from pushing the series of tanks out of the U-tube. The leading as well as the succeeding tanks behind it are made buoyant in sequence. In rising through the water-filled leg of the U-tube water is pushed through a nozzle which is made to operate hydroelectric devices. Provision is made to recycle both the water and air-filled tanks.
[0010] U.S. Pat. No. 6,445,078 B1 to Cieslak Jr. describes a system for gravity generation of electricity which includes upper and lower water reservoirs with a conduit between the reservoirs and a pump to continuously pump water from the lower reservoir to the upper reservoir. A number of water containers are positioned side-by-side and mounted for up and down travel between the upper and lower reservoirs. When the containers have attained their upper most position at the upper reservoir, they are engaged by limit switch mechanisms to fill the containers with water from the upper reservoir. Upon being filled the containers travel by gravity to their lower most position to the lower reservoir wherein additional limit switch mechanisms are employed to drain the containers into the bottom reservoir. As the containers travel downwardly, they engage and drive an electric generator for generating large quantities of electricity. Once the containers are at their lower most position and have been fully drained they are driven back up to the upper reservoir for refill by independent geared motors.
[0011] U.S. Pat. No. 6,388,342 B1 to Vetterick, Sr. et al. describes an apparatus and method for converting renewable wave action energy to electrical energy that harnesses fluid wave power by employing a plurality of low-mass buoys floating on a fluid surface connected to low-volume pumps. The pumps transfer fluid from a source to an elevated storage tank. There, the water can be held in the tank as a reserve, when not being immediately used to generate electrical power. When there is a demand for electrical power, the reserve is released from the storage tank and flows, by gravity, through a hydro-electric generator creating an electrical current.
[0012] U.S. Pat. No. 5,430,333 to Binford et al. describes a plurality of inflation devices that are linked to one another to form a loop that is movably restrained so that a segment of the loop is disposed at a lower reference location at the given depth in a first body of water, another segment of the loop is disposed at an upper reference location situated above the lower reference location, another segment of the loop extends along a first path that extends generally upward from the lower reference location to the upper reference location, and another segment of the loop extends along a second path that extends generally parallel to the first path and upward from the lower reference location to the upper reference location. At least a majority of the inflation devices occupying the first path are inflated with gas and at least a majority of the inflation devices occupying the second path are deflated so that inflation devices in the first path move upward and inflation devices in the second path move downward. While each inflation device is proximate to the upper reference location, it is deflated by a compression facility that employs a differential temperature to controllably “stroke” Nitinol. The traveling or movement of the inflation devices is utilized to elevate water that flows, under the force of gravity, through a hydroelectric generating facility that generates electricity.
[0013] U.S. Pat. No. 4,100,743 to Trumbull et al. describes a gravity engine that converts one form of energy into another by using the expansion of a fluid medium to propel each of a plurality of bodies upwardly within one of a pair of adjacent vertical passageways. The expansion of a gas, such as steam supplied from a boiler heated by a solar panel, in a chamber and controlled by valves provides the force to propel the bodies against the force of gravity upwardly to the top of the first passageway. A guide directs the bodies from the top of the first passageway to the top of a second passageway wherein the bodies are stacked so that their combined weight acts upon a pocketed drive wheel at the bottom of the second passageway. The drive wheel is coupled to means such as an electrical generator to convert at least a portion of the potential energy of the stacked bodies into another form of energy. The pocketed wheel may also drive a pump used to return condensate water from the engine case to the boiler. The pocketed wheel carries the bodies, e.g., spheroids, from the lower end of the second passageway for passage into the expansion chamber and thence in the next succeeding cycle, along the first vertical passageway.
[0014] U.S. Pat. No. 29,149 to J. W. Durham describes an engine to obtain motive power which includes an endless chain of buckets arranged within a box of water with suitable pipes or other means of ingress or egress to and from the said box.
[0015] United States Patent Application Publication No. 2003/0127860 A1 to Baron describes a recirculating hydroelectric power generation system that is disclosed. The system includes a reservoir and at least one confinement column connected, and open to the reservoir at the base of the at least one confinement column. A source of pressurized air is provided and means for delivering the air to an air diffuser located near the base of the at least one confinement column. A guide chute is located at the top of the at least one confinement column in such a way that water exiting the top of the at least one confinement column is directed to a waterwheel or turbine, said waterwheel or turbine being operably connected to an electric generator unit.
[0016] Notwithstanding the prior art, the present invention is neither taught nor rendered obvious thereby.
SUMMARY OF INVENTION
[0017] The present invention, in one broad embodiment, is a hydropower system with reciprocal floatation device for generating electric power. It includes a physical structure establishing a circuitous loop for flow of liquid that includes a liquid for circulating in the loop, an upper level, an upper midlevel and a lower midlevel and a lower level, the physical structure including components as follows: a) a liquid return conduit having a conduit outlet at the upper level; b) at least one reservoir located below the conduit outlet, the at least one reservoir being located between the upper level and the lower level, and having liquid dispensing means for dispensing the liquid from the at least one reservoir to a plurality of displacement columns reservoir; c) the plurality of displacement columns, each displacement column being located functionally below the reservoir liquid dispensing means; d) control means and valve means connected to the reservoir liquid dispensing means and the displacement column for sequentially adding and removing liquid to and from the displacement column for upward floatation of at least one weight and corresponding float for subsequent removal of liquid from the displacement column via gravitational force of the weight; e) a weight positioned within each of the displacement columns and arranged therein to reciprocally move up and down and to seal liquid under it at least during downward travel within the displacement column; f) a float connected to each the weight, the float having sufficient buoyancy to lift the weight; g) means for engaging the float to the weight for upward movement of the float and weight in rising liquid and disengagement of the float from the weight for removal of liquid from the displacement column via gravitational force of the weight; wherein, the weight and float have a reciprocal cycle having four positions, the four positions being: a first position with liquid rising, a second position with liquid at its maximum capacity, a third position with liquid releasing, and a fourth position with liquid at its lowest capacity, such that when the liquid is at its lowest capacity the disengaged weight and float engage, when the liquid rises, the engaged weight and float rise in the displacement column, when the liquid is at its maximum capacity the engaged weight and float disengage, and when the liquid is releasing the disengaged weight travels downward via gravity displacing the liquid from the displacement column through the appropriate valve means to the liquid return conduit with the conduit outlet at the upper level, completing a circuitous loop.
[0018] In some preferred embodiments of the present invention hydropower system with reciprocal floatation device for generating electric power, the system valve means includes at least a first valve and a second valve, wherein the first valve is located at the at least one reservoir liquid dispensing means and is functionally connected to the control means to control liquid flow from the reservoir to at least one of the plurality of displacement columns, and the second valve is a one way valve located between at least one displacement column and the liquid return conduit to permit liquid to flow from the at least one displacement column to the liquid return conduit and not vice versa.
[0019] In some preferred embodiments of the present invention hydropower system with reciprocal floatation device for generating electric power, the system includes four displacement columns, and four corresponding liquid dispensing means, four weights, four floats, four means for engaging and disengaging a float to a weight and four first valves and four second valves. In some of these preferred embodiments of the present invention hydropower system with reciprocal floatation device for generating electric power, each of the four weights and four floats are in different of the first position, and second position, the third position and the fourth position of its reciprocal cycle during operation thereof.
[0020] In some preferred embodiments of the present invention hydropower system with reciprocal floatation device for generating electric power, the at least one electric power producing hydro turbine is positioned between the reservoir and the plurality of displacement columns.
[0021] In some preferred embodiments of the present invention hydropower system with reciprocal floatation device for generating electric power, the system further includes a distribution tank for distributing liquid to the plurality of displacement columns, and wherein the return conduit is located at the upper level, the reservoir is located at the upper midlevel, the distribution tank is located at the lower midlevel and the plurality of displacement columns is located at the lower level.
[0022] The present invention, in a second broad embodiment, is a hydropower system with reciprocal floatation device for generating electric power that includes a physical structure with separate float displacement columns and weight displacement columns that are interconnected. The physical structure establishes a circuitous loop for flow of liquid that includes a liquid for circulating in the loop, an upper level, an upper midlevel and a lower midlevel and a lower level. The physical structure including components as follows: a) a liquid return conduit having a conduit outlet at the upper level; b) at least one reservoir located below the conduit outlet, the at least one reservoir being located between the upper level and the lower level, and having liquid dispensing means for dispensing the liquid from the at least one reservoir to a plurality of float displacement columns; c) the plurality of float displacement columns, each float displacement column being located functionally below the reservoir liquid dispensing means; d) a plurality of weight displacement columns located below the plurality of float displacement columns; e) at least one electric power producing hydro turbine located within the loop and upstream from the plurality of displacement columns; f) control means and valve means connected to the reservoir liquid dispensing means and the float displacement columns for sequentially adding and removing liquid to and from the float displacement columns and the weight displacement columns for upward floatation of at least one weight and corresponding float for subsequent removal of liquid from the displacement column via gravitational force of the weight; g) a weight positioned within each of the weight displacement columns and arranged therein to reciprocally move up and down and to seal liquid under it at least during downward travel within the weight displacement column; h) a float connected to each the weight, the float being within the float displacement columns and having sufficient buoyancy to lift the weight; i) means for sequentially filling the float displacement columns to raise the float and the weight, holding one of the float and the weight at a float displacement column liquid filled position, moving the liquid from the float displacement columns to the weight displacement columns, releasing the float and connected weight, so as to permit the weight to remove liquid from the weight displacement columns to the liquid return conduit via gravitational force of the weight; wherein the weight and float have a reciprocal cycle having four positions, the four positions being: a first position with liquid rising in the float displacement columns and the float lifting the weight, a second position with liquid at its maximum capacity in the float displacement columns wherein one of the float and the weight is held to hold the weight in an elevated position in the weight displacement columns, a third position with liquid releasing from the float displacement columns to the weight displacement columns to fill the weight displacement columns with liquid up to the weight, and fourth position with the float or weight released and the weight removing liquid from the weight displacement columns caused by the weight traveling downward via gravity and displacing the liquid from the weight displacement columns through the appropriate valve means to the liquid return conduit with the conduit outlet at the upper level, completing a circuitous loop and driving the at least one electric producing power hydro turbine.
[0023] In some preferred embodiments of the present invention hydropower system with reciprocal floatation device for generating electric power with separate displacement columns for the floats and weights, the system valve means includes at least a first valve and a second valve, wherein the first valve is located at the at least one reservoir liquid dispensing means and is functionally connected to the control means to control liquid flow from the reservoir to at least one of the plurality of float displacement columns, and the second valve is a one way valve located between at least one weight displacement column and the liquid return conduit to permit liquid to flow from the at least one weight displacement column to the liquid return conduit and not vice versa.
[0024] In some preferred embodiments of the present invention hydropower system with reciprocal floatation device for generating electric power with separate displacement columns for the floats and weights, the system includes four float displacement columns and weight displacement columns, and four corresponding liquid dispensing means, four weights, four floats, and four first valves and four second valves. In some of these preferred embodiments of the present invention hydropower system with reciprocal floatation device for generating electric power with separate displacement columns for the floats and weights, each of the four weights and four floats are in different of the first position, and second position, the third position and the fourth position of its reciprocal cycle during operation thereof.
[0025] In some preferred embodiments of the present invention hydropower system with reciprocal floatation device for generating electric power with separate displacement columns for the floats and weights, the at least one electric power producing hydro turbine is positioned between the reservoir and the plurality of displacement columns.
[0026] In some preferred embodiments of the present invention hydropower system with reciprocal floatation device for generating electric power with separate displacement columns for the floats and weights, the system further includes a distribution tank for distributing liquid to the plurality of float displacement columns, and wherein the return conduit is located at the upper level, the reservoir is located at the upper midlevel, the distribution tank is located at the lower midlevel and the plurality of float displacement columns is located at the lower level with the weight displacement columns located below the float displacement columns.
[0027] Additional features, advantages, and embodiments of the invention may be set forth or apparent from consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that both the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate preferred embodiments of the invention and together with the detail description serve to explain the principles of the invention. In the drawings:
[0029] FIG. 1 is a block diagram of one preferred embodiment of the present invention system with floats and weights paired in single displacement columns;
[0030] FIG. 2 is a detailed block diagram of one preferred embodiment of the present invention shown in FIG. 1 ;
[0031] FIG. 3 is a block diagram of another preferred embodiment of the present invention system such as shown in FIG. 1 , but without the distribution tank;
[0032] FIG. 4 is a cross-sectional view of the present invention system of the type shown in FIG. 2 in a first position of its reciprocal cycle;
[0033] FIG. 5 is a cross-sectional view of the present invention system of the type shown in FIG. 2 in a second position of its reciprocal cycle;
[0034] FIG. 6 is a cross-sectional view of the present invention system of the type shown in FIG. 2 in a third position of its reciprocal cycle;
[0035] FIG. 7 is a cross-sectional view of the present invention system of the type shown in FIG. 2 in a fourth position of its reciprocal cycle;
[0036] FIG. 8 is a manifold diagram of a present invention system with four reservoir outlets;
[0037] FIG. 9 is a block diagram of another preferred embodiment of the present invention wherein the weights and floats are located in separate, connected displacement columns;
[0038] FIG. 10 is a detailed block diagram of one preferred embodiment of the present invention system shown in FIG. 9 ;
[0039] FIG. 11 is an a block diagram of another preferred embodiment of the present invention system shown in FIG. 9 ;
[0040] FIG. 12 is a cross-sectional view of the present invention system shown in FIG. 10 in one position of its reciprocal cycle;
[0041] FIG. 13 is a cross-sectional view of the present invention system shown in FIG. 10 in a second position of its reciprocal cycle;
[0042] FIG. 14 is a cross-sectional view of the present invention system shown in FIG. 10 in a third position of its reciprocal cycle;
[0043] FIG. 15 is a cross-sectional view of the present invention system shown in FIG. 10 in a fourth position of its reciprocal cycle;
[0044] FIG. 16 is a manifold diagram of the present invention system shown in FIG. 10 with four reservoir outlets.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0045] The present system generates electric power using a system with a continuous or semi-continuous loop of a circulating liquid. The loop is one or more complete loops and a “semi-continuous” loop is one wherein the flowing liquid is not continuous. The loop includes the circulating liquid, e.g. water, one or more reservoirs, one or more weights, and one or more floatation devices. The liquid flows from a reservoir located above a distribution tank through one or more turbines that can be used to generate power. (In some embodiments, the reservoir simultaneously serves as the distribution tank, in which case a separate distribution tank is not utilized.) The liquid exits from the distribution tank into a plurality of displacement columns which are lower than the distribution tank. Each displacement column includes at least one or more weights and floatation devices. The liquid raises the weight and flotation device to a predetermined height. When the floatation device reaches this height, the weight disengages from the float. The disengaged weight drops via gravity and forces the liquid, e.g. water, through each displacement column. The liquid flows out of the displacement column through a one way valve to prevent backflow and then up a conduit to return to the reservoir.
[0046] Stated in another manner, a circulating liquid flows through a continuous or semi-continuous loop, starting first in a reservoir. The liquid in the reservoir is released from the reservoir, turning at least one turbine, and flows into a distribution tank. The purpose of the distribution tank is to act as an outlet with at least one valve means to empty the liquid into a plurality of displacement columns. Each displacement column has one or more weights and floats, and at least one displacement column has a corresponding engaged pair of a float and weight which rests at the bottom of its column. The density of the weight multiplied by its volume in addition to the density of the float multiplied its volume must be less than the density of the liquid multiplied by the combined volume of the weight and float. Correspondingly, the density of the weight multiplied by its volume must be greater than the density of the liquid multiplied by the volume of the weight. As the liquid enters the displacement column, the float and the weight rise to a predetermined height, at which point the float disengages from the weight. The weight drops via gravity and forces the liquid out of the column through a one way valve to prevent any backflow into the column. The float then engages with the weights at the bottom of the empty displacement column. Once the liquid passes through the one way valve, it passes through a return conduit and returns through an outlet to the aforementioned reservoir.
[0047] Generally, there are two possible arrangements for floatation systems within the scope of the present invention. One arrangement involves physical or distal separation between the float and the weight, as just described, while a second arrangement involves a fixed relationship between the float and the weight with no distance change or separation between the two. The first arrangement is illustrated by FIGS. 1 through 8 and the second arrangement is illustrated by FIGS. 9 through 16 . A detailed discussion of each follows.
[0048] In one preferred embodiment of the hydropower system, a continuous or semi-continuous circuitous loop system shown in both FIG. 1 and FIG. 2 includes a reservoir 1 , with a loop conduit outlet 11 located above it at an upper height (predetermined height h 1 ). The reservoir is located at an upper midlevel height (predetermined height h 2 ), and one or more turbines 2 are located downstream from the reservoir 1 , as shown. One or more distribution tanks 3 , at a lower midlevel position (predetermined height h 3 , wherein h 1 is greater than h 2 , and h 2 is greater than h 3 ). Thus, the reservoir 1 is located above the one or more turbines 2 and below a conduit outlet 11 . The reservoir 1 includes a liquid for circulation, represented by thick arrows in FIG. 1 and FIG. 2 (and all other FIGURES throughout this application). The reservoir 1 has at least one inlet and at least one outlet for the circulating liquid to enter and exit. The circulating liquid exits the reservoir 1 at the one or more outlets and turns one or more turbines 2 to create electric power 10 . While FIG. 1 and FIG. 2 show the one or more turbines 2 between the reservoir 1 and distribution tank 3 , the one or more turbines 2 may be located above the reservoir 1 , at the reservoir 1 , between reservoir 1 and distribution tank 3 , at the distribution tank 3 , between the distribution tank 3 and a plurality of displacement columns 4 , or any combination thereof without exceeding the scope of the present invention. As indicated in FIG. 2 , the electric power 10 can be used for, but is not limited to, stored energy 18 , electric power sent to a grid 17 , energy to power a nearby village 16 or any other consuming entity, or to power an optional auxiliary pump 15 that would help the flow of circulating liquid up a return conduit 7 , as well as any combination of the foregoing, or any other use.
[0049] In one preferred embodiment of the invention, the reservoir 1 has a constant flow of circulating liquid entering and exiting through the inlet and outlet (not shown). The constant flow exiting the reservoir 1 would turn the one or more turbines 2 continuously, allowing a continual generation of electric power 10 .
[0050] The circulating liquid turns the one or more turbines 2 and enters the distribution tank 3 through one or more inlets. The distribution tank 3 is located between the reservoir 1 and a plurality of displacement columns 4 . The distribution tank 3 includes one or more outlets that allow the circulating water to enter the plurality of displacement columns 4 . The distribution tank 3 retains the circulating liquid before the liquid exits into the plurality of displacement columns 4 and acts both as a water level control point and a timing sequence control point for manifolding the liquid to the displacement columns 4 . In some embodiments of the system, the number of outlets on the distribution tank 3 may be directly related to the number of inlets on the each displacement column 4 .
[0051] Each displacement column 4 includes one or more weights and one or more floats. The one or more weights and floats combined are more buoyant than the circulating liquid and rise in the displacement column 4 as the liquid enters through the inlet. Referring to FIG. 2 , the one or more floats and weights rise to a predetermined height 57 at which point the weight disengages from the float 58 , but may or may not still be attached to the float. The weight is less buoyant than the circulating liquid and drops via gravity 59 , forcing the water through a one way valve 6 located in some given position between the displacement column outlet and a return conduit 7 . The one way valve 6 is to prevent backflow into the displacement column 4 . The weight and float may then engage by an engagement mechanism 56 , and reciprocate the rise and drop motions represented by frame 55 in the displacement column 4 .
[0052] Referring to both FIGS. 1 and 2 , the circulating liquid enters the return conduit 7 through the one way valve 6 and, in some preferred embodiments, may pass through one or more optional turbines 8 to generate electric power 9 . The return conduit 7 completes the circuitous loop, allowing the liquid to travel through the conduit outlet 11 and into the aforementioned reservoir 1 through the conduit outlet 11 . It is the rise of the weight by the float and subsequent release of the weight from the float that, in these embodiments, pushes the liquid through the loop to generate power. It is relevant to have a mechanism for making sure that the liquid filling the displacement column lifts the float and attached weight by surrounding both the float and the weight with liquid; yet maintaining the liquid that is below the rising weight to stay below it when the weight has been released and is falling. This may be accomplished by any number of arrangements, such as an annulus or other opening between the weight and the displacement column that is open when the liquid is filling the column and closed when the weight is dropping and pushing the liquid out of the column. Time-based or event-based or movement-based opened/closed one way valves are well known and are well within the abilities of the artisan, and are thus not detailed herein. To put it simply, a one way valve would be located at the weight that would open during the displacement column filling step (float and weight rising) and this one way valve would be closed during the displacement column emptying step (weight falling).
[0053] Each of the plurality of displacement columns 4 includes a set of one or more weights and one or more floats having a reciprocal cycle. The system shown in FIGS. 4 through 7 is the same system shown in FIG. 2 . FIGS. 4 through 7 , respectively, display the system in its four cyclical positions: with liquid rising 48 , with liquid at its maximum 49 , with liquid releasing 50 , and with liquid at its minimum 51 .
[0054] In some preferred embodiments, referring again to the FIGS. 4 through 7 , the displacement column 4 may have two predetermined heights at which point the float 22 and weight 23 will engage and disengage by an engage/disengage mechanism 24 . This mechanism 24 may be swing latches, pin locks or any other lock/unlock device, and may be operated by hydraulics, pneumatics, mechanics, magnetics, electronics or combinations and may effect engagement and disengagement by opening and closing via computer controls, sensors, timers or otherwise. The predetermined height 25 at which the float 22 engages with the weight 23 may be lower than the predetermined height 26 at which the float 22 disengages from the weight 23 in the displacement column 4 . As shown in FIG. 4 , the system is in its first position where liquid is rising 48 . In the first position, the weight 23 and float 22 are engaged and rest at a lower predetermined height 26 in at least one displacement column 4 . The engaged float and weight rise to the predetermined height 22 as the circulating liquid enters the displacement column 4 through the one or more inlets 52 . When the engaged float 22 and weight 23 reach the upper predetermined height 26 , the circulating liquid is at its maximum 49 as shown in FIG. 5 . Some mechanism 24 then disengages the float 22 from the weight 23 and the weight 23 drops via gravity. FIG. 6 shows the third position as the circulating liquid releases 50 from the displacement column 4 . When the weight 23 reaches the lower predetermined height 25 , the circulating liquid is at its minimum 51 , as shown in FIG. 7 , and the weight 23 and float 22 may engage per some mechanism 24 .
[0055] When the weight 23 and float 22 reach the upper predetermined height 26 , the weight 23 disengages from the float 22 , but may or may not still be attached to the float 22 per the engaging and disengaging mechanism 24 . In one preferred embodiment of the present invention, the float 22 is attached to the weight 23 using a pole and key locking mechanism. The pole connects the weight 23 to the float 22 and may connect the two at all times throughout the engaging and disengaging process. The key is used to engage and disengage the two at the predetermined heights. The exact details of the mechanism 24 may be any described above or otherwise, as long as engagement and disengagement are accomplished at the correct water levels and times to effect the sequence of steps described. In another preferred embodiment of the present invention, the float 22 may inflate and deflate at the upper 26 and lower 25 predetermined heights in the displacement column 4 to rise and sink with the weight 23 . As the float 22 inflates, the weight 23 and float 22 rise, and as the float 22 deflates, the weight 23 drops forcing the liquid through the outlet of the displacement column 4 . The exact method of the mechanism is not limited to, but may include, any of these embodiments, as the exact method of the weight 23 and float 22 engagement and disengagement mechanism 24 for the system is a matter of design choice.
[0056] In each displacement column 4 , the disengaged weight 23 must seal the circulating liquid 50 below it on downward travel. In one preferred embodiment of the invention, the weight 23 has one way flaps (one way valves choice) that allow water 29 to flow from above the weight 23 to below the weight 23 and not vice versa. The purpose of the one way flaps is to keep liquid below the weight 23 at all times when the weight 23 drops via gravity so that the releasing liquid 50 can be forced out of the displacement column 4 rather than circulate in the column 4 .
[0057] When the weight 23 is disengaged and dropped via gravity, the circulating liquid 50 is forced through the outlet of the displacement column 4 and through a one way valve 6 at the entrance to a return conduit 7 . The one way valve 6 prevents any backflow of the liquid into the displacement column 4 and therefore prevents the liquid from equilibrating between the return conduit 7 and the displacement column 4 . As the liquid 50 is forced out of the displacement column 4 , the liquid is forced through the return conduit 7 . In some preferred embodiments, an auxiliary pump may or may not be used to help the flow of the liquid through the return conduit 7 . The return conduit 7 is a method of transporting the circulating liquid from the one plurality of displacement columns 4 back to the original reservoir 1 , making the system a continuous loop. In some preferred embodiments, an optional turbine 8 may be located in the return conduit 7 . The optional turbine 8 , like the turbines 2 and 36 between the reservoir 1 and the distribution tank 3 , may generate electric power 9 which can be used for, but is not limited to, stored energy 13 , electric power sent to a grid 12 , energy to power a nearby village 19 , or to power the optional auxiliary pump 14 . The optional turbine 8 may be located anywhere at or between the one way valve 6 and the conduit outlet 11 . The circulating liquid may pass through the optional turbine 8 and exit the return conduit 7 through the conduit outlet 11 located above the reservoir 1 . The liquid may then repeat its course and circulate continuously through the system.
[0058] If more than one displacement column 4 is used, the starting heights of the liquid levels and engaged floats 22 and weights 23 may vary. The purpose of the alternating heights or steps in different displacement columns is to keep a steady flow of circulating liquid through the system.
[0059] FIG. 8 is a manifold 68 of one preferred embodiment of the present invention with four reservoir outlets, two open and two closed, and four distribution columns: one filling, one full, one emptying, and one empty. The four different displacement columns 4 are in four different stages of the reciprocal motion. The first outlet is open, allowing liquid to enter and rise in one displacement column at the position shown in FIG. 4 , frame 60 . Simultaneously, the second outlet is closed, because the circulating liquid is at its maximum capacity in a second column shown in the position in FIG. 5 , frame 61 . A third outlet is closed, preventing circulating liquid to enter into a column in the position shown in FIG. 6 , frame 62 , where liquid is releasing from the column. The fourth outlet is open, and circulating liquid enters a column in the position shown in FIG. 7 , frame 63 , where liquid is at its minimum. For the system to maintain a steady flow, the alternate starting heights may be dependant on the number of displacement columns 4 . In a preferred embodiment, the net flow rates of the liquid entering and filling the column may be equal to the net flow rates emptying and exiting the displacement column 4 . This staggering prevents every displacement column 4 from filling and emptying at the same time, allowing the liquid to flow continuously through the return conduit 7 .
[0060] In one preferred embodiment of the present invention shown in FIG. 3 , a distribution tank is not required. Like the present invention systems in FIG. 1 and FIG. 2 , the system includes a circulating liquid, one or more reservoirs, one or more weights, and one or more floatation devices. Rather than exiting the reservoir 1 to a distribution tank, the reservoir 1 has at least one or more outlets that transport the circulating liquid in one or more distribution conduits 30 to one or more displacement columns 4 . The one or more distribution conduits 30 include at least one or more turbines 2 that the circulating liquid turns to generate electric power 10 . When the liquid enters the one or more displacement columns 4 , the system is similar to the embodiments in FIG. 1 and FIG. 2 , and use a float 22 and weight 23 system to force water out of the columns, through a one-way valve 6 into a return conduit 7 with an optional turbine 8 and back into the reservoir 1 .
[0061] In another broad type of preferred embodiment of the present invention hydropower system, a continuous or semi-continuous circuitous loop system shown in both FIG. 9 and FIG. 10 includes of a reservoir 1 , with a loop conduit outlet 11 located above it at an upper height (predetermined height h 1 ). The reservoir is located at an upper midlevel height (predetermined height h 2 ), and one or more turbines 2 are located downstream from the reservoir 1 , as shown. One or more distribution tanks 3 , at a lower midlevel position (predetermined height h3 wherein h 1 is greater than h 2 , and h 2 is greater than h 3 .) Thus, the reservoir 1 is located above the one or more turbines 2 and below a conduit outlet 11 . Liquid circulation is represented by thick arrows, as mentioned. FIGS. 12 through 15 show two-dimensional cross sections of the system displayed in FIG. 10 in four different positions or the reciprocal cycle. The reservoir 1 is located above one or more turbines 2 and below a conduit outlet 11 . The reservoir 1 has at least one inlet and at least one outlet for the circulating liquid to enter and exit. The circulating liquid exits the reservoir 1 at the one or more outlets and turns one or more turbines 2 to create electric power 10 . While FIG. 9 and FIG. 10 show the one or more turbines 2 between the reservoir 1 , and distribution tank 3 , the one or more turbines 2 may be located above the reservoir 1 , at the reservoir 1 , between reservoir 1 and distribution tank 3 , at the distribution tank 3 , between the distribution tank 3 and a plurality of displacement columns 4 , or any combination thereof without exceeding the scope of the present invention. As indicated in FIG. 10 , the electric power 10 can be used for, but is not limited to, stored energy 18 , electric power sent to a grid 17 , energy to power a nearby village 16 or any other consuming entity or to power an optional auxiliary pump 15 that would help the flow of circulating liquid up a return conduit 7 , as well as any combination of the foregoing, or any other use.
[0062] The circulating liquid 29 from the reservoir 1 passes through a valve 5 , turns at least one turbine 2 , and enters the distribution tank 3 through one or more inlets 38 . The distribution tank 3 is located between the reservoir 1 and a plurality of float displacement columns 31 . The distribution tank 3 includes one or more outlets with a controlled valve 27 that allows the circulating liquid to enter the plurality of float displacement columns 31 located at some height above a plurality of weight displacement column 32 . The distribution tank 3 retains the circulating liquid 37 before the liquid exits into the plurality of float displacement columns 31 .
[0063] Each float displacement column 31 includes one or more floats. The plurality of float displacement columns 31 are located functionally above at least one of the plurality of weight displacement columns 32 . The plurality of float displacement columns 31 with a plurality of floats 22 may run in sequence or in parallel and may have simultaneous lift with sequential drainage.
[0064] Referring to the FIGS. 12 , 13 , 14 AND 15 , A mechanism 39 connects at least one weight 23 and one float 22 from one float and weight column. The liquid enters the float displacement columns 31 . When the liquid is at a maximum in the float displacement column 31 , the liquid passes through at least one valve and enters the weight distribution column 32 . When the liquid in the weight distribution column 32 is at its maximum, the weight 23 drops, forcing the liquid to exit the weight distribution column 32 through a one way valve 6 and into a return conduit 7 . The liquid may then pass through an optional turbine 8 to generate electric power 9 before exiting through a conduit outlet 11 into the reservoir 1 .
[0065] FIGS. 12 through 15 , respectively display the system in its four possible positions: with liquid at its maximum 40 in the float displacement column 31 and liquid at its minimum 41 in the weight displacement column 32 , with liquid releasing 42 in the float displacement column 31 and liquid rising to its maximum 43 in the weight displacement column 32 , with liquid at its minimum 44 in the float displacement column 31 and liquid releasing from its maximum 45 in the weight displacement column 32 , and with liquid rising 46 in the float displacement column 31 and the liquid at its minimum 47 in the weight displacement column 32 . There are two valves shown in the figures in the pipe or conduit connecting the float displacement column 31 to the weight displacement column 32 . Although valve 33 and valve 34 are displayed, the system only involves at least one valve which may be positioned either at the outlet of the float displacement column 31 , the inlet to the weight displacement column 32 , anywhere in between the two, or any combination thereof.
[0066] The mechanism 39 may keep the weight 23 and float 22 at a predetermined distance from one another and may maintain that constant distance throughout each reciprocal motion. The one or more floats 22 attached the to the one or more weights 23 have a combined buoyancy greater than the circulating liquid, allowing each to rise in their respected columns as the liquid passes through the valve 27 and enters the float displacement column 31 . FIG. 12 shows the position with liquid at its maximum 40 in the float displacement column 31 and liquid at its minimum 41 in the weight displacement column 32 . At this position, the float 22 is at its maximum predetermined height 53 and is connected by some mechanism 39 to the weight 23 at its maximum predetermined height 54 . When the weight and float reach this height, both valve 33 and valve 34 open, allowing the liquid to release 42 from the float displacement column 31 and rise to its maximum 43 in the weight displacement column 32 as shown in FIG. 13 . FIG. 14 shows the liquid at its minimum 44 in the float displacement column 31 and the liquid releasing from its maximum 45 in the weight displacement column 32 . When the liquid reaches its maximum 43 in the weight displacement column 32 , the weight 23 attached to the float 22 both drop. The weight is less buoyant than the circulating liquid and seals the liquid by some method below it. The float 22 drops through the empty float displacement column 31 as the weight 23 drops forcing the liquid out of the weight displacement column 32 . FIG. 15 shows the fourth position with liquid rising 46 in the float displacement column 31 and the liquid at its minimum 47 in the weight displacement column 32 . As liquid continues to enter the float displacement column 31 , the float 22 rises to its predetermined height 53 and continually reciprocates the rise and fall motions.
[0067] If more than one float displacement column 31 and weight displacement column 32 are present in the system, the starting heights of the liquid levels may be different in each column. The purpose of the alternating heights is to keep a steady flow of circulating liquid through the system. FIG. 16 is a manifold 21 of one preferred embodiment of the present invention with four reservoir outlets, two open and two closed, four float displacement columns 31 and four weight displacement columns 32 : one weight displacement column empty, one weight displacement column filling, one weight displacement column full, and one weight displacement column emptying. The four different weight and float distribution columns are in four different stages of the reciprocal motion. The first outlet is open, entering one float displacement column at the position shown in FIG. 12 , frame 64 with the circulating liquid rising in the float displacement column. Simultaneously, the second outlet is closed, as another float displacement column in the position shown in FIG. 13 , frame 65 is releasing its liquid. A third outlet is closed, preventing circulating liquid to pour into another float displacement column in the position shown in FIG. 14 , frame 66 , where liquid is at its minimum in the column. The fourth outlet is open, and circulating liquid enters another float displacement column in the position shown in FIG. 15 , frame 67 , where liquid is rising in the column. For the system to maintain a steady flow, the alternate starting heights may be dependant on the number of float 31 and weight displacement columns 32 . In a preferred embodiment, the net flow rates of the liquid entering and filling the float displacement column 31 may be equal to the net flow rates emptying and exiting the weight displacement column 32 . This staggering prevents each float displacement column and weight displacement column from filling and emptying at the same time, allowing the liquid to continuously enter and exit the return conduit 7 .
[0068] In one preferred embodiment of the present invention shown in FIG. 11 , a distribution tank is not required. Like the systems in FIG. 9 and FIG. 10 , the system includes a circulating liquid, one or more reservoirs, one or more weights, and one or more floatation devices. Rather than exiting the reservoir 1 to a distribution tank, the reservoir 1 has at least one or more outlets that transport the circulating liquid in one or more distribution conduits 3 to one or more float displacement columns 31 then to one or more weight displacement columns 32 . The one or more distribution conduits 3 include at least one or more turbines 2 that the circulating liquid turn to generate electric power 10 . When the liquid enters the one or more float displacement columns 31 , the system is similar to the embodiments in FIG. 9 and FIG. 10 , and used a float, weight, and valve system to force water out of the two columns, through a one-way valve 6 into a return conduit 7 with an optional turbine 8 to generate power 9 , through an outlet 11 and back into the reservoir 1 .
[0069] The system displayed in FIGS. 12 through 15 is similar to the system displayed in FIGS. 4 through 7 , with the exception of utilizing separate displacement columns for floats and weights, and the fact that these new embodiments do not involve engagement and disengagement of the floats and corresponding weights. In FIGS. 4 through 7 , the system includes a plurality of displacement columns 4 that each contains at least one weight 23 and float 22 connected by some mechanism 24 . In FIGS. 12 through 15 the system includes a plurality of float displacement columns 31 and a plurality of weight displacement columns 32 connected by at least one valve 33 . The system includes a mechanism 39 that connects a float 22 and a weight 23 within the two columns. In each system, the liquid follows an identical path until it exits the distribution tank 3 and passes through the valve 27 and continues to follow an identical path once the liquid passes through the one way valve 6 .
[0070] Both systems shown FIGS. 4 through 7 and systems shown in FIGS. 12 through 15 include valves. Each valve may be connected to the control system 28 that may open and close the valves at predetermined increments for a predetermined amount of time. Each valve may be controlled by, but is not limited to, the control system 28 via a remote control, a pre-programmed timer, a computerized system, or any combination thereof.
[0071] Although some the outlets in FIGS. 4 through 7 and FIGS. 12 through 15 are shown to end above the circulating liquid and some below, the figures do not restrict the design. Each of the outlets may end either above, below, or at an equal level with the circulating liquid.
[0072] Although particular embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those particular embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.
[0073] For example, the present invention has been described in accordance with the Summary and the description of the drawings without specific mechanical or physical details. Any functional design of the present invention systems may be used and are within the skills of the artisan. For example, the conduits could be metal or plastic piping and could include natural or man-made viaducts; the displacement columns could be tanks of any footprint shape, including but not limited to circle, square, rectangle, ellipse, or polygon. The floats may be foam, airbags, closed containers such as metal or plastic drums or may be balloons made of heavy duty fabric with air or lighter than air gasses and may be permanently inflated or cyclically inflated and deflated.
[0074] The present invention systems may include natural or man-made supplementive features, such as natural lakes or ponds as system reservoirs. Auxiliary pumps that may be solar powered or otherwise powered may be included for priming, supplementing, regulating, backing up, or otherwise assisting the present invention systems to move fluids from levels below the reservoir to the return conduit outlet or to the reservoir.
[0075] The hydro turbines utilized in present invention systems may be positioned at any location where they will function effectively and in those embodiments where there are separate float displacement columns and weight displacement columns, one or more hydro turbines may be located between these two different columns, as well as other positions shown or described above.
[0076] As mentioned above, the present invention systems use a plurality of displacement columns, and at least two are necessary to minimize down time or idol time (no hydro turbines being driven), but much like a automobile engine where at least four cylinders make for a smooth drive, at least four displacement columns are utilized in some embodiments. However in some embodiments, tens or hundreds of displacement columns may be included within the scope of the present invention. Also the floats and weights are described generally as one float for each weight. However, some present invention systems could have two, three, or more floats for each weight. These plural floats for a single weight may operate in separate or the same tanks and could operate in series or in parallel and could include float displacement columns at different elevations so as to include cascading fluid flow to increase any lift capacity of the system and/or provide structural design options.
|
A hydropower system generating electric power includes a circuitous loop for flow of liquid with: a) a liquid return conduit; b) at least one reservoir below the conduit outlet, with a dispenser for dispensing liquid from the reservoir to a plurality of displacement columns; c) displacement columns below the reservoir; d) controls and valves connected to the reservoir dispenser and displacement column for sequentially adding and removing liquid to and from the displacement column for upward floatation of the weight and corresponding float and for subsequent removal of liquid from the displacement column via gravitational force of the weight; e) weights within the displacement columns; f) floats connected to each weight; g) engagement mechanism for engaging the float to the weight for upward movement of the float and weight in rising liquid and disengagement of the float from the weight for removal of liquid from the displacement column via gravitational force.
| 5
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 14/607,007, filed on Jan. 27, 2015, the disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to improvements in hospital basins, and more particularly to improvements in a basin being usable for retaining water for sponge bathing of a patient or for emesis, or a basin being alternatively and particularly adapted for irrigating wounds, each of which may be efficiently accomplished using the transformable basin of the present invention.
BACKGROUND OF THE INVENTION
A basin, particularly at a hospital and other facility that cares for patients, may be used for washing of the patient (i.e., a sponge bath). An example of such a basin is shown, for example, by U.S. Pat. No. 3,611,450 to Bost, and by U.S. Design patent No. D546,943 to Kammer. This type of basin may also be used for carrying fluids, carrying tools, as a hospital admission kit, as a waste bin, or the basin may be further adapted to serve as an emesis basin, as shown by U.S. patent Design No. D197,106.
A number of prior art devices have been developed to be more particularly adapted for irrigating a patient's wounds. Several examples of such devices are shown by U.S. Pat. No. 2,709,435 to Kress, U.S. Pat. No. 6,609,257 to O'Geary, U.S. Pat. No. 7,785,303 to Tapadiya, U.S. Patent Application Pub. No. 2011/0225726 to Dominguez, and U.S. Patent Application Pub. No. 2012/0222210 to Wiggins.
However, none of the prior art basins are adapted to efficiently and effectively serve in both roles. Certain basin embodiments disclosed herein are each adapted to transform to be effectively used for either purpose.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a first embodiment of a basin built in accordance with the present invention, having opposing hinged doors that are shown in a closed position.
FIG. 2 is a rear view of the tub member and hinged doors of the basin of FIG. 1 , but shown with its doors in an open position.
FIG. 3 is a top view of the basin of FIG. 1 .
FIG. 4 is an end view of the basin of FIG. 1 .
FIG. 5 is the view of FIG. 2 , but shown enlarged and without the hinged door.
FIG. 6 is a side view of a small door used for the basin of FIG. 1 .
FIG. 7 is a top view of the small door of FIG. 6 .
FIG. 8 is a side view of a large door used for the basin of FIG. 1 .
FIG. 9 is a bottom view of the large door of FIG. 8 .
FIG. 10 is a perspective view of the fastening pin used for the pivotal mounting of the hinged doors for the basin of FIG. 1 .
FIG. 11 is a cross-sectional view of the side wall of the tub member and the corresponding door of a basin with opposing hinged doors built in accordance with the present invention, with the door shown in the open position.
FIG. 12 is a side elevational view of a section of the side wall of the tub member and corresponding door of a basin with opposing hinged doors built in accordance with the present invention with the door in the closed position.
FIG. 13 is a side perspective view of a basin with opposing hinged doors built in accordance with a round embodiment of the present invention having its doors in the closed position.
FIG. 14 is a perspective view of a second embodiment of a basin built in accordance with the present invention, having opposing hinged doors.
FIG. 15 is an end view of the basin of FIG. 14 .
FIG. 16 is a top view of the basin of FIG. 14 .
FIG. 17 is a side view of the basin of FIG. 14 .
FIG. 18 is a reverse perspective view of the basin of FIG. 14 , showing the doors prior to attachment to the tub portion.
FIG. 19 is an enlarged perspective section view through the tub and one of the doors and its elastomeric spring, for the basin of FIG. 14 .
FIG. 20 is the section view of FIG. 19 , but shown with the door actuated away from its sealed position against the tub.
FIG. 21 illustrates the dimensions for certain features of the 5 th percentile male and female, the 50 th percentile male and female, and the 95 th percentile male and female.
FIG. 22 illustrates the dimensions for certain features of the thigh and calf for the 5 th percentile male and female, the 50 th percentile male and female, and the 95 th percentile male and female.
FIG. 23 illustrates the dimensions for certain features of the mid-arm and forearm for the 5 th percentile male and female, the 50 th percentile male and female, and the 95 th percentile male and female.
FIG. 24 is a reverse perspective view of the basin of FIG. 14 , but shown with the door in the unsealed position, and with a patient's arm extending across the two reduced height wall areas, in preparation for wound irrigation therein.
FIG. 25 is an idealized side view showing a representative arm cross-section resting upon the top of the reduced height wall area, and showing the clearances that would be obtained between the arm and the transitional portions of the reduced height wall area.
FIG. 26 is a perspective cross-sectional, view of the basin of FIG. 24 , shown with two liters of water in the bottom of the tub.
FIG. 27 is a reverse perspective view of the basin of FIG. 14 , but shown with the door in the unsealed position, and with a patient's leg extending across the two reduced height wall areas, in preparation for wound irrigation therein.
FIG. 28 is an idealized side view showing a representative leg cross-section resting upon the top of the reduced height wall area, and showing the clearances that would be obtained between the leg and the transitional portions of the reduced height wall area.
FIG. 29 is a bottom perspective view of the basin of FIG. 14 , showing anti-skid waveforms protruding from the bottom of the tub portion of the basin.
FIG. 30 is a perspective cross-sectional view showing the anti-skid waveforms protruding outward from the bottom of the tub portion of the basin, as seen in FIG. 29 , and showing waveform shapes protruding inwardly to form anti-splash baffles.
FIG. 31 is a perspective view of a third embodiment of a basin built in accordance with the present invention, having tear-away door panels.
FIG. 32 is an end view of the basin shown in FIG. 31 .
FIG. 33 is a top view of the basin of FIG. 31 .
FIG. 34 is a side view of the basin of FIG. 31 .
FIG. 35 is a reverse perspective view of the basin of FIG. 31 , but shown with one of the tear-away door panels partially removed.
FIG. 36 is a reverse perspective view of the basin of FIG. 31 , but shown with one of the tear-away door panels having been completely removed.
FIG. 37 is a perspective section view through one of the tear-away door panels and the tub of the basin of FIG. 31 .
FIG. 38 is a cross-sectional view through one of the tear-away door panels and the tub of the basin of FIG. 31 .
FIG. 39 is a perspective view of a fourth embodiment of a basin built in accordance with the present invention, having elastomeric end panels overmolded with the tub.
FIG. 40 is an end view of the basin of FIG. 39 .
FIG. 40A is the end view of FIG. 40 , but shown prior to overmolding of the flexible elastomer end panels onto the reduced height wall areas at each end of the tub.
FIG. 41 is a top view of the basin of FIG. 39 .
FIG. 42 is a side view of the basin of FIG. 39 .
FIG. 43 is a perspective section view through, one of the elastomeric end panels and the tub of the basin of FIG. 39 .
FIG. 44 is a reverse perspective view of the basin of FIG. 39 , shown with the elastomeric end panels deforming to conform to, and support, a patient's arm, in preparation for wound irrigation therein.
FIG. 45 is a perspective view of a fifth embodiment of a basin built in accordance with the present invention, having accordion-shaped wall portions.
FIG. 46 is an end view of the basin of FIG. 45 .
FIG. 47 is a top view of the basin of FIG. 45 .
FIG. 48 is a side view of the basin of FIG. 45 .
FIG. 49 is a perspective section view through the basin of FIG. 45 .
FIG. 50 is a reverse perspective view of the basin of FIG. 45 , shown with the accordion end panels deforming to conform to, and support, a patient's arm, in preparation for wound irrigation therein
DETAILED DESCRIPTION OF THE INVENTION
Referring to the embodiment shown in FIGS. 1, 2, 3, and 4 , a basin with opposing hinged doors 100 is shown as a four-sided tub member 110 that includes a first side wall 111 , a second, side wall 112 , a large door side wall 113 , and a small door side wall 114 , each of which extend up from a tub floor 115 . In this embodiment, the tub member 110 is defined by a rectangular shape with the first side wall 111 and the second side wall 112 defining its longitudinal sides. It is contemplated, however, that in other embodiments the large door side wall 113 and small door side wall 114 may define the longitudinal sides, or the tub member 110 may be defined by an alternate shape suitable for a basin, such as a kidney shape, a round shape, an oval shape, etc. It is additionally contemplated that the tub member 110 may be constricted in a range of sizes, whether to accommodate different body parts or just different size requirements for different patients.
In this embodiment, the large door side wall 113 includes a large door frame section 130 and the small door side wall 114 includes a small door frame section 140 . The large door frame section 130 outlines a semi-circular shaped large opening extending down from the top of the large door side wall 113 into the body of the large door side wall 113 . The large door frame section 130 includes a large mounting frame 131 which defines a frame structure that extends around the border of the large opening that extends into the large door side wall 113 , thereby creating a large border surface area 132 having increased thickness relative to the thickness of the large door wall 113 . The large opening may have, for example, a diameter of 5.5 inches, resulting in it extending 5.5 inches wide across the large door side wall 113 at the widest point and 2.75 inches into the large door side wall 113 at its deepest point.
The large door frame section 130 may have a large door member ISO pivotally attached thereto, and sized to fit into the large mounting frame 131 , thereby allowing it to be moved into a closed position in the large door frame section 130 , as illustrated by FIG. 1 , into an open position relative to the large door frame section 130 , as illustrated in FIG. 2 , as well as into other positions between the closed and open positions. It is contemplated, however, that the large door frame section 130 and corresponding large door member 150 may together be constructed in alternate shapes and different sizes relative to the large door side wall 113 .
The small door side wall 114 may be structured in a similar manner as the large door side wall 113 , with the only substantive difference being that the small door frame section 140 is smaller than the large door frame section 130 . Accordingly, the small door frame section 140 outlines a semicircular shaped small opening extending down from the top of the small door side wall 114 into the body of the small door side wall 114 . The small door frame section 140 includes a small mounting frame 141 which defines a frame structure that extends around the border of the small opening that extends into the small door side wall 114 , thereby creating a small border surface area 142 having increased thickness relative to the thickness of the small door side wall 114 . In this embodiment, the small opening has a diameter of 4 inches, resulting in it extending 4 inches wide across the small door side wall 114 at the widest point and 2 inches into the small door side wall 114 at its deepest point.
The small door frame section 140 may have a small door member 160 pivotally attached thereto, and sized to fit into the small mounting frame 141 , thereby allowing it to be moved into a closed position in the small door frame section 140 , as illustrated in FIG. 1 , into an open position relative to the small door frame section 140 , as Illustrated in FIG. 2 , as well as into other positions between the closed and open positions. It is contemplated, however, that the small door frame section 140 and corresponding small door member 160 may together be constructed in alternate shapes and sizes relative to the small door side wall 114 .
It is contemplated that by including the large door frame section 130 and the small door frame section. 140 , the tub member 110 may provide a modified basin means for collecting debris, water, run-off materials or specimens. Further, by corresponding to the respective large door frame section 130 and the small door frame section 140 , the large door member 150 and small door member 160 each provide a door means for selectively opening and closing an entry point in the tub member 110 .
Referring now to FIGS. 3, 4, 5, 6, 7, 8, 9, 10, 11, and 12 , the large border surface area 132 and small border surface are 142 each include a centrally disposed ridge member 133 , 143 running longitudinally through it. The ridge members 133 , 143 , along with corresponding centrally disposed recesses 151 , 161 in large door member 150 and small door member 160 , respectively, provide a locking means for securing the large door member 150 and small door member 160 in the large door frame section 130 and small door frame section 140 , respectively, when the respective door member is in the closed position. The locking means is operative to allow the large door member 150 to snap into the large door frame section 130 when the large door member 150 is moved to the closed position. In this regard, when the large door member 150 is moved to the closed position, the ridge member 133 frictionally passes along the circumferential surface of the large door member 150 as it moves toward the closed position and engages the recess 151 once the large door member 150 is in the closed position (i.e., is retained therein in a friction fit). When secured in the closed position, the large door member 150 is operative to close off the large opening outlined by the large door frame section 130 , and forms a watertight seal.
The locking means operates in essentially the same manner with the small door member 160 and the small door frame section 140 . Thus, the small door member 160 snaps into the small door frame section 140 when the small door member 160 is moved to the closed position. When the small door member 160 is moved to the closed position, the ridge member 143 frictionally passes along the circumferential surface of the small door member 160 as it moves toward the closed position and engages the recess 161 once the small door member 160 is in the closed position. As with the large door member, when the small door member 160 is secured in the closed, position, it closes off the small opening outlined by the small door frame section 140 and forms a watertight seal.
A small door hinge mechanism enables the small door member 160 to be pivotally attached to the small door side wall 114 . The small, door hinge mechanism is defined by two hinge attachment arms 162 which extend down from the bottom of the small door member 160 , a small wall receiving member (not shown, but identical to the large wall receiving member 123 discussed below) which extends out from the side of the small door side wall 114 underneath the small door frame section 140 , and a fastening pin 120 . The fastening pin 120 is structured to pass transversely through holes in both the small wall receiving member and the two hinge attachment arms 162 and remain fixed therein, thereby forming a pivot axis about which the small door member 160 rotates relative to the small door side wall 114 .
The large door member 150 and large door side wall 113 are connected through a large door hinge mechanism, which employs the same type of components as the small door hinge mechanism. Accordingly, the large door hinge mechanism is defined by two hinge attachment arms 152 which extend down from the bottom of the large door member 150 , a large wall receiving member 123 which extends out from the side of the large door side wall 113 underneath the large door frame section 130 , and another fastening pin 120 . As with the small door hinge mechanism, the fastening pin 120 is structured to pass transversely through holes in both the large wall receiving slot member 123 and the two hinge attachment arms 152 and remain fixed therein, thereby forming a pivot axis about which the large door member 150 rotates relative to the small door side wall 113 .
In this embodiment, a secondary locking means may be included for securing the large door member 150 and small door member 160 in the large door frame section 130 and small door frame section 140 respectively, when the respective door member is in the closed position. The second locking means, as illustrated on the large door side wall 113 in FIGS. 11 and 12 , may include a locking recess 153 formed in the area between the two hinge attachment arms 152 and the large door member 150 and the abutment formed by large mounting frame 131 as it extends outward from the large door side wall 113 . The corresponding locking recess 153 and abutment engage when the large door member 150 is in the closed position relative to the large door frame section 130 , thereby providing a supplemental lock for keeping the large door member 150 in place. It is understood that the small door member 160 and small door frame section 140 include identical structures, thereby enabling such a supplemental lock in their operation.
Referring now to FIG. 13 , an alternate embodiment of a basin with opposing hinged doors 200 is shown as a circular tub member 210 with a circumferential side wall 211 that includes a large door frame section 230 surrounding a large opening 231 and small door frame section 240 surrounding a small opening 241 . As with the rectangular embodiment, integral with the large door frame section 230 is a large door member 250 sized to fit into the large opening 231 , thereby allowing it to be moved into a closed position in the large door frame section 230 and integral with the small door frame section 240 is a small door member 260 sized to fit into the small opening 241 , thereby allowing it to be moved into a closed position in the small door frame section 240 . It is contemplated that the large door frame section 230 and large door member 250 and the small door frame section 240 and small door member 260 , respectively, are operative to move between an open and closed position in the same manner as described above for the rectangular embodiment.
It is also contemplated that for any of the above described embodiments, that the large and small door members may alternatively be configured to pivot inwardly into the basin to be in the open position.
FIG. 14 illustrates a perspective view of another embodiment of a basin formed in accordance with the present invention. Basin assembly 300 may include a tub portion 301 that is formed with a substantially flat base 302 , from which may upwardly extend a wall 303 . Wall 303 may be integrally formed with base 302 , and may be formed as a single continuous member, which, as noted above, may be formed to be any desired shape including a circular shape, a rectangular shape, etc. Merely to be illustrative, a rectangular shape is shown throughout FIGS. 14-47 . The wall 303 may have markings 303 Mi, 303 Mii, etc., integrally formed therein, or stenciled thereon, to indicate the fluid level (e.g., 2 liter, 3 liters, etc.).
A first set of opposing portions of the top of the wall 303 may have a return flange that forms a first lip 304 A and a second lip 304 B, which may be used for carrying and handling of the basin assembly 300 . The return flange that forms the lip 304 A and 304 B may gradually reduce in size, until no lip is formed at the top of wall 303 . A second set of opposing portions of the wall 303 may not have a lip formed thereat, and each of those portions may instead have a reduced height wall area, as seen in FIG. 18 .
A first reduced height wall area 305 may have a central portion being substantially horizontal, which may then gradually transition upwardly at each end to the full wall height. Alternatively, the reduced height area may be semi-circular, or half-moon shaped, as described above. The second reduced height area 306 may be formed the same as the first reduced height area 305 , being formed to have the same height and length and transition. Alternatively, any or all of the dimensions of the second reduced height area may be different than the first reduced height area (i.e., the first and second reduced height areas may be different as the unique shape may accommodate different sized door panels, discussed hereinafter).
The reduced height areas 305 and 306 of wall 303 may permit a patient's limb to extend out from those openings, with a wounded portion of the limb being positioned over the base 302 of tub 301 , as seen for example in FIG. 24 , to undergo irrigation therein. To help provide ergonomic support for the patient's limb, the wall 303 may have a first inward bulge 307 and a second inward bulge 308 respectively formed at the first reduced height area 305 and the second reduced height area 306 . The extent of the inward bulge may serve to provide an area of sufficient width, so as to be comfortable when supporting the patient's limb, rather than the limb merely being supported, by a narrow flange that may dig into the skin of the person's arm or leg. The underside of the inward bulges 307 and 308 may also serve as a stable set of handles for lifting of the basin assembly 300 , instead of using the lip 304 A/ 304 B, particularly when it may contain a substantial quantity of fluid therein.
The first reduced height wall area 305 and the second reduced height wall, area 306 may each be releasably sealed using a door panel, so that the basin may be capable of holding fluid all the way up to the top of wall 303 (i.e., at a level above the reduced height wall areas). A first door panel 350 may be configured to releasably seal the first reduced height area 305 , and a second door panel 360 may similarly be configured to releasably seal the second reduced height area 306 . Each door panel may be formed of a suitable material, including, but not limited to, polypropylene-based thermoplastic elastomer.
To effectively seal the reduced height areas of wall 303 , each of the door panels 350 and 360 may be respectively shaped to correspond to a portion of the periphery of the first reduced height area 305 and the second reduced height area 306 . To releasably seal the reduced height areas of wall 303 , each of the door panels 350 and 360 may be mounted to the tub 301 using respective elastomeric spring members 370 and 380 .
As seen in FIG. 19 , a first end 371 of the elastomeric spring member 370 may be fixedly secured to a portion of the tub 301 proximate to the top of the first reduced height area 305 , and a second end 372 of the spring member may be fixedly secured to a corresponding location on the door panel 350 . The ends of each of the elastomeric spring members 370 / 380 may each be fixedly secured to the tub 301 and respective door panels 350 / 360 using any suitable attachment means, including, but not limited to, adhesive, mechanical fasteners, ultrasonic welding, etc., or any combination of the above.
When the nurse or other medical practitioner desires to use the basin assembly 300 for wound irrigation of a patient's limb, he/she may move the door panels 350 / 360 away from the first and second reduced height areas 305 / 306 of the wall 303 , causing the elastomeric spring members 370 / 380 to deform elastically, as shown generally in FIG. 20 .
To releasably retain the door panels 350 / 360 away from the sealed position at each of the reduced height areas of wall 303 , hook and loop fastening materials (e.g., Velcro®) may be used. As shown in FIG. 20 , a first piece 353 of the hook and loop fastening material (either the hook material or the loop material) may be fixedly secured to the exterior of the door panel 350 , and the corresponding piece of material 354 (the other of the hook material or loop material) may be fixedly secured to the tub 301 . When the door panel 350 is displaced from its sealed position it may be secured using the Velcro to be as shown in FIG. 24 . The size of the pieces ( 353 / 354 ) of hook and loop materials, and the peel strength may be selected to be able to withstand separation due solely to the restoring force provided by the elastomeric spring member 370 so that the door panel may only be returned to the sealed position by being detached by the nurse or other medical personnel. The door panel 360 may similarly be secured using hook and loop materials.
To enhance, the leak-proof nature of the door panels 350 / 360 , which, are biased into contact with the tub 301 by the elastomeric spring members 370 / 380 , each panel may be made of a stiff plastic material, and the faying portion of its edge may have a more pliable seal member 350 S/ 360 S fixedly attached thereto, as seen in FIG. 20 . The respective seal members 350 S/ 360 S may be formed of a suitable material, which may include, but is not limited to, PTFE, nitrile, neoprene, EPDM rubber, fluorocarbon, silicone, etc.
To further enhance the leak-proof nature of the door panels 350 / 360 being biased into contact with the tub 301 , the reduced height areas 305 / 306 of the wall 303 may have respective curved flanges 305 F/ 306 F protruding outwardly therefrom ( FIG. 20 ), which may form a wedge-shaped opening. The corresponding portion of the seal members 350 S/ 360 S on each door panel may be formed to have a similar wedge-shaped flange 350 SF, so that the biasing provided by the elastomeric spring members 370 / 380 may cause the seal members to become wedged within the wedge-shaped opening formed by the curved flange of the reduced height wall areas 305 / 306 of the wall 303 , as seen generally in FIG. 19 .
FIGS. 21-23 illustrate key anatomical dimensions for each of the 5 th percentile man and woman, the 50 th percentile man and woman, and the 95 th percentile man and woman, which are useful for determining suitable sizes for the door panels 350 / 360 , and corresponding sizes/shapes for the reduced height wall areas 305 / 306 of the wall 303 .
FIG. 24 illustrates a patient's forearm disposed across the reduced height wall areas 305 / 306 of basin assembly 300 , and resting on the inward bulges 307 and 308 . As shown therein a live inch separation may be used at the largest gap tor each of the reduced height areas. FIG. 25 illustrates a cross-sectional view of the arm at the reduced height wall area, and the clearance afforded the arm. A five inch gap would provide adequate clearance for the largest arm dimensions of the 95 th percentile man (i.e., from FIG. 23 , 4.7 inch mid-arm width and 4.1 inch forearm width), which would also provide clearance for the 95 th percentile woman, with the woman's features each being correspondingly smaller than the man's features. Alternatively, a 5.25 inch or a 5.5 inch gap may be used to provide additional clearance for the 95 th percentile man. Also, different sized door panels 350 / 360 , and corresponding reduced height wall areas 305 / 306 may be used at the two locations (i.e., a smaller door panel for the forearm and a larger door panel for the mid-arm). However, use of the same size door panels eliminates the need to specifically orient the basin assembly during use, to match the larger and smaller basin openings with the patient's forearm and mid-arm.
FIG. 26 illustrates that for the use of a panel assembly with a base width of roughly ten inches, a length of approximately 15 inches, a wall height of five inches, and a reduction in wall height of roughly 2.5 inches, that two liters of saline solution would fill approximately one-half of the basin volume below the door opening.
FIGS. 27-28 illustrate that a larger gap may be needed for use of the basin assembly 300 for wound irrigation of a patient's leg (i.e., as seen in FIG. 22 , the 95 th percentile thigh width of a man is 7.5 inches).
FIG. 29 illustrates that the bottom of the tub 302 of basin assembly 300 may be formed with protruding waveform shapes 302 TP that may protrude outward from the bottom of base 301 , to provide an anti-slip feature. FIG. 30 also shows the outward protruding waveform shapes 302 TP, and additionally shows that waveform shapes 302 IP may be formed to protrude inwardly to form anti-splash baffles that may reduce the walk and splash effect.
It should be noted that each of the herein disclosed basin embodiments may be formed, to be stackable (i.e., at least wall 303 may be appropriately formed, and may be outwardly angled—see FIG. 15 and FIG. 17 ). Each of the basin embodiments may also be formed to be sterilizable, and autoclavable.
FIGS. 31-38 illustrate views of another embodiment of a basin formed in accordance with the present invention. Basin 400 may be formed substantially the same as basin 300 , except that instead of having actuable door panels formed as separate parts that may be attached to the tub using an elastomeric spring, it may include a pair of tear-away panels 450 / 460 that may be integrally formed with the tub. The tear-away panels 450 / 460 may be formed according to the teachings of U.S. Pat. No. 3,458,080 to Laurizio, the disclosures of which are incorporated herein by reference. The tear-away panels 450 / 460 may be formed, by creating a weakened zone at the desired periphery tor each panel (i.e., periphery 450 P for panel 450 ), by forming the tub with a notch, therein, or by scoring of the tub along the desired periphery, after the tub is formed. The notch or scoring may be sufficiently deep so that medical personnel possessing even minimal strength may be able to remove the panel, by peeling it away from one of its ends, similar to the pop top on a can of soda. The strength provided by the weakened connection between the panel and the tub, prior to being torn away, should be sufficient to avoid inadvertent tear-out, and should be water-tight FIG. 35 shows panel 460 in the process of being removed, while FIG. 36 shows the panel completely removed. FIGS. 37 and 38 show that the lowermost periphery of each of the panels may preferably be positioned below the top surface of the corresponding inward bulge (e.g., inward bulge 407 ), so that the patient's limb would be supported by the bulge, and not the flange from where the panel had been torn away.
FIGS. 39-44 illustrate views of another embodiment of a basin formed in accordance with the present invention. Basin 500 may be formed of a tub 501 with an overmolded elastomer. Tub 501 may be formed with a substantially flat base 502 , from which may upwardly extend a wall 503 . Wall 503 may be integrally formed with base 502 , and may be formed as a single continuous member, which, as noted above, may be formed to be any desired shape including a circular shape, a rectangular shape, etc. Merely to be illustrative, a rectangular shape is shown throughout FIGS. 39-44 . The wall 503 may have markings 503 Mi, 503 Mii, etc., integrally formed therein, or stenciled thereon, to indicate the fluid level (e.g., 2 liter, 3 liters, etc.).
A first set of opposing portions of the top of the wall 503 may have a return flange that forms a first lip 504 A and a second lip 504 B, which may be used for carrying and handling of the basin assembly 500 . The return flange that forms the lip 504 A and 504 B may gradually reduce in size, until no lip is formed at the top of wall 503 . A second set of opposing portions of the wall 503 may not have a lip formed thereat, and each portion may instead have a reduced height wall area 505 / 506 , as seen in FIG. 40A .
Each of the reduced height wall areas 505 / 506 of tub 581 may be semi-circular, or half-moon shaped, or shaped like half of an oval or other similar curved shape. Alternatively, a rectangular shape or even an irregular shape may also be used. The reduced height areas 505 / 506 may be formed to be different sizes, or may preferably be formed to be the same size, as seen in FIG. 40A , and may be large enough to accommodate the thigh of the 95 th percentile man. Each of the reduced height wall areas 505 / 506 may then be overmolded with a flexible elastomeric materials 550 / 560 , as seen in FIGS. 39-40 . As seen in FIG. 43 , the reduced height wall areas 505 / 506 of tub 501 may be formed with a structural bezel (e.g., 550 B), which may support the bottom of the overmolded elastomer material (e.g., 550 ). The top (e.g., 550 T) of the elastomer materials may be formed to bow outwardly in a central region, as seen in FIG. 43 , which may initially receive the limb of the patient when the basin is to be used for wound irrigation, as illustrated in FIG. 44 . The elastomer materials 550 / 560 may stretch and conform to the patient's limb, and portions of it may also fold under the weight of the limb, to conform to the shape of the limb.
FIGS. 45-50 illustrate views of another embodiment of a basin formed in accordance with the present invention. Basin 600 may be formed with a substantially flat base 602 , from which may upwardly extend a wall 603 . Wall 603 may be integrally formed with base 602 , and may be formed as a single continuous member, which, as noted above, may be formed to be any desired shape including a circular shape, a rectangular shape, etc. Merely to be illustrative, a rectangular shape is shown throughout FIGS. 46-50 . The wall 603 may have markings 603 Mi, 603 Mii, etc., integrally formed therein, or stenciled thereon, to indicate the fluid level (e.g., 2 liter, 3 liters, etc.)
A first set of opposing portions of the wall 603 may have a return flange at a top of the wall that forms a first lip 604 A and a second lip 604 B, which may be used for carrying and handling of the basin 600 . The return flange that forms the lips 604 A and 604 B may gradually reduce in size, until no lip is formed at the top of wall 603 . This first set of wall portions may generally be smooth. A second set of opposing portions 605 / 606 of the wall 603 may not have a lip formed thereat, and each portion may instead be formed like a bellows (i.e., alternate ridges and grooves), so that the wall areas 605 and 606 seen in FIG. 50 may be easily compressed and may contract like an accordion, and/or may elastically deform as a result of a downward force applied thereat (i.e., the patient's limb). The bellows may thus generally conform to a portion of the shape of the patient's limb. Basin 600 may be formed as a single part using a single material.
The top-most flange of the bellows (e.g., 605 F in FIG. 49 ) for each of the opposing wall portions 605 / 606 may extend further than each of the other ridges, as it is intended to provide a larger surface area for the comfort of the patient, similar to the inward bulges 307 and 308 of basin assembly 300 . The top-most flange may also be formed to be generally parallel to the flat base 601 .
To enable greater flexure of the bellows, upon receiving the patient's limb thereon, the bellows of the opposing wall portions 605 / 606 may be formed to extend through a greater portion of the periphery of the wall 603 than the smoothly formed first set of opposing wall portions. For the square-shaped basin 600 illustrated within FIG. 45 , the bellows of the opposing wall portions 605 / 606 may extend beyond the respective sides of the rectangular shape, and therefore at least a portion of all four sides of the rectangular shape of basin 600 may have the corrugations formed thereon. Analogously, for a basin formed with a generally circular shape (i.e., 360 degrees of curvature), the opposing bellows sections may be formed on more than 180 degrees of the curvature (e.g., 240 degrees of the 360 degrees of curvature, with roughly 120 degrees of bellows on one side and roughly 120 degrees of bellows formed on the opposing side).
The sidewall flexibility provided by the bellows of opposing wall portions 605 / 606 may thus accommodate various different patient limb sizes and orientations.
Accordingly, it will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the disclosure. The breadth and scope of the present disclosure should not be limited by any of the above-described example embodiments, but should be defined only in accordance with the following claims and their equivalents.
|
A hospital-grade basin holds water for washing patients, or alternatively converts easily/quickly for a patient's limb to rest comfortably within and across a portion of the basin. In a first embodiment, half-moon shaped openings on opposite sides of the basin side wall(s) comfortably support the limb at a reduced height with respect to adjacent side wall portions, which serve as a partial shield during wound irrigation, and aid fluid collection. The shaped openings may each be sealed with a hinged door in a closed position, using a friction fit, to form the traditional, watertight basin. In an alternate embodiment, the doors may be secured in the closed position using an elastomeric leaf-spring-shaped member. In other embodiments, rather than cutouts and doors, opposing portions of the side wall may instead be formed of an over-molded elastomeric material that conforms to the patient's limb, or may instead be formed like a bellows.
| 0
|
FIELD OF THE INVENTION
This invention relates to portable tape applicators, and more particularly to a lightweight pressure sensitive tape holder selectively usable either to apply a selected length of tape directly to a surface or as a desk mounted tape dispenser.
BACKGROUND OF THE INVENTION
The wide scale use of pressure sensitive masking tape and scotch type tapes has inspired a proliferation of devices for dispensing and/or applying these tapes. Prior constructions provided to meet these needs are subject to numerous shortcomings and disadvantages including complexity, costly construction, complex means for severing the tape at the end of an application cycle, unsatisfactory means for retaining the tape captive between dispensing cycles and for presenting a sufficiently long free end in a viewable and accessible position for accurate anchoring to a surface without displacement or damage to that surface at the start of and during a dispensing cycle, lack of means for storing the free end of the tape in a protected position concealed within the housing when the device is not in use and other shortcomings. Fritzinger U.S. Pat. No. 2,582,979, Zbinden U.S. Pat. No. 3,523,053, Urushiazaki U.S. Pat. No. 4,097,328 and U.S. Pat. No. 4,238,271 and Iiama U.S. Pat. No. 4,345,966 patents each propose tape applicators having retractable tape carriers but each requires linkage means to move a cutting knife into a severing position upon retraction of the tape carrier. Fritzinger U.S. Pat. No. 2,486,470, Cutter U.S. Pat. No. 2,606,682, Regan U.S. Pat. No. 3,725,182 and U.S. Pat. No. 4,253,905 and Weick U.S. Pat No. 3,813,275 patents each propose a tape applicator having a handgrip portion, but in no instance is the handgrip foldable, operatively connected with a retractable carrier, or useful in protecting the free tape end when the applicator is not in use. Boyce U.S. Pat No. 3,586,587, Regan U.S. Pat No. 3,725,182, Parker 3,745,086 and Fritzinger 2,486,470 and U.S. Pat. No. 3,785,901 patents show applicators having severing blades with protective expedients during a dispensing cycle, but in no instance is the guard mechanism operatively associated with a retractable tape carrier. Robison U.S. Pat. No. 3,707,426 proposes a hand held tape applicator having two tape dispensing ports, one of which is useful in applying tape to a long flat surface and the other of which is useful when it is desired to detach short lengths of tape for hand application. In either mode of use the device must be hand held.
SUMMARY OF THE INVENTION
To avoid the shortcomings and disadvantages of these and other prior tape applicators or dispenser, the present invention provides a combined compact, lightweight device selectively usable as a tape applicator or as a hand held tape dispenser mountable in a supporting base on a desk top. The tape holder carrier proper is reciprocally supported in a main housing and is normally biased toward its extended position to display a preselected length of tape in a viewable and accessible position for accurate application to a surface as the applicator is pulled rearwardly. At the end of the tape applicating step the operator manually presses a trigger to retract the tape carrier, thereby suddenly unlocking a guard member for a cutter blade and simultaneously capturing the tape on a carrier-mounted tape catcher well before the cutter blade and a new free tape end that is about to be created. While the carrier is held retracted, continued rearward movement of the applicator now serves to sever the tape by its contact with the blade, leaving a free end of tape extending beyond the tape catcher to the cutter blade. The tape carrier trigger is then released and the carrier is extended slightly until trigger latches are frictionally engaged. This slight extension of the carrier initiates relocking of the cutter guard in its guard position, moving the free tape end (which is now held substantially within the applicator and thus out of contact with any underlying surface) away from the cutter blade. Upon release of the trigger latches the carrier is free to move to a fully extended position, presenting the free end of the tape in an exposed position for the next applicating cycle.
The applicator has a handgrip selectively lockable in its extended position and in a retracted position. The movement of the handgrip to its retracted position automatically retracts the tape carrier and withdraws the free end of the tape to a concealed protected position. The end of the handgrip includes a tape dispensing port for use when the dispenser is clipped or frictionally held seated in a weighted base for use as a desk mounted dispenser. This base includes its own combined tape catcher and severing blade for use in cutting the tape and in supporting the tape end between dispensing cycles.
In one embodiment, the complete applicator, excluding the weighted base, is formed of seven components, five of which are molded plastic and all of which are arranged for interlocking assembly without the need for fasteners or adhesives. The only nonplastic parts are a torsion spring and a cutting blade.
Accordingly, one object of this invention is to provide an improved hand held compact tape applicator formed of a minimum of components held assembled without fasteners.
Another object of the invention is to provide a tape applicator operable without surface pressure and having a handgrip equipped with a finger operated trigger for retracting a tape carrier normally biased to an extended position and having a tape catcher presenting the free end of the tape exposed and visible for accurate registry with a surface to be taped.
Another object of the invention is to provide a tape applicator having a fixed cut off blade normally guarded from contact with the tape but operatively connected to a manually operable control to unlock the guard in readiness for severance of the dispensed tape.
Another object of the invention is to provide a tape applicator having a retractable tape carrier with a cutter blade guard normally locked in guard position but releasable to an unlocked condition when the tape carrier is manually retracted to a predetermined position.
Another object of the invention is to provide of a hand-held tape applicator having a short length of tape exposed and freely visible and accessible for accurate placement on a surface to be taped, and wherein the applicator can be manipulated to dispense a selected length of tape out of contact with the surface before being lowered into contact therewith whereby the deposited tape remains untensioned.
Another object of the invention is to provide a tape applicator operable to dispense and cut off a selected length of tape against a surface in a smoothly executed simple movement free of twisting or altered direction of movement.
Another object of the invention is to provide a tape applicator having a retractable tape carrier normally biased to an extended tape dispensing position and selectively manually movable to a retracted position with the free end of the tape held selectively and protectively retracted between operating cycles.
Another object of the invention is to provide a combination hand-held tape applicator and a desk-mounted tape dispenser.
DESCRIPTION OF THE DRAWINGS
These and other more specific objects will appear upon reading the following specification and claims and upon considering in connection therewith the attached drawings to which they relate.
Referring now to the drawings in which a preferred embodiment of the invention is illustrated:
FIG. 1 is a side elevational view of an illustrative embodiment of the invention tape applicator with portions of the cover and handgrip broken away to show constructional details and with the applicator in use to apply a strip of tape to an underlying horizontal surface;
FIG. 2 is a view similar to FIG. 1 but showing the tape carrier trigger held retracted to unlock the cutter guard and enable the tape to be severed;
FIG. 3 is a fragmentary cross sectional view on an enlarged scale taken along line 3--3 on FIG. 2 to show one of the cover locking tangs for holding the cover closed;
FIG. 4 is a perspective view of the housing cover as viewed from its interior side;
FIG. 5 is a fragmentary view showing the handgrip unlatched and pivoted partially and fully toward the closed storage position thereof;
FIG. 6 is a side view of the applicator showing the handgrip latched in closed position and the applicator frictionally seated in the well of a weighted base and in readiness for use as a desk-mounted tape dispenser; and
FIG. 7 is a side view of the applicator tape cutter having sharp edged serrations lying in an inclined plane across the length thereof.
DETAILED DESCRIPTION
Referring to FIG. 1, there is shown an illustrative embodiment of a combined tape applicator and tape dispenser, designated generally 10, formed almost entirely from molded plastic components designed to be held assembled without fasteners. The main housing 11 is of modified elliptical cup-shaped configuration normally closed by a detachable cover 12 held in assembled position by integral resilient detents 13. These are best shown in FIGS. 3 and 4 as having protuberances 14 seating in shallow wells 15 on the interior sidewall of housing 11. Cover 12 has a finger grip 16 (FIGS. 1 and 4) protruding therefrom to facilitate removal of the cover.
Slidably supported lengthwise of the interior of housing 11 is a tape carrier 17 having a hub 18 upstanding from the central portion thereof for rotatably retaining a roll of pressure sensitive tape 19. Interiorly of hub 18 is a low height tubular boss 20 embraced by the coil of a spring 21 having one end 22 engaged with a boss 23 integral with the bottom of the tape carrier 17. The other end 24 of spring 21 extends through an opening slot in the sidewall of the carrier 17 into a pocket formed in the sidewall of the applicator housing 11.
Spring 21 operates to bias the tape carrier 17 to the extended position thereof shown in FIG. 1 with its semicircular innermost end spaced downwardly from the semicircular upper end wall of housing 11 by a substantial amount. However, when the carrier 17 is forcibly and manually retracted in opposition to spring 21, its semicircular innermost wall is moved upwardly to a retracted position closely spaced from the similarly shaped upper end wall of the applicator housing 11 as shown in FIG. 2. Preferably, the exterior of carrier 17 has a plurality of low height projections 27 along its exterior sidewall serving as stops and cooperating with the adjacent interior sidewalls of the applicator housing to restrict the carrier to generally linear movement lengthwise of the interior of housing 11. Thus, the carrier is free to slide lengthwise of the main housing but is restrained from any substantial twisting or rotary movement.
The upper end of carrier 17 is of low height cup-shape and its lower end 30 is bifurcated and formed with rear and front legs 30a and 30b respectively which reciprocate through the generally open lower end 31 of housing 11. Projecting downwardly from the lower end wall of carrier 17 is a manually operable trigger 33 having a rounded lower rear corner 34 for a purpose to be described presently. The foremost lower end of leg 30a has a flat surface 36 facing forwardly and slightly upwardly toward the adhesive underside of the advance end 66 of the tape on coil 19. Accordingly, surface 36 of the carrier is conveniently designated a "tape catcher" to hold the end of the tape captive between dispensing operations. Carrier legs 30a and 30b straddle a sideways V-shaped tape guide 37 integral with and extending crosswise of the lower front end of housing 11 inwardly of its open lower end 31. As shown in FIGS. 1 and 2, one leg of tape guide 37 extends downwardly and the other leg extends forwardly with its end bearing against a rib 38 projecting rearwardly from the rearward side of front carrier leg 30b, which is thereby guided accurately as carrier 17 is moved between the extended position of FIG. 1 and the retracted position of FIG. 2. Socketed in the interior apex of the sideways V-shaped tape guide 37 is the rounded end of a cutter blade guard member 40. In the position of the parts shown in FIG. 1, blade guard 40 is shown locked in its blade guarding position by the rearward face of the lower rear end 42 of the front carrier leg 30b. It is noted that cutter guard 40 is held in its locked guard position against the lower forward end of the downwardly extending leg of sideways V-shaped tape guide member 37. In the blade guarding position, the tape contacts the end surface of the guard member 40 and is thereby held away from contact with the blade.
A stationary tape cutter blade 44, best shown in FIG. 7, is held captively assembled in a tape presser pad 45 extending crosswise of the foremost lower corner of the applicator housing 11. The cutting edge preferably comprises sharp-edged serrations lying in a plane inclined acutely to a plane normal to the axis of the cutter. Accordingly, the leading serration is effective to nick the edge of the tape and initiate expedited severance of the tape. When the cutter guard 40 is locked in its extended position shown in FIG. 1, it is clear that it is impossible for the dispensed end of the tape to come into contact with the cutter blade 44. However, as carrier 17 is retracted to its fully retracted position shown in FIG. 2, the lower rear corner of the lower end 42 of front carrier leg 30b moves to a position past the upper end 46 of the front surface of the cutter guard 40, thereby leaving the blade guard 40 suddenly free to pivot about its fulcrum on tape guide 37. The blade guard suddenly pivots toward the blade and unblocks the tape and thereby allows the tape to move toward the blade. The blade guard 40 is thus unrestrained and freely pivots in response to pressure applied to it by the tape as the tape is drawn across the preferably serrated edge of cutter blade 44 to sever the tape in a sudden slicing manner. At the same time, the adhesive side of the tape is contacted by the tape catcher surface 36 to hold the tape in a fixed position after a lower portion thereof has been cut off by the blade. It is important that the cutter blade be positioned such that, when exposed as shown in FIG. 2, the cutting edge is still protected from contacting the surface being taped, but is as close as possible to that surface to allow accurate positioning of the cut end of the tape on that surface. In the present embodiment of the invention, the cutter blade is very close to the surface 69 being taped but lies above and forward of an imaginary straight line between the presser foot 45 and the outer lower end of the handle 50. When the invention is handheld in the position of FIG. 2, with the presser foot 45 on a surface 69 and then rotated clockwise, the lower outer end of the handle 50 (or the operator's hand) will contact the surface and stop further rotation before the cutting edge of cutter blade 44 contacts the surface 69 being taped. It is also important that the angle between the plane of the cutter blade and the plane of the tape at the point where the tape is cut be an acute angle, generally as small an angle as practical. A desired range is an angle of about 10 degrees to about 20 degrees. This ensures a rapid cutting of the tape without tearing of the tape.
The applicator is provided with a folding handgrip 50 pivotally connected to the main housing on trunnions 51 integral with and projecting from the opposite sides of the main housing. The handgrip is rigidly latchable in its normal open position by a pair of latching hooks 52 and 53. Hook 52 is integral with the sidewall of housing 11 and hook 53 is integral with the upper sidewall of the handgrip 50, as best seen in FIGS. 1 and 2. Preferably, the opposite lateral edges of hook 53 are separated from the handgrip wall for a short distance by narrow slots, thereby imparting flexibility to hook 53.
The interior of the handgrip is provided with reinforcing webs 55 including the longitudinal web 56, the arcuate edge 57 of which acts as a camming surface engageable with the rounded nose 34 of trigger 33. Thus, as best shown in FIG. 5, the clockwise pivoting of handgrip 50 about trunnions 51 enables the camming surface 57 within the handgrip to contact the nose 34 of trigger 33 thereby and is effective to cam the attached tape carrier 17 inwardly. By the time the handgrip has been pivoted substantially to the 9 o'clock position shown in FIG. 6, carrier 17 has been retracted to the position slightly short of its fully retracted position, wherein the surface of handgrip hook 53 (FIG. 5) at the base of the handgrip is captively seated against the lower face of trigger 33. The outer end of the handgrip then embraces presser pad 45. This latches the handgrip in its closed retracted position with the nose 34 of the trigger resting against the inner side of the latching hook 53. It will be noted that this hook is mounted cantilever fashion on a long stem formed of the resilient plastic material of the handgrip. The resiliency of this stem is adequate to aid in latching the handgrip in its retracted position but is insufficient to hold the tape carrier fully retracted. Since the tape carrier is not fully retracted, the rearward face of the lower rear end 42 of the carrier leg 30b rests against cutter guard member 40 slightly below its upper front end 46, thereby firmly retaining this guard against clockwise pivotal movement and holding it firmly in its guard position as shown in FIG. 5. It will be noted that the outermost interior web 55 contacts the rear carrier leg 30a when the handgrip is folded, as shown in FIG. 5, to complete the enclosure of the interior of the applicator 10. The edges of the longitudinal webs 58 prevent the adhesive side of the tape from firmly gripping the interior of the handgrip.
Referring to FIG. 6, applicator 10 is illustrated with its handgrip 50 in its folded retracted position just described and snugly seated in an upwardly opening well 61 of a heavy base 60, thereby converting the applicator into a desk supported tape dispenser. The upper forward end of base 60 is provided with a transverse opening 63 crosswise of the base and rearwardly of a pedestal 64 supporting a combined tape cut off blade 65 and catcher or support for the free end of the tape 66. Preferably, blade 65 is serrated and performs similarly to cutter blade 44 shown in FIG. 7. This tape 66 passes over the lower end of the cutter guard member 40 which is now locked in its extended position holding the tape free of contact with the applicator cutter 44. When the handgrip 50 is in its retracted latched position, the tape carrier 17 is less than fully retracted within the main housing, with the result that its lower end 42 still bears against the inner front end portion of guard member 40 so as to lock the guard member in its normal extended position. Accordingly, tape flows unhampered from its supply role over the lower end of guard member 40 on to the catcher surface of the dispenser cut off blade 65.
The operation of the invention tape applicator and dispenser shown in FIGS. 1-7 will be readily understood from the foregoing detailed description of its structure and principal operating characteristics. The invention is operated as a hand held tape dispenser and applicator by positioning it as shown in FIG. 1 by first pivoting the handgrip 50 from the retracted position of FIG. 5 to the fully extended position of FIG. 1. Latching hooks 52 and 53 cooperate to automatically snap firmly interlocked, and then release the carrier 17 to its fully extended position. When the tape carrier is retracted and the handgrip 50 is extended as best seen in FIG. 2, movement of the tape carrier to the fully extended position is halted by frictional contact of carrier trigger latches 70 and 71 which temporarily hold the tape carrier in a nearly fully retracted position. Light manual pressure applied downwards on the upper side of the lower edge of trigger 33 cooperates with the spring 21 and the resiliency of trigger latch 70 to overcome the frictional hold of said trigger latches and releases the tape carrier to its fully extended position of FIG. 1.
A roll of pressure sensitive tape 19 can be installed by first removing cover 12 by applying lifting pressure to finger grip 16 thereby releasing first one then another of cover latching detents 13. A roll of tape 19 is then telescoped over hub 18 centrally of tape carrier 17 such that the adhesive side of the tape will contact catcher face 36. The free outer tape end 66 is pulled past tape guide 37 and lowered edgewise into the open-sided free space between the lower end of the cutter guard 40 and the catcher face 36. Before attaching the tape 66 to catcher 36 as shown by dotted lines in FIG. 1, the free outer end of the tape is pulled well outwardly of the dispensing port so that a clearly visible and accessible length thereof is exposed beyond the outer end of the tape presser surface 45. Cover 12 is snapped back in place while properly oriented to register its cylindrical posts 68 (FIG. 4) with wells for these posts formed in the underlying portions of the main housing. Operation of the tape applicator 10 as a hand-held dispenser as hereinafter described will provide a clean and untouched free tape end 66 of appropriate predetermined length as shown by dotted lines in FIG. 1. Accordingly, the applicator 10 is now ready for use.
To use the applicator as a hand-held dispenser, the operator holds the applicator by handgrip 50 in one hand and with the other hand grasps the free tape end 66 that extends below catcher face 36. The tape is then pulled outwardly of the dispensing port and forwardly toward the tape presser surface 45, causing the tape to peel off said catcher face 36. After the desired length is dispensed the operator severs the tape by holding said tape firmly and utilizing the index finger of the hand holding the handgrip 50 to apply pressure against the trigger 33 to slide the tape carrier 17 upwardly to its fully retracted position as shown in FIG. 2. As the tape carrier reaches this position, the blade guard member 40 is suddenly unlocked and free to pivot to its retracted position (shown in FIG. 2),whereupon the applicator is pulled rearwards with the aid of the handgrip (or conversely the free end of the tape is pulled forward against cutter guard member 40). This causes the tape to press against and pivot the blade guard 40 and then contact the fixed cutter blade 44 and sever it from the tape supply. The blade is thus initially shielded by the blade guard 40 and then becomes suddenly exposed for rapidly cutting the tape. At about the same time the tape attaches to the face of the tape catcher. After cutting, the blade guard suddenly pushes the tape away from the blade when the carrier is returned to its initial position in FIG. 1. After cutting, a new and untouched free end of the tape adhesively attaches to and rests against the tape catcher surface 36 to which it remains captive with a substantial length of the free end of the tape extending therebeyond. To be observed at this time is the fact that spring 21 functions to automatically return the tape carrier towards its fully extended position. Accordingly, as the operator releases pressure on the trigger 33, the tape carrier extends slightly until trigger latches 70 and 71 are frictionally engaged and temporarily hold the tape carrier in a substantially retracted position. Accordingly, the aforementioned free tape end attached to the tape catcher face 36 is releasably held substantially within the applicator and will not become attached to nearby objects. The tape carrier extends sufficiently before engaging the trigger latches to cause the lower end 42 of carrier front leg 30b to engage the upper front surface of cutter guard 40 and quickly lock said cutter guard in the guard position. This pushes the free tape end 66 away from cutter blade 44 and prevents any adhesion of the tape to the cutter blade.
To apply a length of tape to a flat surface 69 the operator releases the tape carrier to the fully extended position of FIG. 1 as heretofore described. The operator holds the applicator in the position shown in FIG. 1 and generally normal to the surface 69 with the free end of the tape 66 there shown in dotted lines projecting slightly beyond the front edge of the applicator housing 11 and underlying the applicator presser pad 45. The operator can see and access this free tape end and can position it directly over the spot desired before depressing it against the surface by the aid of presser pad 45. The operator may place a finger on the exposed nonadhesive side of the tape extending beyond presser pad 45 to maintain the position of the tape and underlying surface 69 during tape application. If the operator wishes to use presser pad 45 to press the free tape end extending beyond it firmly to the surface, the trigger 33 can be retracted a corresponding distance immediately before or after the presser pad is positioned overlying the tape on surface 69. Accordingly, the free tape end 66 attached to the catcher face 36 will be retracted such that the free tape end will lie directly under presser pad 45 and not extend beyond it. Upon retraction of the tape carrier trigger, frictional contact of trigger latches 70 and 71 provides tactile warning that additional retraction of the tape carrier may result in premature severance of the tape. The operator also takes care not to retract the tape carrier beyond this point when positioning and applying the tape. The operator now employs handgrip 50 to pull the applicator rearwards, to the right as shown in FIG. 1, while pressing the tape against the surface with the desired pressure on the tape. Alternatively, if the operator has a finger on the free tape end extending beyond presser pad 45 and holds it firmly to the surface, the applicator can be lifted from the surface and pulled rearwards to dispense additional unapplied tape out of contact with the surface to be taped. This unapplied tape can then be laid onto the surface very accurately in an untensioned condition, thereby avoiding curling or damaging a delicate surface material. As the applicator is moved rearwards, the tape is peeled away from the catcher surface 36 and then feeds past the tape guide surface member 37, past the outer end of guard member 40 and across the presser pad 45 to the surface 69. The application process is repeated and continued until the desired continuous length of tape has been applied.
After the desired length of tape has been applied in this manner, the operator utilizes the index finger against trigger 33 to shift tape carrier 17 inwardly to its fully retracted position past tape trigger latch 70, as best seen in FIG. 3. This causes tape to be severed in the aforementioned mentioned manner. Tape application and severing can be done in a continuous movement without stopping. Where high accuracy is required, the operator ceases the rearward movement of the tape applicator, holding it positioned at the desired cut off point while depressing the trigger 33. Continued rearward movement of the applicator severs the tape in the aforementioned manner. After severing the tape, the trigger 33 is released and tape carrier 17, biased toward the extended position by spring 21, extends a slight distance downwards until trigger latches 70 and 71 are frictionally engaged to releasably hold the tape carrier in a substantially retracted position with a sufficient length of the tape end extending from catcher face 36 for accurate and visible registry with a surface to be taped in the next operating cycle of the applicator. Accordingly, the free tape end is held releasably retracted substantially within the interior of the applicator and will not become reattached to the surface just taped or to another nearby object until the carrier is released at the start of the next application cycle.
As soon as the operator has finished using the applicator, he depresses handgrip latching member 53 and folds the handgrip clockwise about its pivot 51. As this operation takes place, nose 34 of trigger 33 engages the camming surface 57 of handgrip web 56 and cams the carrier toward its nearly fully retracted position. As the handgrip reaches its fully collapsed position, handgrip latch 53 bears against surface of trigger 33 closely adjacent nose 34 of the trigger in the position shown in FIG. 5 wherein it is effective to latch the handgrip retracted. The free end of the tape is now retracted and held captive on catcher face 36 in a fully concealed and protective condition. The edges of handgrip webs 58 prevent the free end of the tape adhering to the interior of the handgrip.
If the applicator is to be used as a desk-mounted tape dispenser, the operator first unlatches the handgrip sufficiently to grasp the free end of the tape and pull a sufficient portion thereof outwardly beyond presser pad 45 to extend through a dispensing port formed by a small gap between the outer end sidewall of the handgrip and presser pad 45, as best seen in FIG. 6. This having been done, handgrip 50 is latched in its retracted position and then inserted into the well of dispenser base 60, with the free end of tape 66 held captive against the surface of the cutoff blade and tape catcher 65. The operator may now dispense the tape manually by grasping the same rearwardly of pedestal 64 and pulling a desired portion thereof outwardly from the main housing. A desired length having been dispensed, it is cut off by the aid of cutter 65 as is customary in the use of well known desk-mounted tape dispensers.
While the particular combination tape applicator and tape dispenser herein shown and disclosed in detail is fully capable of attaining the objects and providing the advantages hereinbefore stated, it is to be understood that it is merely illustrative of the presently preferred embodiment of the invention and that no limitations are intended to the detail of construction or design herein shown other than as defined in the appended claims.
|
Disclosed is a combined tape dispenser and hand-held tape applicator formed of a minimum of molded components designed for interlocking assembly without fasteners. The housing includes a handgrip lockable either in an extended position when employed to apply tape to a surface or in a retracted position when not in use or when used to dispense tape from a desk top support. The tape is mounted on a tape carrier normally biased to an extended tape-applicating position and manually retractable to expose a normally guarded cutting blade for severing the tape. While the carrier is moving between retracted and extended positions, a tape catcher clutches the tape reawardly from its free end and holds it captive with the free end thereof extending outwardly beyond the dispensing port in visible readiness for precise visible attachment to a surface to be taped. The tape carrier is movable toward its retracted position either by a trigger adjacent the handgrip or by pivotal movement of the handgrip substantially to its retracted position. A blade guard is normally held in a position to shield the cutter from the tape when the carrier is in its extended position. When the carrier moves to its retracted position, the blade guard is suddenly released to rotate freely from its shielding position to an unblocking position allowing the tape to be suddenly forced against the fixed blade for rapidly cutting the tape.
| 8
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. Ser. No. 09/463,449 filed Jan. 27, 2000 abandoned which is the national phase of PCT/EP98/04390 filed Jul. 15, 1998.
BACKGROUND OF THE INVENTION
A. Field of the Invention
The present invention relates to a method of and machine for writing a pattern the surface of a substrate by an electron beam.
B. Background of the Invention
The writing of patterns on substrates, for example circuits on wafers, by electron beam lithography is subject to closely controlled parameters to ensure accurate writing of pattern features in conjunction with a high throughput rate. The beam current downstream of a final focussing stage, i.e. probe current, is set in dependence on a number of factors, including accelerating voltage for producing the beam, beam spot size on the substrate surface, rate of step of the beam between successive writing positions during scanning of the substrate surface, i.e. dose clock or exel clock, sensitivity of an electron-sensitive resist on the surface, and correction needed for the proximity of features of the pattern. Proximity correction is required because the electron doses in adjoining areas can generate mutual influencing by the backscatter effect of secondary electrons and this leads to impairment of the writing accuracy. The doses need to be less in such areas and also in corner areas and inner areas of pattern shapes. Accordingly, constant alteration of dose has to be carried out during writing.
Various methods are at present employed for the purpose of changing dose. A first method is to vary the step rate or dose clock. This method has the disadvantage of reducing throughput, as part of the pattern then has to be written below the maximum rate. The maximum rate can otherwise be quite readily achieved by an electron beam machine equipped to provide a high density of the probe current. A second method is to change the probe current by altering one or more of the factors determining beam spot size or focus. This method, too, has the disadvantage of reducing throughput, due to the time taken to make the alteration. The alteration time may amount to several seconds and this time is lost whenever a dose change is required.
In W094/28574 there is disclosed a third method, which employs variation in electron dose level for particular pixels between 100 percent and two lesser values. Inner regions of a pattern are written with maximum dose and edge regions with a selectable one of the lesser doses, the dose variation being achieved by beam modulation under the control of blanking pulses of different widths. This method serves the purpose of defining the position of the edges of written patterns, in particular by displacing the edges relative to grid lines of a scanning raster, and is not concerned with dose control for any other corrective purpose. A similar method is disclosed in Murray et al, ‘Experimental evaluation of an electron-beam pulse modulated blanker (160 MHz) for next-generation electron-beam raster scan systems’ in Journal of Vacuum Science & Technology B, Vol. 13, No. 6 (November/December 1995), which describes use of three, rather than just two, sub-maximum dosage levels for writing pattern edges.
SUMMARY OF THE INVENTION
It is therefore the object of the invention to provide a method and a machine by which, in the course of pattern writing by an electron beam, dose rate may be varied as required for specific problematic parts of the pattern without loss in writing throughput time.
Other objects and advantages of the invention will be apparent from the following description.
According to a first aspect of the present invention there is provided a method of writing a pattern on the surface of a substrate by an electron beam, the method comprising the steps of exposing the substrate surface to an electron beam controlled to progressively describe the pattern by stepped movement of a focussed spot of the beam over the surface, and varying the exposure of the surface to the beam by selectably modulating the beam in the periods between successive movement steps to reduce the level of electron dose in predetermined positions of the beam spot on the surface, wherein said predetermined positions of the beam spot comprise positions associated with inner regions of feature shapes in the pattern, positions associated with pattern features of such proximity to one another as to be susceptible to mutual influencing during writing, and/or positions associated with linear pattern features liable to contain noise components when written, the writing of said linear pattern features by the modulated beam being repeated at least once to average the components.
The writing of the entire pattern is preferably carried out with a predetermined substantially constant rate of stepped movement of the beam spot, i.e. a substantially constant dose clock. This rate of movement is preferably the maximum rate still allowing sufficient exposure for writing of those features of the pattern requiring the highest level of dose. In that case, the beam modulation allows the dose level to be varied as required, so that the pattern can be written at the maximum step rate established by reference to the particular pattern shapes, the substrate resist sensitivity and the various beam parameters. No change in the step rate or other beam parameters is then necessary for the purpose of dose variation.
The predetermined positions of the beam spot where beam modulation is carried out are positions in which the dose level required for writing of the associated pattern parts is less than that required for the part requiring the highest level, namely positions associated with inner regions of feature shapes in the pattern, where a lesser dose is needed, and/or those associated with pattern features of such proximity to one another that mutual influencing, such as from backscattered secondary electrons, might occur during writing, and/or those associated with linear pattern features liable to contain noise components when written. In the last-mentioned case, the features can be written repeatedly by the modulated beam so as to average the noise components.
The beam modulation is preferably carried out substantially without change in the beam spot size or displacement of the beam spot during the writing. The modulation is preferably between maximum dose and zero dose, thus with complete blanking of the beam. This can be achieved by, for example, deflection of the beam to and from a blanking surface. The rate of stepped movement of the beam and the rate of modulation of the beam can be in any desired ratio, such as a ratio in which the dose is reduced by substantially one half by the beam modulation.
According to a second aspect of the invention there is provided an electron beam pattern writing machine for carrying out the method of the first aspect of the invention, the machine comprising beam generating and focussing means for generating an electron beam and focussing the beam as a spot on a surface of a substrate on which the pattern is to be written, control means for controlling the beam to progressively describe the pattern while moving the beam spot in steps over the substrate surface, and modulating means for selectably modulating the beam in the periods between successive movement steps to reduce the level of electron dose in predetermined positions of the beam spot on the surface, wherein said predetermined positions of the beam spot comprise positions associated with inner regions of feature shapes in the pattern, positions associated with pattern features of such proximity to one another as to be susceptible to mutual influencing during writing, and/or positions associated with linear pattern features liable to contain noise components when written, the writing of said linear pattern features by the modulated beam being repeated at least once to average the components.
The modulating means preferably comprises electrostatic deflecting elements extending parallelly to the beam, the elements being actuable by, for example, bipolar switching amplifier means. When the stepped movement of the beam spot is controlled by the control means to be at a substantially constant rate; the rise and fall times of the amplifier means are preferably less than that rate.
BRIEF DESCRIPTION OF THE DRAWINGS
An example of the method and embodiment of the machine according to the invention will now be described in more detail with reference to the accompanying drawings, in which:
FIG. 1 is a diagram illustrating end stages of an electron beam lithography machine embodying the invention and showing an unblanked electron beam effective for writing on a substrate surface; and
FIG. 2 is a diagram similar to FIG. 1, but showing the beam in a blanked state.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, there is shown in schematic representation the lower part of an electron beam column of an electron beam lithography machine for writing patterns on substrates, for example electronic circuits on wafers coated with electron-sensitive resists. Such a circuit pattern can be fractured into fields containing individual parts of the pattern and the fields, in turn, into sub-fields. The pattern parts generally have the form of lines and solid shapes and are written by focussing the beam to define a spot on the resist-coated surface of a substrate and displacing the beam, in particular the spot, in steps to scan successive individual areas of the surface in correspondence with the shapes present in successive sub-fields of the pattern. The scanning can be performed on a raster basis, but preferably is vectored to follow the shapes. The beam is completely cut-off or blanked at any point where no pattern shape is present, such blanking being minimised with vectored scanning. The substrate itself is periodically displaced to dispose successive fields in a predetermined scanning zone of the beam.
A writing procedure of this kind is well-known and FIGS. 1 and 2 show the final focussing stage of an electron beam column, namely two lenses 10 and 11 which are part of a series of three lenses serving to focus a deflectable electron beam 12 on the resist-coated top surface of a substrate 13 removably mounted in a substrate holder 14 on a displaceable stage (not illustrated). The axis of the column and thus of the beam in an undeflected state is denoted by 15 .
As already explained, different levels of electron dose may be needed at different exels in the pattern. The dose variation can be applied, for example, to avoid writing errors otherwise arising from electron backscatter effect at closely adjacent pattern features, such as in the inner regions of a pattern shape. To achieve this variation, the machine embodying the invention has a blanking element 16 with a knife-edge aperture bounding the beam path and two electrostatic deflecting plates 17 extending parallelly to the beam axis 15 and controlled to deflect the beam across the blanking element 16 so that, as indicated by FIG. 2, the beam action on the substrate surface is interrupted. The deflecting plates are preferably positioned in the plane of the image of the upper lens 10 , so as to allow conjugate blanking in which the beam spot maintains a stationary position on the substrate surface during beam deflection to and from the blanking element 16 .
The control of the deflecting plates 17 to deflect the beam is carried out, in the case of a method exemplifying the present invention, in such a manner as to selectably modulate the beam in periods between successive steps, that is to say the modulation is enabled in predetermined positions of the beam spot on the substrate surface so that the spot dwell time and thus electron action on the resist coating is reduced. Each deflecting plate 17 is controlled by a respective fast bipolar switching amplifier 18 having rise and fall times significantly less than the rate of step, i.e. the dose clock rate, of the beam spot from one writing position to the next. In the case of a 100 megahertz dose clock, these times are preferably less than 200 picoseconds. The rise/fall time specification can be relaxed, however, if conjugate blanking as described above is employed. In that case, the susceptibility of the beam spot to jitter is lessened or removed. The jitter is normally very small, for example 2 nanometers for a 100 nanometer step in the beam spot at a dose clock of 100 megahertz.
The beam modulation carried out under the control of the amplifiers 18 is preferably such as to cut off or blank the beam completely, so that the probe current is reduced to zero. In the case of a 50% duty cycle performed at the applicable dose clock rate, the probe current is halved. Total blanking can be achieved by, for example, +/−20 volt amplifiers operating under conditions in which the accelerating voltage for beam generation is 20 to 50 kilovolts, the probe current is 10 picoamps to 100 nanoamps and the aperture of the final lens 11 is 200 to 600 micrometers. In the example of a 100 megahertz dose clock, each amplifier is modulated at the same rate of 100 megahertz to provide 5 nanoseconds of blanked beam and 5 nanoseconds of unblanked beam. Other ratios of beam modulation are possible in the case of lower dose clock rates, for example 3:1 at 67 megahertz and 4:1 at 50 megahertz.
The blanking voltage for beam cut-off by the knife edge of the blanking element 16 does not have a sharply defined value. The blanking voltage/probe current characteristic is S-shaped and varies in dependence on the accelerating voltage, initial beam current, final lens aperture, field deflection and other parameters, the greatest variation being about +/−1 volt to +/−19 volts.
The beam spot positions in which beam modulation is to be applied during pattern writing can be established at the time of setting up a software control governing the beam deflection for scanning the substrate surface areas in correspondence with the shapes in the pattern sub-fields. The modulation produced by the beam blanking is distinct from any blanking applied for beam spot movement over non-writing areas, such as between distinct shapes and between successive sub-fields and fields. The dose control by beam modulation can allow the entire pattern to be written at maximum dose clock rate, thereby increasing writing throughput time.
|
A method of writing a pattern on the surface of a substrate by an electron beam is provided comprising exposing the substrate surface to an electron beam controlled to progressively describe the pattern by stepped movement of a focussed spot of the beam over the surface, and varying the exposure of the surface to the beam by selectably modulating the beam in the periods between successive movement steps to reduce the level of electron dose in predetermined positions of the beam spot on the surface.
| 7
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to farm implements and, more particularly, to an air conveying apparatus for replenishing particulate material such as seed, fertilizer, herbicide or insecticide in one or more tanks of an air seeder. The invention may be used with other farm implements such as planters or fertilizer application equipment.
2. Description of the Related Art
Air seeder systems include a traction unit with an air cart in tow and frequently include a third unit such as a cultivator either intermediate the traction unit and air cart or towed behind the air cart. Agricultural implements that employ an air seeder system to apply seed, fertilizer, or other particulate material, either sub-surface or to the surface of a farm field, typically have a material supply source such as one or more tanks that are loaded with the particulate material. The tanks have or are associated with a metering device, which typically consists of a rotating element, which meters the particulate material from the tanks into a set of distribution channels, such as conduits, hoses, etc., for application to the farm field. In most systems, a pneumatic source such as a fan or blower provides air to convey and distribute material through the distribution channels. Periodically, the tank's supply of particulate material must be replenished. Typically, a screw auger or belt conveyor feeds the material from a source such as a supply vehicle to the tank. Grain augers, conveyor belts and similar mechanical seed handling equipment may cause damage to certain types of seeds. The conveying of canola seeds in particular is a delicate process. Seeds are expensive and physical damage to seeds may affect their germination and germination rate, thus, damage to the seeds while filling the tanks should be minimized.
A departure from these mechanical seed handling techniques is shown in U.S. patent application Ser. No. 14/301,717 filed Jun. 11, 2014. The technique disclosed therein employs an air conveying system where an air flow, either from the air cart fan or from a dedicated pneumatic source, is supplied to a material reservoir, such as a seed hopper, where that air flow passes through one or more restrictions to create a region of increased air velocity and reduced air pressure and a so-called venturi effect. The venturi effect essentially creates a suction effect to minimize the contact friction of particles against the bottom portions of the hose and for ingesting as many particles as possible of agricultural material from the hopper providing an air entrained flow of material. This air flow and material particles are conveyed to the tank where the material is deposited and excess air vented. The air conveying systems significantly reduce seed damage, however the potential for damage to seeds and other fragile agricultural products remains. Moreover, the products tend to accumulate more in some tank areas than others resulting in a non-uniform product distribution and corresponding non-uniformity of product delivery to the metering system.
What is needed in the art is a gentile yet efficient product handling system for fragile materials.
SUMMARY OF THE INVENTION
The present invention provides an agricultural product air conveyor system which minimizes product damage and distributes the product more uniformly within the tank.
The invention in one form is directed to a method of replenishing the supply of a particulate agricultural material in the tank of a pneumatic agricultural material delivery system which includes the steps of supplying air from an air flow source to a hopper or other agricultural material reservoir and passing the supplied air through a restriction to create a region of increased air velocity and reduced air pressure for ingesting agricultural material from the reservoir creating an air entrained flow of material. The flow of air entrained material is conveyed to the tank and gently released from multiple spaced apart locations within the tank to provide a more uniform distribution of material within the tank. Excess air is vented from near the top of the tank to maximize the seed volume without exhausting seeds from the outlet of the tank.
The invention in another form is directed to an air cart which has a pneumatic source for supplying a flow of air entrained agricultural product from a cart product tank to be applied by a utilization implement to an agricultural field. The air cart includes an air system for supplying product to the cart tank. The product supply system has an air supply and at least one elongated conduit with an inlet near one end for occasionally receiving product from a product supply source and multiple spaced apart outlets within the tank for delivering product to the tank. A venturi box has an air inlet for receiving air flow from the air supply and an outlet coupled to the conduit one end for providing a region of reduced air pressure to draw product from the supply source into an air flow. There is also an exhaust air system for venting excess air from the tank which has an inlet near the top of the tank.
In a further form of the invention, a pneumatic agricultural product delivery system has at least one product supply tank, a pneumatic source, and a plenum normally receiving air flow from the pneumatic source. There is a metering system for supplying product from the supply tank and a plurality of distribution lines which extend from plenum outlets to a utilization implement for applying air entrained product to an agricultural field. There is an air conveying system for occasionally receiving product from a supply source and delivering product to the tank to replenish the product supply in the tank. The air conveying system includes an air flow source. There is a venturi box having an inlet and at least one venturi coupled to the air flow source, an inlet for receiving product from the supply source, and an outlet for providing product from the supply source entrained within air flow from the pneumatic source. A plurality of supply conduits receive an air entrained product flow from the venturi box outlet and deliver the air entrained product flow to the product supply tank. Each conduit extends into the product supply tank for releasing the air entrained product flow and at least two conduits release their respective air entrained product flows at different locations within the tank.
An advantage of the present invention is a more uniform distribution of product within a tank and resulting more uniform feeding of product to multiple metering devices.
Another advantage is a reduction in damage to fragile agricultural products during a tank filling operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a side view of an air cart part of an air seeder equipment, and may include an air conveying system for filling and refilling the cart tank according to the present invention;
FIG. 2 is a front view of an air cart showing the air conveying system of FIG. 1 and an exhaust air diffuser;
FIG. 3 is a schematic cross-sectional representation of a product supply system incorporation the invention in one form;
FIG. 4 is a schematic cross-sectional representation of the product supply system of FIG. 3 from the left side thereof;
FIG. 5 is a schematic cross-sectional representation of the air lock, fan and hopper portions of the product supply system of FIGS. 3 and 4 showing a control valve in the tank filling position;
FIG. 6 is a schematic cross-sectional representation similar to FIG. 5 , but showing the control valve in the tank sealed position;
FIG. 7 is a schematic cross-sectional representation similar to FIGS. 5 and 6 , but showing the control valve in a position to drain agricultural product from the entire tank filling system;
FIG. 8 is an isometric view of the air lock, fan and hopper portions of the product supply system with the control valve in the tank filling position of FIG. 5 ;
FIG. 9 is a schematic cross-sectional representation of a pneumatic agricultural product delivery system incorporation the invention in another form;
FIG. 10 is an isometric view of an air cart tank with air conveying nozzles visible therein;
FIG. 11 is an isometric view of an air cart tank similar to FIG. 10 , but with alternative air conveying nozzles visible therein; and
FIG. 12 is an isometric view of an air cart tank similar to FIGS. 10 and 11 , but with a further variation on the air conveying nozzles visible therein.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, and more particularly to FIGS. 1 and 2 , there is shown an air cart 10 comprising a portion of a known pneumatic agricultural product delivery system which generally includes a traction unit (not shown) which may be coupled to air cart 10 for towing the air cart 10 in the direction of arrow 12 . The system usually includes as a third unit, a utilization implement such as an air drill (not shown) for a seeding, cultivating and/or fertilizing operation. As is known in the art, the air cart 10 has one or multiple large product supply tanks 14 which store a certain quantity of the agricultural product, typically a particulate material, e.g., seed and/or inoculant, or fertilizer, and a metering system that meters the particulate material from the tank or tanks 14 to the air drill. In addition to being mechanically linked with the air drill, the air cart 10 and the air drill are interconnected by an air/product delivery system which includes a plurality of distribution lines. Air is supplied to the product delivery system by a fan assembly or other pneumatic source sometimes mounted adjacent the front of the tank 14 and near the metering unit. Alternately, the fan assembly may be mounted rearward of the tank or adjacent a side of the tank. As known in the art, the fan creates a turbulent air flow that carries particulate material metered by metering system into and along air/product distribution lines to the utilization implement for applying the air entrained product to an agricultural field.
The supply of particulate material in the tank 14 is occasionally replenished from a supply vehicle. In the past the tanks have been refilled by auger or conveyor systems which may cause damage to fragile materials. As shown in the aforementioned Ser. No. 14/301,717 application, these mechanisms have been improved upon by an air material delivery system employing an air flow source such as a dedicated fan 16 and motor. The supply of particulate material in the cart tank 14 is replenished from a hopper 18 which receives material, for example, by gravity flow, from a supply source such as a truck or other delivery vehicle. The material passes through a rotary feeder and air lock mechanism 20 , and passes upwardly through hose 22 and, from tank inlet 24 , into the tank 14 . The front end view of FIG. 2 includes an exhaust air diffuser 26 to be discussed later. When the material in tank 14 requires replenishing, a supply source such as the agricultural material reservoir or hopper 18 provides, by way of an air lock 20 , a material flow to be mixed with the air passing into the venturi region 28 ( FIG. 4 ). The air entrained material is then conveyed by conduit 22 from a venturi region outlet to replenish the material in the tank 14 . The material particles settle in the tank and exhaust air flows through conduit 30 to the diffuser 26 .
FIGS. 3 and 4 illustrate some details of the rotary feeder and air lock 20 and venturi region 28 . The rotary feeder and air lock portion has a cylinder 32 rotatable about an axis 49 ( FIG. 8 ) in a counter-clockwise direction as shown by the arrow in FIG. 3 . The cylinder 32 has a plurality of wedge-shaped pockets such as 34 which take on product from the hopper 18 when opening upwardly and release product downwardly into the venturi region after about one-half revolution. The cylinder fits within cylindrical sidewalls sufficiently closely to prevent any significant air passage. At around a five o'clock position, the material falls from the wedge shaped segments and is funneled by seed ramps into the venturi region 28 below.
It is important to be able to purge the tank filling system, for example, prior to an extended period of non-use or preparatory to utilizing the air cart with a different agricultural product. A valve 36 is pivotable about a pivot 38 from the horizontal or 9 o'clock position of FIG. 5 clockwise to the 12 o'clock position of FIG. 6 . FIG. 5 shows the valve in the normal tank filling position where air flow from the venturi nozzle 40 joins with agricultural material from the hopper 18 and proceeds through the conduit 22 to the tank inlet. The valve may also assume this position during normal product distribution to maintain the tank pressurized and aid material flow. When moved to the location shown in FIG. 6 , the conduit 22 is blocked and material is free to fall from the venturi region 28 emptying the hopper. Both the hopper and the conduit 22 may be emptied by moving the valve to the position illustrated in FIG. 7 . Returning to FIG. 3 , this last feature may also be achieved by a simple drop floor 42 which may be opened to purge both the hopper 14 and the conduit 22 . A pair of slide valves 41 and 43 may optionally be included. Valve 41 is operable to isolate the hopper 14 from the air lock 20 while valve 43 provides a similar function between the air lock and the venturi region 28 .
In FIG. 8 , lever 45 is shown in the fill position corresponding to the FIG. 5 fill position of valve 36 . Rotation by ninety degrees clockwise about axis 47 moves the valve to the drain condition of FIG. 7 while rotation by ninety degrees counter-clockwise moves the valve to the tank sealed condition of FIG. 6 . The motor 51 of FIG. 4 is for driving the air lock cylinder about its axis 49 in the sense indicated by the arrow. A grid 53 may be included to prevent large objects from passing down the hopper and into the air lock.
With an air conveying system, there is a need for an improved configuration of a multiplicity of inlet and outlet hoses to convey product and air into the tank and to exhaust excess air properly from the tank into an air diffuser (or back into the air cart). In FIGS. 3 and 4 , the conduit 22 actually includes four separate inlet hoses or tubes 44 , 46 , 48 or 50 which extend into the tank four different distances each terminating in a downwardly directed nozzle 52 , 54 , 56 or 58 . The tubes extend into the tank different distances so that product is released from the nozzles at multiple spaced apart locations within the tank. This provides a fairly uniform distribution of product in the tank.
At the tank outlet is a porous media grid such as a set of staggered parallel cylindrical rods 60 to minimize the probability of canola seeds or other product from reaching a vertical sieve or screen 62 . Rods 60 may be staggered or offset vertically and may be bolted or otherwise fixed to the tank ceiling. Perforated plates could also be employed. A rotary valve 64 selectively allows or prevents air from exiting the tank. Closing this valve pressurizes the tank and aids the normal product distribution process while opening the valve facilitates air egress while refilling the tank. The valve may have brushes on the perimeter which rub against the screen thereby cleaning the screen each time the valve is opened or closed. The valve could be located lower closer to the air diffuser where it would be easier to reach by the operator.
When open, valve 64 vents exhaust air from the tank by way of conduit 30 to the diffuser 26 beneath the cart. A smooth and uniform air release is achieved through gradually larger openings along the bottom of the diffuser with the smallest opening 66 closest to the connection with the exhaust air conduit 30 where the air pressure is highest and the largest opening 68 most remote from the conduit 30 .
FIG. 9 illustrates some variations on a system for gently replenishing the material supply in a tank and returning exhaust air from the tank. The venturi box 70 provides an air entrained flow of agricultural product to inlet hoses 72 , 74 , 76 and 78 which are coupled with inlet tubes 80 , 82 , 84 and 86 within the tank 14 . An inlet hose and tube pair such as 72 and 80 function as a supply conduit for conveying product from the venturi box to the tank 14 . In FIG. 9 , the tubes 80 , 82 , 84 , and 86 extend into the tank different distances so that product is released from the respective tube ends at multiple spaced apart locations within the tank.
Moreover, some tubes such as 86 release product in a generally horizontal direction while others such as 80 are directed obliquely downward. This multiple outlet array provides a more uniform distribution of product 88 within the tank than is achieved from a single outlet. The uniform distribution, in turn, contributes to a more uniform distributing of product through multiple product meters to multiple distribution lines. Excess air is vented from the tank through one or more exhaust system conduits or tubes 90 which have screen 92 covered slots or other exhaust apertures. The screen 92 mesh is sized to help prevent seed or other product from escaping form the tank with the exhaust air.
In FIG. 9 , the air entrained flow of material is conveyed to the tank as shown by arrow 94 and the flow of air entrained material is released from multiple spaced apart locations within the tank to provide a more uniform distribution of material within the tank. The excess air from the tank is vented from a location above the inlet tubes 80 , 82 , 84 and 86 by sieving the excess air through a screen 92 to minimize the egress of agricultural product from the tank. Excess air is vented from the tank as shown by arrow 96 and vented downward to an air diffuser 34 beneath the tank as in FIG. 3 . The diffuser of FIG. 9 receives exhaust air at each end and the diffuser vents may be uniform as shown, however, smallest diffuser vents 98 may be located closest to the exhaust lines 90 and larger vents 100 nearer the diffuser center to provide a more uniform exhaust distribution. When the exhaust air is diffused in this way operator exposure to undesirable chemicals or other remaining particles is minimized.
FIG. 10 illustrates one of many further possible configurations for the present invention. The tank 14 is shown in phantom with the interior components visible. The inlet tubes 102 , 104 , 106 and 108 extend various lateral distances into the tank and are also spaced longitudinally (front to rear of the tank) from one another. Further the open tube ends may be variously shaped or louvered to direct material flow downwardly at various angles relative to vertical. The shortest tube 108 is directed obliquely downward while the other tubes release their product in a generally horizontal direction. This configuration results in a product pattern which accumulates first near the tank end remote from the inlet as illustrated.
A more horizontal layer of product is achieved by the inlet arrangement shown in FIG. 11 . All four nozzles 110 , 112 , 114 and 116 are directed vertically downward at intervals spaced laterally across the tank 14 . FIG. 12 illustrates a technique for accumulating product more quickly near the outboard ends of the tank. Here the central pair of nozzles 120 and 122 are directed somewhat obliquely away from one another as are the laterally outboard nozzles 118 and 124 . The number of outlets or nozzles as well as their location and direction may be deployed in various other ways to achieve any desired product accumulation pattern.
While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
|
A system for replenishing the supply of a particulate agricultural product in the tank of an air cart. A mixture of air and product comes out of a venturi delivery system and enters in a multiplicity of inlet hoses. Then the product enters into inlet tubes of various lengths and release angles from which product particles are gently spread strategically forming a pile that is more or less horizontal to ensure even feeding of meters during dispensing operations. Then the air exits through one or more fine screens to avoid product escaping as well and is conveyed through the exhaust hoses until reaching an air diffuser. The air diffuser has a series of varying size holes or louvers at the bottom so the air can come out at a uniform low velocity which minimizes any discomfort to nearby operators.
| 0
|
CROSS REFERENCE TO RELATED APPLICATTION
[0001] This Nonprovisional application claims priority under 35 U.S.C. §119(a) on Patent Application No. 2004-094572 filed in Japan on Mar. 29, 2004, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a test terminal negation circuit in which a test signal from a test terminal is not received using a nonvolatile memory after a test is completed.
[0004] 2. Description of the Related Art
[0005] Recently, an IC card on which a nonvolatile memory is mounted has been a focus of attention. Although a terminal of the IC card is standardized in ISO7816, there are various kinds of test terminals to facilitate a test. In a normal operation, since data is exchanged by authenticating the reader/writer and the like and encrypting the data, secret data is not leaked.
[0006] As a conventional technique, there is a method of outputting a test signal from a test terminal to a test object circuit by activating an output of a test mode signal generation circuit to turn on a switch circuit when the test terminal is used, and a circuit constitution in the method is shown in FIG. 3 (refer to Japanese Unexamined Patent Publication No. 2002-269523, for example). Referring to FIG. 3 , each circuit comprises a test terminal 301 , a switch circuit 302 , a nonvolatile memory circuit 303 to be tested, and a test mode signal generation circuit 304 . The switch circuit 302 is turned on when an output N 3 of the test mode signal generation circuit 304 is activated, and then an output N 1 of the test terminal 301 is transmitted to an output N 2 of the switch circuit 302 to control the nonvolatile memory circuit 303 . In addition, the switch circuit 302 is turned off when the output N 3 of the test mode signal generation circuit 304 is inactivated, so that the output N 1 of the test terminal 301 is not transmitted to the output N 2 of the switch circuit 302 . As a result, the nonvolatile memory circuit 303 cannot be controlled from the test terminal 301 .
[0007] However, when a test mode is activated falsely by operating the test mode signal generation circuit for use other than the test, information in an IC card could be easily read out using the test terminal.
[0008] In addition, although Japanese Unexamined Patent Publication No. 2002-269523 discloses a method of erasing information stored in a nonvolatile memory in an IC card when it is detected that a test mode is activated falsely, it is necessary to provide an additional circuit to detect the false activation of the test mode in this method.
SUMMARY OF THE INVENTION
[0009] The present invention has been made in view of the above problems and it is an object of the present invention to prevent a test mode from being falsely activated from a test terminal by negating the test terminal in a simple circuit constitution.
[0010] A test terminal negation circuit according to the present invention to attain the object comprises a switch circuit which receives a test signal from one or more test terminals and outputs it in an asserted state as it is or in a predetermined negated state to a test object circuit, a test signal control circuit which controls an output signal in the asserted state or the negated state of the switch circuit, a test mode signal generation circuit which generates a test mode signal which asserts the output signal of the switch circuit and outputs it to the test signal control circuit at the time of a test mode, and a negating signal generation circuit which can output a negating signal to negate the output signal of the switch circuit by force, to the test signal control circuit and comprises an electrically rewritable nonvolatile memory element, in which when the negating signal is outputted from the negating signal generation circuit, the test signal control circuit negates the output signal of the switch circuit even when the test mode signal is outputted from the test mode signal generation circuit.
[0011] In addition, the test terminal negation circuit according to the present invention is characterized in that the negating signal generation circuit comprises a first nonvolatile memory element and a second nonvolatile memory element which have a MOSFET structure, a first inverter circuit and a second inverter circuit, in which sources of the first nonvolatile memory element and the second nonvolatile memory element are connected to the ground voltage, gates of the first nonvolatile memory element and the second nonvolatile memory element are connected to a power supply voltage, a drain of the first nonvolatile memory element is connected to an input of the first inverter circuit and an output of the second inverter circuit, and a drain of the second nonvolatile memory element is connected to an output of the first inverter circuit and an input of the second inverter circuit, and the output of the second inverter circuit is an output of the negating signal generation circuit.
[0012] Furthermore, the test terminal negation circuit according to the present invention is characterized in that an output level of the negating signal generation circuit is varied by a threshold voltage difference between the first nonvolatile memory element and the second nonvolatile memory element.
[0013] According to the test terminal negation circuit of the present invention, once the negating signal generation circuit outputs the negating signal, since the test signal for activating the test mode is outputted in a negated state from the switch circuit, the test mode is prevented from being falsely activated from the test terminal without detecting false activation.
[0014] A method of negating a test terminal according to the present invention to attain the object is characterized in that the negating signal is outputted by performing electrical rewriting in the nonvolatile memory element in the negating signal generation circuit in the test terminal negation circuit according to the present invention after a test is completed. Especially, when the negating signal generation circuit comprises the first nonvolatile memory element and the second nonvolatile memory element having the MOSFET structure, the first inverter circuit and the second inverter circuit as described above, it is preferable that the negating signal is outputted by performing electrical rewriting in either one of the first nonvolatile memory element or the second nonvolatile memory element in the negating signal generation circuit after a test is completed.
[0015] According to the test terminal negating method of the present invention, since the negating signal generation circuit outputs the negating signal using the test terminal negation circuit according to the present invention after the test is completed, the test mode is prevented from being activated falsely from the test terminal, so that data in the test object circuit is prevented from being operated by the test terminal.
[0016] A nonvolatile semiconductor memory device according to the present invention is characterized by comprising the test terminal negation circuit having the above characteristics. In addition, an IC card of the present invention is characterized by comprising the nonvolatile semiconductor memory device having the above characteristics. Thus, information in the nonvolatile semiconductor memory device or the IC card is prevented from being read illegally.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a circuit diagram showing an embodiment of a test terminal negation circuit according to the present invention;
[0018] FIG. 2 is a circuit diagram showing an embodiment of a negating signal generation circuit of the test terminal negation circuit according to the present invention;
[0019] FIG. 3 is a diagram showing a conventional circuit constitution example to transmit a test signal from a test terminal to a test object circuit effectively at the time of a test mode;
[0020] FIG. 4 is a block diagram showing an embodiment of a nonvolatile semiconductor memory device according to the present invention; and
[0021] FIG. 5 is a block diagram showing an embodiment of an IC card according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] An embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a circuit diagram showing an embodiment of a test terminal negation circuit according to the present invention (referred to as “the circuit of the present invention” occasionally hereinafter). As shown in FIG. 1 , a circuit 100 of the present invention comprises a switch circuit 102 , a test mode signal generation circuit 103 , a negating signal generation circuit 104 , and a test signal control circuit 105 .
[0023] The switch circuit 102 receives a test signal from a test terminal 101 and outputs it in an asserted state as it is or in a predetermined negated state, to a nonvolatile memory circuit 106 which is an object circuit to be tested, depending on a level of an output node N 1 of a test signal control circuit 105 . The switch circuit 102 comprises, for example, a CMOS transfer gate and the like.
[0024] The test mode signal generation circuit 103 outputs a test mode signal which asserts a signal outputted from an output node N 5 of the switch circuit 102 , from an output node N 3 to the test signal control circuit 105 at the time of a test mode, so that the test signal from the test terminal 101 is outputted to the nonvolatile memory circuit 106 as it is in the asserted state.
[0025] The negating signal generation circuit 104 is so constituted that it can output a negating signal which negates the signal outputted from the output node N 5 of the switch circuit 102 by force, from an output node N 2 to the test signal control circuit 105 . More specifically, as shown in FIG. 2 , the negating signal generation circuit 104 comprises a first nonvolatile memory element 201 and a second nonvolatile memory element 202 which have an MOSFET structure, a first inverter circuit 203 and a second inverter circuit 204 . Here, an output node of the first inverter circuit 203 is the output node N 2 of the negating signal generation circuit 104 . The first and second nonvolatile memory elements 201 and 202 may have the same structure as that of a nonvolatile memory element used in the nonvolatile memory circuit 106 . According to an example shown in FIG. 2 , a flash memory element having a stack type of floating gate structure is assumed as each of the nonvolatile memory elements 201 and 202 .
[0026] According to the negating signal generation circuit 104 shown in FIG. 2 , threshold voltages of the first and second nonvolatile memory elements 201 and 202 are lower than a power supply voltage and a voltage difference between the threshold voltages is small in an initial state when the test is started. For example, when the first and second inverter circuits 203 and 204 are CMOS inverters, in a case where W/L (gate width/gate length) of a P-type MOSFET is 1.0/9.8 (μm), and W/L of an N-type MOSFET is 1.8/0.8 (μm), since the gate length of the P-type MOSFET of each of the inverter circuits 203 and 204 is long and a current driving ability is low in a state where the first and second nonvolatile memory elements 201 and 202 are both ON, outputs of the inverter circuits 203 and 204 become the ground voltage or close to it.
[0027] When the test is completed, a writing operation is performed in the second nonvolatile memory element 202 to increase its threshold voltage to become a power supply voltage level or more, for example. As a result, a difference is generated in drain currents flowing in the first nonvolatile memory element 201 and the second nonvolatile memory element 202 , so that an output of the first inerter circuit 203 becomes a high level (for example, the power supply voltage level) and an output of the second inverter circuit 204 becomes a low level (for example, the ground voltage level). Thus, the voltage levels are maintained by the two inverter circuits 203 and 204 . Therefore, an output level of the negating signal generation circuit 104 is transited from the low level to the high level by performing the writing operation in the second nonvolatile memory element 202 when the test is completed, to generate a threshold voltage difference between the first nonvolatile memory element 201 and the second nonvolatile memory element 202 , and then a negating signal is outputted.
[0028] When the test is started, the voltage level of the output node N 2 of the negating signal generation circuit 104 is at the low level and when the test mode signal generation circuit 103 is activated and the test mode signal is output from the output node N 3 , the test signal control circuit 105 is activated and an activated signal is outputted from the output node N 1 to the switch circuit 102 . Then, the switch circuit 102 is turned on and transmits the test signal outputted from the output node N 4 of the test terminal 101 , to the output node N 5 as it is in the asserted state, to control the nonvolatile memory circuit 106 .
[0029] When the test is completed, as described above, by transiting the level of the output node N 2 of the negating signal generation circuit 104 to the high level, the output signal from the output node N 1 of the test signal control circuit 105 is inactivated to turn off the switch circuit 102 regardless of the output state of the test mode signal from the output node N 3 of the test mode signal generation circuit 103 . As a result, the test signal outputted from the output node N 4 of the test terminal 101 is negated to be in a predetermined state and it is not transmitted to the output node N 5 , so that the nonvolatile memory circuit 106 cannot be controlled from the test terminal 101 .
[0030] Therefore, although the nonvolatile memory circuit 106 can be controlled by the test signal outputted from the test terminal 101 at the time of the test, the nonvolatile memory circuit 106 cannot be controlled from the test terminal 101 after the test is completed.
[0031] The circuit constitution of the negating signal generation circuit 104 is not limited to that shown in FIG. 2 in this embodiment. In addition, although one test terminal 101 is illustrated in FIG. 1 , a plurality of test terminals 101 may be provided.
[0032] FIG. 4 shows an embodiment of a nonvolatile semiconductor memory device according to the present invention. As shown in FIG. 4 , a nonvolatile semiconductor memory device 400 according to the present invention comprises a test terminal 401 , a test terminal negation circuit 402 according to the present invention, a control circuit 403 , and a nonvolatile memory 404 . The control circuit 403 receives a test signal from the test terminal 401 and carries out a predetermined test mode process to the nonvolatile memory 404 . Since the test terminal negation circuit 402 according to the present invention is provided, the test signal from the test terminal 401 can be negated after a test, so that a test mode is prevented from being activated falsely and the nonvolatile memory 404 is prevented from being controlled from the test terminal 401 .
[0033] FIG. 5 shows an embodiment of an IC card according to the present invention. As shown in FIG. 5 , an IC card 500 according to the present invention comprises a test terminal 510 , a microcomputer 509 , a non-contact interface circuit 507 , and a contact interface circuit 508 . The microcomputer 509 comprises a test terminal 501 , a test terminal negation circuit 502 according to the present invention, a CPU 503 , a nonvolatile memory 504 , a ROM 505 and a RAM 506 , so that the test terminal negation circuit 502 according to the present invention is provided similar to the nonvolatile semiconductor memory device 400 shown in FIG. 4 . A test signal inputted to the test terminal 510 of the IC card 500 is outputted to the test terminal negation circuit 502 through the test terminal 501 in the microcomputer 509 , and the test signal is outputted to the nonvolatile memory 504 in an asserted state or a negated state depending on an internal state of the test terminal negation circuit 502 . Since the test terminal negation circuit 502 according to the present invention is provided, the test signal from the test terminal 510 is negated after the test, so that the test mode is prevented from being activated falsely and the nonvolatile memory 504 in the IC card is prevented from being controlled from the test terminal 510 .
[0034] According to the present invention, as described above, since the signal from the test terminal is negated after the test, there can be provided a nonvolatile semiconductor memory device which will not leak inside information. Furthermore, an IC card provided with the above nonvolatile semiconductor memory device can be an IC card with a high-security level.
[0035] Although the present invention has been described in terms of the preferred embodiments, it will be appreciated that various modifications and alterations might be made by those skilled in the art without departing from the spirit and scope of the invention. The invention should therefore be measured in terms of the claims which follow.
|
A test terminal negation circuit comprises a switch circuit which receives a test signal from a test terminal and outputs it in an asserted state as it is or in a predetermined negated state to a test object circuit, a test signal control circuit which controls an output signal of the switch circuit to be asserted or negated, a test mode signal generation circuit which generates a test mode signal which asserts the output signal of the switch circuit, and a negating signal generation circuit which can output a negating signal for forcing the output signal of the switch circuit into negated state and comprises an electrically rewritable nonvolatile memory element. When the test signal control circuit receives the negating signal, it does not assert the output signal of the switch circuit even it receives the test mode signal.
| 6
|
TECHNICAL FIELD
This invention relates to direct gas-fired heating and ventilating systems for industrial and commercial buildings and the like and more particularly to using variable amounts of fresh air therein.
BACKGROUND OF THE INVENTION
There are current two types of direct gas-fired heating and ventilating systems used in industrial and commercial buildings and the like to meet the needs of make-up air for that which is exhausted from the building. Basic to both systems is the supplying of heated air into a building by passing fresh outside air directly over a gas flame with the burner utilizing the kinetic energy of the air flow to complete combustion without adverse by-products prior to delivery into the building space. In one type of system, 100 percent outside air is supplied to the gas flame and thence in a thus heated condition into the building to replace that amount of air which is exhausted. Moreover, in such a system, it is also possible to bring in an excess of make-up air over that exhausted to ensure a positive pressure in the area to prevent outside air infiltration and cold drafts, down or backdrafts in heating equipment flues, ventilators and stacks, and to compensate for reduced exhaust fan air volumes that could result in inadequate removal of possible contaminants. Normally, the exhaust system in this type of arrangement is interlocked with a make-up air system so that both units are in operation at the same time. During operation of this type of direct gas fired system, air flow is continuous with the discharge of air normally regulated either by modulating the gas flow or by electronic gas flame modulation. In either event, each of these control systems allows the burner to operate at any point on its turn-down range to provide a constant heater air discharge temperature.
In the other type of conventional direct gas-fired heating and ventilating system, there is incorporated a return air damper downstream of the direct gas-fired burner which provides an option of 50 percent fresh air and 50 percent return air, or 100 percent fresh air and no return air. The latter mode is generally recommended for multiple exhaust fan installations and other applications with variable exhaust air requirements recognizing that less fuel is expended to heat less make-up air. In a system with multiple exhaust fan applications, the 100 percent fresh air damper position is established when all the exhaust fans are operating. On the other hand with only one fan in operation, the unit is typically switched to handle 50 percent make-up air and 50 percent return air. This kind of system lends itself to those ventilation applications incorporating supplemental space heating with make-up air requirements. In such an application, the total air volume circulated need not be 100 percent make-up air but can be a mixture of 50 percent fresh air and 50 percent return air. However, since the heat output of the burner at the 50 percent fresh air and 50 percent return air condition must not be allowed to normally exceed one-half that of the 100 percent fresh air condition, the unit must be capable of providing needed supplementary heat at the reduced firing rate. And thus the later system has the same modulating discharge air control as in the fresh mentioned system and in addition has a fresh air/return air control.
While the above systems have proven generally satisfactory, they are at best a compromise as the total amount of air being handled and the amount of outside air being discharged by the air handling equipment must be held constant to ensure proper conditions for good combustion at the gas flame. A significantly better system would be where both the outside air and the return air could be modulated to satisfy any air conditioning and ventilation demand while heating or cooling.
SUMMARY OF THE PRESENT INVENTION
The present invention accomplishes the above objective with method and apparatus employing a variable bypass of fresh air around the gas flame that operates in conjunction with a variable amount of fresh air to the gas flame and a variable amount of return or recirculating air. According to the present invention, there is delivered a variable amount of fresh air from outside the building to a gas flame and thence in a thus heated condition into the building. In addition, a variable amount of fresh air is bypassed from outside the building around the gas flame and thence into the building. Moreover, a variable amount of air inside the building is recirculated. Given such an arrangement, the system is initially adjusted so that a predetermined pressure drop that will effect good efficient combustion occurs across the gas flame when there is no bypass flow and no recirculation flow. In one condition then the fresh air delivered to the gas flame and also the recirculated air are both modulated so that the predetermined pressure drop is maintained when there is no bypass flow. Alternatively, the fresh air delivered to the gas flame and also both the reciruclated air and the bypass air are all modulated so that the predetermined pressure drop is maintained when there is both bypass flow and recirculation. As a result, it has been found that there is afforded the capability of supplying varying quantities of outside air from as little as 40 percent up to 100 percent if so desired while maintaining good efficient combustion at the gas flame.
These and other objects, advantages and features of the present invention will becomes more apparent from the following description and drawing in which:
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a diagrammatic representation in side elevation of an industrial building having a preferred embodiment of the direct gas-fired heating and ventilating system according to the present invention.
FIGS. 2 and 3 are similar to FIG. 1 but show the system in different operating modes.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown an industrial building generally designated as 10 having a floor 12 and a roof 14 and within which is installed a direct gas-fired heating system generally designated as 16.
The system 16 comprises ducting 18 having an inlet stack 20 that extends through the roof and is open to the fresh air outside the building beneath a stack cover 22. A plurality of outside or fresh air dampers 24 are mounted in the inlet 20 immediately above a direct gas fired burner 26 of conventional type. Bypass air dampers 28 are mounted on opposite sides of the gas-fired burner 26 and together with the latter are located upstream of recirculation or return air dampers 30 that are mounted in a return air duct 31 open to the interior of the building. The outside air dampers 24 are adjustable to modulate or restrict the fresh air flow in the outside or fresh air duct 20 from no restriction to an absolute barrier with no flow. Similarly, the bypass air dampers 28 are adjustable to modulate or restrict the fresh air flow around the burner from no restriction to an absolute barrier. And also similarly, the return air dampers 30 are adjustable to modulate or restrict the return air flow in the return air duct 31 from no restriction to an absolute barrier with no flow. A plurality of air filters 32 are located across the ducting 18 between the burner 26 and the respective bypass and return air dampers 28 and 30. And a fan 34 which provides for forced air circulation and itself has a variable inlet vane operable to vary the amount being handled in the system is located in the ducting 18 immediately downstream of the filters. And finally there is provided a chilled water cooler 36 of conventional type located in the ducting 18 for cooling the filtered air prior to delivery out an outlet 38 of the system to the interior of the building.
As is well known, good combustion occurs when the proper mixture of gas and air is achieved to minimize carbon monoxide and maximize carbon dioxide. A good visual indication of good or effective combustion is a clear blue flame. It has been found that proper conditions of good combustion is maintained with a 0.30 to 0.77 inchs water column pressure difference or drop across the direct gas fired burner 26. According to the present invention, the variable amounts of air delivery by the dampers is adjusted to maintain good combustion and is accomplished as follows. Initially, with the equipment installed as shown in FIG. 1, the system is adjusted so that a predetermined pressure drop of preferably about 0.4-0.6 inches water column approximately centered in the above desired range occurs across the gas flame with the inlet dampers 24 wide open when there is the maximum allowed bypass flow and no recirculation (i.e. the bypass dampers 28 are full open and the recirculation damper 30 are closed) and thus 100% fresh air delivery. With the inlet dampers 24 and bypass dampers 28 wide open and the recirculation dampers 30 closed, the fan capacity is then adjusted to produce this pressure drop as well as meet the base make-up air and circulation requirements within the building. With the system thus initially adjusted, both the fresh air delivered to the gas flame and the recirculated air may then be modulated by operation of the fresh air, bypass and return air dampers 24, 28 and 30 so that the predetermined pressure drop is maintained by not permitting this pressure drop to fall below about 0.4 to 0.45 inches water column while there continues to be no bypass flow with the bypass dampers 28 closed. In this condition, which is shown in FIG. 2, there is obtained minimum delivery of outdoor air of for example about 40 percent with the outside dampers 24 almost closed and the return dampers almost fully open while the bypass dampers remain fully closed.
Then to supply additional outside air, the outside air, recirculated air and the bypass air are all simultaneously modulated with the outside air return air, and bypass air dampers 24, 30 and 28 so that the predetermined pressure drop is maintained by not permitting the pressure drop to fall below a slightly higher figure of about 0.45 to 0.55 inches water column when there is both bypass flow and recirculation. In this mode which is shown in FIG. 3, there is then available anywhere from about 50 to 90 percent outdoor air thus giving greater flexibility to matching the outside air needs to the amount of outside air that can be cost effectively delivered when heating of the outside air and building space is required. It will also be appreciated that in each of the above modes, the air may be chilled downstream of the burner by operation of the water cooler 36 to provide cooling as well as heating and ventilation .
Moreover, it will be appreciated that since all the operating conditions are determined empirically from the outside, bypass and return dampers, there is no need for sensors and feedback control to maintain the desired pressure drop across the burner. And thus the dampers may all be controlled by a simple conventional positioning system 40 comprised for example of electrical, mechanical and/or fluid actuators.
Thus the foregoing description of the preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications and variations are possible in light of the above teaching. The embodiment was chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention and various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.
|
A direct gas-fired heating and ventilating system for industrial and commercial buildings and the like comprises a direct gas-fired burner, fresh air dampers, fresh air bypass dampers and recirculation dampers.
| 5
|
CROSS-REFERENCES TO RELATED APPLICATIONS
This is a non-provisional application claiming the benefit-pursuant to 37 C.F.R. §1.53(c) of an earlier-filed provisional application. The provisional application was filed on Aug. 21, 2007 and was assigned application serial number 60/965,680. The provisional application listed the same inventor.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was developed using United States Department of Defense funding issued through a grant by the Office of Naval Research (Grant No. N0014-02-1-0623).
MICROFICHE APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of mechanical gear systems. More specifically, the invention comprises a controlled damper motor placed between the gearbox output and the load.
2. Description of the Related Art
Many mechanical systems require the use of speed-changing gears. These are conventionally housed in a gearbox, which may include two or more sets of meshing gears. FIG. 1 shows one simple depiction of such a system. Prime mover 24 is intended to provide rotational mechanical energy to load 28 . Unfortunately, the speeds at which the two devices operates are incompatible. The prime mover in this example is a steam turbine, which typically operates in excess of 10,000 RPM. The load is a synchronous electric generator, which operates at 360 RPM. The prime mover and the load may obviously not be directly connected.
The solution to this problem is the use of reduction gearbox 26 . Reduction gearbox 26 houses several sets of meshing gears. Input shaft 30 is spinning at the speed of the turbine, but output shaft 32 is reduced to the rotational velocity needed for load 28 .
While the reduction gearbox solves the speed compatibility issue, it introduces other problems. Those skilled in the art will know that every set of mating gears creates a backlash issue. The term backlash generally means the amount of rotational “slop” which exists between two mating gears. If an input shaft feeds torque into a single set of mating gears and an output shaft transmits that torque from the mating gears, it will be possible to turn the input shaft back and forth through some amount of rotation without turning the output shaft (and vice versa). This amount is referred to as backlash.
When the input and output shafts are loaded (such as by transmitting a fixed torque from a prime mover to a load) backlash is not typically a problem since the gear teeth remain engaged. However, when the load varies (or the system is unloaded or reversed), the gear teeth may become transiently disengaged and reengaged. This can produce resonant problems, as well as excessive gear tooth wear.
The problems associated with backlash have traditionally been addressed through gear design. Some of the prior art solutions include (1) designing specialized gear teeth which are better suited for dynamic loading conditions; (2) reducing tolerances between the interfacing gears; and (3) adding a fixed biasing torque which keeps the teeth engaged in one direction. Gear systems employing these solutions are often expensive to manufacture. The use of such specialized gears may reduce “clanging” and vibration. However, the gears still experience additional stress under dynamic loading and unloading conditions. Furthermore, tight gear interface tolerances often increase mechanical friction and present lubrication problems.
Backlash within a gear system also causes problems with resonance. A gear train possesses one or more critical speeds. When operated around these critical speeds, cyclic torsional vibration tends to increase. Vibration obviously reduces gear and bearing life. However, in many large systems, it is simply unsafe to operate the gear train at a critical speed. The system must then be designed to quickly pass through this speed (both accelerating and decelerating) in order to avoid damage.
An example of a rotating mechanical system is shown in FIG. 2 . Motor 1 ( 34 ) and motor 2 ( 36 ) are connected to rotate in unison. These are collectively an input torque generating device. Motor 1 drive ( 44 ) and motor 2 drive ( 46 ) control motor 1 and motor 2 , respectively. The two motors feed into low speed gear box 38 . This component increases the rotational speed before feeding into high speed gearbox 40 , which further increases the rotational speed. The output of high speed gearbox 40 is connected to load 28 .
Such an arrangement can be used to evaluate the performance of the components involved. It is desirable to be able to control the input torque and the load torque. The motor drives control the input torque while load controller 42 controls the load torque. The reader may wish to consider exemplary specifications for the system of FIG. 2 . Motor 1 and motor 2 are each 2.5 MW variable speed motors capable of producing a peak torque of 78,220 ft-lbf@225 RPM. Low speed gearbox 38 has an input range of 0-450 RPM and an output range of 0-3,600 RPM. High speed gearbox 40 has an input range of 0-3,600 RPM and an output range of 0-24,000 RPM. The load in this example spins in the range of 0-24,000 RPM and consumes a maximum of 5 MW.
Highly precise control of the input and output shaft torques can avoid the backlash and resonance problems discussed previously. However, those skilled in the art will realize that such control is often impossible. Returning to the example of FIG. 1 , the reader will appreciate that one cannot rapidly adjust the torque produced by a prime mover such as a steam turbine. By the same token, one cannot rapidly adjust the torsional load created by a device such as a large electrical generator. Thus, it is desirable to introduce a new element which can provide rapid torque control to minimize backlash-related problems. The present invention proposes just such a device.
BRIEF SUMMARY OF THE INVENTION
The present invention comprises a torque damper motor connected to the output side of a mechanical gear system. The damper motor, along with its associated control system, mitigates backlash problems, reduced torsional resonance, and provides improved output torque control. In the preferred embodiment, the damper motor is powered by a power electronics-based variable speed drive. The damper motor can be significantly less powerful than the overall rating of the gear system (typically 5-10% of the overall rating) while still providing the enhanced performance.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a perspective view, showing a simplified depiction of a prior art primer mover feeding a load through a reduction gearbox.
FIG. 2 is a schematic view, showing a prior art motor and gearbox arrangement with an attached load.
FIG. 3 is a schematic view detail view, showing a the addition of torque damper motor and associated controller.
FIG. 4 is a sectioned perspective view, showing one example of a torque damping motor.
FIG. 5 is a sectioned perspective view, showing a second example of a torque damping motor.
FIG. 6 is a graphical view, showing a plot of output shaft torque over time.
REFERENCE NUMERALS IN THE DRAWINGS
18
torque damper motor
20
load shaft
24
prime mover
26
reduction gearbox
28
load
30
input shaft
32
output shaft
34
motor 1
36
motor 2
38
low speed gearbox
40
high speed gearbox
42
load controller
44
motor 1 drive
46
motor 2 drive
48
armature winding
50
field winding
52
damper motor controller
54
homopolar rotor
56
load torque
58
gearbox output torque
60
damper motor torque
62
gearbox output shaft
DETAILED DESCRIPTION OF THE INVENTION
The present invention proposes adding a controlled torque damper motor on the output side of a rotating mechanical system. FIG. 3 shows the addition of such a motor to the system of FIG. 2 . In FIG. 3 , the reader will observe that torque damper motor 18 has been added between high speed gearbox 40 and load 28 . Gearbox output shaft 62 provides the rotating output from the two gearboxes. It is directly connected to load shaft 20 , which powers load 28 . Torque damper motor 18 rotates in unison with load shaft 20 . It could be directly connected to the gearbox output shaft, or attached to the load shaft itself.
Rapid control of the torque damper motor is preferable, so damper motor controller 52 is provided. This provides rapid fluctuation in both the magnitude and direction of the torque produced by the torque damper motor. Those skilled in the art will know that such control can be provided by a variety of known methods. However, one good approach is to use a pulsed output from the damper motor controller to simulate a variable speed AC drive. Such a pulsed output may assume the form of a pulse-width-modulated drive, though other forms may be suitable in some applications.
Many different configurations could be used for the damper motor itself FIGS. 4 and 5 illustrate two examples among the many possibilities. In FIG. 4 . armature winding 48 of torque damper motor 18 has been directly attached to load shaft 20 . It spins with the load shaft and is selectively energized by a stationary field winding 50 .
FIG. 5 shows an alternate configuration known as a “homopolar motor.” If a ferromagnetic material is used for load shaft 20 , then the portion lying within torque damper motor 18 can serve as a homopolar rotor 54 . Field winding 50 selectively energizes the homopolar rotor to produce the desired direction and magnitude for the torque produced by the device.
Of course, there are many other types of motors which could be used for this application. While not all motor types are suitable for service as a torque damper motor, the reader should bear in mind that many more possibilities exist beyond the two examples of FIGS. 4 and 5 .
Having now described the components of the invention, the reader may wish to know how these components interact to mitigate the problems discussed initially. The invention can be applied to any rotating system having a gear train. The system of FIG. 3 will be used as an example. Motor 1 and motor 2 create rotating input torque. The speed of the rotating input torque is significantly increased as it passes through the low speed gearbox and the high speed gearbox. The output of the high speed gearbox is then transferred from gearbox output shaft 62 to load shaft 20 and then to load 28 . The torque demanded by load 28 is controlled by load controller 42 . Assume as an example that the load is a compressor. The torsional load created by a compressor is controlled by adjusting the output flow rate and/or the output pressure. These values can be varied by load controller 42 .
The need for the present invention is illustrated in the following scenario: The compressor (load 28 ) is set to a specific output pressure and flow rate. The system is then started and accelerated up to operating speed. Resonance may occur for a period when the operating speed is reached (the operating speed being the point where the input torque—less the losses incurred in the drive train—is equal to the torque required by the load). The gearboxes will load and unload as the resonance occurs (“freewheeling”), with resulting clanging and stress on the gears.
A more stark example occurs when the torque demanded by the load is suddenly reduced. If the pressure demanded from the compressor is suddenly reduced, the speed of motor 1 and motor 2 cannot be reduced instantaneously so an “overrun” occurs in which the angular momentum of the load actually drives the system in reverse (with the compressor driving the motors). This situation actually reverses the torque flow through the system (a negative torque). Those skilled in the art will know that going from a positive torque flow to a negative torque flow will cause the gears to go from a first engaged position, through a period of disengagement, and into a second engaged position (with the disengaged position being the backlash). This situation at best causes excessive wear and can even damage the gears.
Torque damper motor 18 can eliminate or at least mitigate these concerns. Damper motor controller 52 causes torque damper motor 18 to produce an appropriate magnitude and direction of torque to create a desired torque at gearbox output shaft 62 . It compensates for variations in the torque demanded by load 28 so that the drive train does not experience damaging fluctuations.
FIG. 6 graphically illustrates the function of the torque damper motor in one scenario. FIG. 6(A) shows a plot of load torque 56 over time. The reader will observe that the load torque fluctuates substantially and even becomes negative at some points (representing an overrun where the load actually feeds torque back into the system). This plot illustrates how a prior art drive train will experience backlash reversals in the gear teeth engagement and resulting “clanging.”
The term “positive” and “negative” torque are somewhat arbitrary. As the system rotates in a first desired direction with torque flowing from the motors to the load, the torque is said to be “positive.” All the gears in the drive train are positively engaged in a first engagement position. If the loading changes so that torque actually flows from the load back to the motors, then the gears will disengage, rotate through the backlash arcs, and reengage in a second engagement position. This torque would then be “negative.” Changing from positive to negative torque—or from positive to zero torque—is generally undesirable.
The use of the term “torque damper motor” should also be explained. Those skilled in the art will quickly realize upon reviewing the drawing figures that the “torque damper motor” acts both as a motor and a generator. In those instances where it exerts a braking force on the rotating shaft, it is of course acting as a generator. The term “motor” in this context is intended to encompass both the motor and generator functions.
FIG. 6(B) represents a desired gearbox output torque for low-stress operation. The best scenario is a constant output torque on gearbox output shaft 62 , which is represented as gearbox output torque 58 .
FIG. 6(C) represents the operation of the system with the torque damper motor producing “biasing” torques. Load torque 56 (shown as a solid line) is the same as for FIG. 6(A) . The damper motor controller then drives the torque produced by the torque damper motor to produce the desired result. The reader will observe that the difference between the load torque 56 (shown as a solid line) and the damper motor torque 60 (shown as a phantom line) equals the desired gearbox output torque 58 (shown as a dashed line). In other words, by appropriately driving the torque damper motor the input drive train (consisting of motor 1 , motor 2 , and the gearboxes) “sees” only a steady-state positive torque. No backlash is experienced, even though the load torque fluctuates and even reverses direction.
The torque damper motor can also be employed to dampen system resonance. Many gear trains experience resonance at certain speeds. Resonance can be simply a fluctuation of positive torque, a fluctuation between positive and zero torque, or a fluctuation between positive and negative torque. All of these are undesirable. The torque damper motor can introduce suitable biasing torque so that the gearbox output torque remains more constant. In some situations it will be possible to completely null the resonance, while in others it may only be possible to dampen the amplitude of the resonance.
The input torque and the load torque may be continually measured so that the damper motor controller can provide appropriate biasing torque to create smooth operation. In other instances, the input and load torques may be accurately predicted in advance. As an example, the start-up torque output of a steam turbine may be well known and mathematical functions can be written to predict its behavior. By the same token, the torque demands of a load such as an electrical generator may likewise be described using empirical or analytical functions. One or more of these function can then be mapped into the damper motor controller so that the controller “knows” what type of biasing torque to apply in a given scenario.
The torque damper motor can have a significantly lower torque output than the overall rating of the drive train, yet still provide effective performance enhancement. Even in those instances where the biasing torque needed exceeds its capability, it can still reduce the amplitude of the harmful effects.
The reader will thereby appreciate how the proposed invention eliminates or at least mitigates many of the problems inherent in rotating gear systems. Although the preceding description contains numerous examples, these are intended only to convey some of the embodiments of the invention and should not be viewed as limiting. As one example, the invention could be used with many types of torque creating devices other than steam turbines, electric motors, and compressors. Likewise, although a speed-increasing gear train was described in detail, the invention is equally applicable to speed-decreasing gear trains. The scope of the present invention should thus be fixed by the following claims rather than the specific examples given.
|
A torque damper motor connected to the output side of a mechanical gear system. The damper motor, along with its associated control system, mitigates backlash problems, reduced torsional resonance, and provides improved output torque control. In the preferred embodiment, the damper motor is powered by a power electronics-based variable speed drive. The damper motor can be significantly less powerful than the overall rating of the gear system (typically 5-10% of the overall rating) while still providing the enhanced performance.
| 8
|
The invention described and defined in this application is an improvement of the invention disclosed and claimed in application Ser. No. 129,069 filed 12/7/87. This application is a continuation in part of application Ser. No. 129,069 filed 12/7/87 issued as U.S. Pat. No. 4,770,273.
BACKGROUND OF THE INVENTION
The present invention relates to an improved lifting apparatus and tool for use by air condition contractors, carpenters, electricians, painters, and roofers who need to move materials to the second, third, and fourth stories or roofs of buildings being constructed or remodeled.
Various lift devices, utilizing hand operated winches or windlasses are known in the art. Typical of those found in the art are illustrated in U.S. Pat. Nos. 2,426,825, 4,232,759, and 4,458,764. In particular U.S. Pat. Nos. 599,169; 4,598,795; and 4,690,248 Alber 2,118,585; Book 3,074,508; Cox 3,902,700; Wilson 3,964,573; Ziegelmann 4,128,228; Killen 4,690,248; disclose ladder bracket and ladder lifts of various types.
The present invention comprises a novel means for attachment of applicants' lift bar comprising a one piece, light weight shoulder mounted, hand held apparatus to be affixed, temporarily or permanently to the two side rails of an industrial ladder to allow the operator to move a piece of equipment or a materials container onto the roof of a multistory building that is usually from 2 to 4 stories high or higher.
The improvements to the invention, as described in this application, illustrate alternative means to fasten the lift bar to the side rails of the ladder and optional means to stabilize the base of the ladder to reduce the risk of sidewise tipping, when heavily loaded at high elevations.
SUMMARY OF THE INVENTION
Accordingly, it is the primary object of the present invention to provide a lifting apparatus which avoids the disadvantages of the prior art.
It is another object of the present invention to provide a ladder lift apparatus which requires little set up time by one man and is sturdy and inexpensive to manufacture and has a total weight of 20 to 40 pounds.
It is still one additional object of the present invention to provide a lifting apparatus and tool that combines a vertically positioned extension ladder with a horizontally positioned lifting bar equipped with winch and cable means to allow an operator standing on the roof to move a heavy load from the ground onto the roof.
It is one further object of the present invention to provide bracket means to attach the lift bar apparatus of this invention to the two side rails of a ladder or extension ladder. A pivot member may be provided, but is not required, to facilitate connection of the lift bar to the bracket means. Such a pivot member readily allows the load to be pulled onto the edge of the roof after the load is suspended at its maximum vertical position, to allow the load to be deposited on the roof or into an open, upper story window.
It is also one additional object of the invention to provide a horizontally positioned lifting bar apparatus with a padded shoulder mount and handle member that allows one end of the lifting bar to be supported by the hand and/or the shoulder of the operator while standing on the roof or on an upper floor of a building and the other end of the lifting bar is supported by the side rails of the ladder.
To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The figures in the drawings are briefly described as follows:
FIG. 1 is a perspective view of one embodiment of the invention illustrating the lift bar in use on top of a building.
FIG. 2 is a perspective view of a modified embodiment of the invention illustrating another means of connecting the lift bar to the ladder.
FIG. 3 is a perspective view of another embodiment of the invention illustrating means of connecting, the lift bar to the ladder.
FIG. 4 is a partly cut away plan view of the lift bar attached to the bracket means that is separated from the ladder.
FIG. 5 is a perspective view, illustrating a stabilizer means to minimize lateral tipping of the ladder.
FIG. 5a is a plan view, partly in cross section, of an alternative embodiment of a lateral stabilizer.
FIG. 5b is a plan view of an alternative embodiment of the lateral stabilizer of the instant invention.
FIG. 6 is a perspective view, partly cut away of another embodiment of the invention with means to connect the lift bar to the end cap bracket.
FIG. 7 is a perspective view of another embodiment of the invention where the lift bar is pivotally attached to the end cap bracket.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, that is a perspective view, a building 1, with a flat roof 2 supports an operator 3. The operator 3 standing on the roof operates lifting bar 4 by placing one end of the bar with shoulder support 5 on the operator's shoulder. The lift bar 4 is supported and attached by a connection on its other end to a ladder or equivalent support member that stands on the ground 6. The ladder 7 may be a conventional industrial grade heavy duty ladder, metal, wood or fiberglass. If an extension ladder 7, is used, it should be an industrially rated ladder, marked to indicate its ability to safely support at least 250 or 300 lbs. The ladder with side rails 7 has rungs 8. The lift bar 4 is attached to and supported by a bracket or plate 17.
A conventional winch or windlass assembly, 10 may be mounted by bolting or by welding the winch 10 to the upper face or the lower face of lifting bar 4. FIG. 1 shows the winch 10 mounted on the lower face of bar 4.
The winch or windlass assembly 10 in FIG. 1, may consist of a conventional winch or windlass, ratchet and pawl. Such a winch assembly may have a ratchet gear ratio of about 1 to 4 to 1 to 17 or more to allow the winch to be turned more easily by the operator.
The winch or windlass 10 has a drum on which 30 to 40 ft. or more of cable is stored and is fed out, when in use. Cable 12 may be fed out through a cable guide means 13. The cable 12 may be used with a pulley 14 having a hook 16A on its lower end. In such arrangement, as shown in FIG. 3, the end of cable 12 is fitted with a hook 16 that is secured in cable guide means 15. In this arrangement, the weight of the load is evenly divided between the two guide means 13 and 15. In such a configuration the operator will find it much easier to turn the crank handle 11 of the windlass or winch 10.
As stated in applicants' co-pending application, Ser. No. 129,069, the lift bar tool illustrated in FIG. 1 is designed to have one end of the lift bar 4 rest on the operators shoulder in order to speed up the operation of lifting and to make it more efficient. In some cases, where the load is over 300 lbs. and particularly in the range of 400 lbs. to 500 lbs. an alternative support means may be used to support the lift bar 4. The lift bar may be supported by a pivotal post or tripod and telescopic leg that may be rotated into position. A tripod 17a may be used to support one end of bar 4 as shown in the co-pending application Ser. No. 129,069 filed Dec. 7, 1987.
In FIG. 1 the end of the lift bar 4 is fitted over top of an end plate or end bracket 17 so that the bar 4 is evenly supported by the upper ends 9 and 9A of the two side rails of the ladder. In FIG. 1 a vertical bolt 19 may be used to connect the lift bar to the end bracket 17. Other structually equivalent brackets and support means may be used to support the lift bar evenly and uniformly by and between the two upstanding side rails 9 and 9A of the ladder.
The end bracket 17 that fits over the upstanding ends of side rails 9 and 9A may be made of an aluminum alloy (6061 or 6063), reinforced fiberglass or other suitable material. The thickness will usually vary from about 1/8 inch to 1/2 inch and in all cases be of adequate strength to support a total load of 400 to 500 pounds. The lift bar 4 may have an opening 18 near the end thereof that is aligned with hole 18 in the end bracket 17. A pin or bolt 19 extends thru bracket 17 to connect bracket 17 to lift bar 4. The bracket 17 may be fastened to the upper ends of side rails 9 and 9A by screws or other suitable connectors (not shown) that physically attach the bracket to the side rails at 9 and 9A. This connection is best shown in FIG. 4.
In FIG. 2 a solid support element 21 may be positioned above the top rung 8 and support the lift bar 4 by a pin or bolt. The flat step bracket that is a solid support 21 may be screwed or bolted to the I beam structure 22 and 23 as shown in FIG. 2 so as to form a horizontal support means 21 for the lift bar. In this structure the solid support element 21 supports the lift bar 4 and evenly distributes the load to each upper end 9 and 9A of the side rails of the ladder, as best shown in FIG. 2.
In FIG. 3 a collar member 25 is supported by a braided nylon rope 27. The braid may be made of any strong fiberous or metallic material that can support a total load of 400 to 500 pounds. In this embodiment the load on lift bar 4 is supported by the collar 25 having an opening 26 that is suspended by the two braided supports 27 that encircle upper ends 9 and 9A of the side rails. A pin or bolt may be inserted in opening 28 to may secure the collar 25 to the lift bar 4. The collar 25 may be made of a rectangular tubular metal about 1/8 to 1/4 inch thick, with a length of 4 inches to 5 inches and capable of supporting a load of 400 to 500 pounds.
In FIG. 5 a triangular shaped lateral reinforcing brace or lateral stabilizer consists of member 31 that is secured at its upper position by a bolt 30 with screw threads on at least one end as shown in FIG. 5a. The bolts 30 and 33 may be positioned thru hole 29 and hole 32 without any loss of any strength of the ladder. In this embodiment the bolts 30 and 33 are positioned thru the inside of tubular rungs 8 and 8' where tubular members 31 and 34 are pinned together by pin 38 at the outer end of the lower member 34 forming a rigid triangular reinforcing brace or lateral stabilizer. Thus a triangular brace or stabilizer may secured and bolted on each side of the ladder. The use of thes two lateral stabilizers, that form triangles on each side of the ladder, steady the ladder on high lifts of 20 feet to 40 feet high. The elements 31 and 34 may be made of tubular metal that may vary from about 3/4 inch to 11/2 inches in diameter, with a wall thickness of about 1/8 inch to 1/4 inch, if contracted of aluminum or aluminum alloy.
In FIG. 5a, that is a partly cut away view, bolt 30 is shown as threaded on its outer ends to receive nut 35. This bolt 30 runs thru the entire length of rung 8 and projects beyond the side rails 7 of the ladder. Elements 31 and 34 may also be constructed of flat metal, preferably 3/4 to 11/2 inches wide and about 1/8 to 1/4 inch thick. Such a flat metal element may be made of aluminum alloyed with steel and/or magnesium. Aluminum alloys 6061 or 6063, that are well known to be high strength and light weight, are particularly useful in this embodiment. The flatened portions 39 at the end of rods 31 and the inner end of rod 34 give a firm, secure contact with the ground and with the ladder rail at rod 33 and tend to stabilize and brace the ladder against sidewise movement.
The outer ends 36 of tubular elements 34 may be partly cut away or scalloped to form opening 37 so as to facilitate joining members 31 and 34 by a pin or bolt 38 or other suitable connector.
In FIG. 5a flat portion 39 is bolted to I beam midsection 22 by a threaded bolt 30.
In FIG. 5b a pair of rods 39 and 40 each being free on the lower ends 41 can be positioned to the side of the ladder to stabilize the ladder. In this embodiment, the length of each rod 39 and 40 is longer than the ladder from the point bolt 30 fastens the tab 39 to the side rail of the ladder and therefore stabilized the ladder against lateral movement, and from side to side as a heavy load is raised to a height of 20 to 40 feet.
In FIG. 6 an end cap bracket 40 fits over both upper ends of the side rails and supports lift bar 4. The side wall 41 of the end cap bracket 40 will usually vary from about 2 inches to 6 inches in height. The thickness of the end cap bracket 40 at the side wall indicated at 42 and on its top load bearing surface may vary from about 1/8 inch to 1/4 inch and may be made of a high strength aluminum alloy such as alloy 6061 or all 6063. In this embodiment end cap 40 is permanently fastened to lift bar 4 by a pair of bolts 44 that extend thru openings 43. A pair of rubber or plastic resilient washers 45 may be used to allow the lift bar 4 to pivot slightly, usually from 2 degrees to 10 degrees when under load. Bolts 44 may be fastened by nuts 46 to securely fasten lift bar 4.
In FIG. 7 end cap bracket 40 may be fastened by a pivot mechanism and means to lift bar 4. The pivot mechanism is a pair of upstanding brackets 47 with openings 48 thru each bracket 47. A threaded rod or bolt 49 extends thru each bracket 47 and supports lift bar 4, in a manner to allow lift bar to pivot above end cap bracket 40. In this embodiment the end cap bracket 40 may be permanently fastened to the upper ends 9 and 9A of both side rails of the ladder. When the lift bar is to be attached for use in lifting a load threaded bolt 49 is extended thru opening 48 and nuts 50 are screwed onto each ends of bolt 49.
A stabilizer means 36 shown in FIG. 1a, in co-pending application Ser. No. 129,069 may be used to assure the safe delivery of the load and the stable vertical position of the ladder 7 during the lifting operation by securing the ladder in a vertical position and parallel to the building 2.
A cable or rope may likewise be used to secure the bottom of the ladder to the building to prevent the ladders movement away from the building while the load is deposited on the roof.
METHOD OF OPERATION
In the method of operating the lift bar of the instant invention the following steps should be followed, in sequence:
(1) The ladder 7, (one piece ladder or extension ladder) should be extended up beside the building so that the upper end of the side rails are above the lowest roof level.
(2) The operator takes the lift bar on his shoulder and climbs to the top of the building and places the lift bar 4 on the roof.
(3) Bolt or clamp the lift bar to the bracket affixed across the two upper ends of the side rails of the ladder. In the alternative the end cap bracket may be bolted to the lift bar 4 and then merely slipped over the two upstanding ends of the side rails as shown in FIG. 7 of this application.
(4) While holding the shoulder-mounted end of the lift bar the operator pushes the top of the ladder out from the building until the ladder is parallel to the building. The ladder should never be set up more than 46 to 48 inches from the building. Optionally a stabilizer means may be attached to the ladder to secure it in a vertical, parallel position, as set forth above.
(5) Optionally attach a flange and safety rope or cable to secure the bottom of the ladder to the building so that the ladder will not kick out during transfer of the load to the building.
(6) The operator then places shoulder mount 5 on his shoulder.
(7) The load is attached to the lower end of the cable and the operator starts the winch to place tension on the cable.
(8) The operation of the winch lifts the load to the general level of the top rung of the ladder and above the roof level.
(9) When the load is in a proper position the operator moves back and pulls the handle and lift bar towards him and away from the edge of the roof so that the load will be pivoted to move onto the roof. The ladder pivots at the ground level and the top of the ladder moves to the edge of the roof.
(10) The load is then deposited on the roof or into an open window in the same manner.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it will be understood that various omissions, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing from the spirit of the invention.
|
An improved ladder lifting apparatus usable to lift heavy loads from the ground to a roof surface including a horizontally positioned, hand or shoulder mounted lifting bar or beam with a winch means, fastened to the bar or beam where one end of the lifting bar or beam is fastened and/or connected to the side rails of a vertically positioned ladder or extension ladder, with means to allow movement of the upper end of the ladder toward the roof to deposit the load on the roof or into a window of a multi-story building combined with optional stabilizing features for the ladder to make use of the lift bar at high elevations more safe.
| 4
|
TECHNICAL FIELD
The present invention relates generally to methods and apparatus for releasably mounting an optical device, such as an optical magnifying device, on a support member in a precise and repeatable manner.
BACKGROUND OF THE INVENTION
Projectile firing apparatus such as rifles are often equipped with optical devices for sighting, such as scopes. Since each sighting device provides a specific magnification and field of view, different optical devices may be preferred for particular situations, depending upon factors such as the type of target, the estimated distance to the target, field conditions, and the like. Moreover, optical sights for use with projectile firing apparatus may be designed for specific ambient light conditions. Such optical devices may be releasably mounted to permit the user to interchange different sighting devices and to facilitate storage and transport of both the optical device and the projectile firing apparatus.
To produce consistent and accurate results, the optical device must be precisely and repeatably mounted on its support. It would also be advantageous to employ releasable mounting means that are easy to use and permit rapid mounting and dismounting of the optical device. Projectile firing apparatus such as guns provide an additional challenge for releasably mounting optical devices. Upon firing, the gun recoils. An optical device mounted on a gun must not move or become misaligned as a result of recoil, since field conditions ordinarily do not permit realignment of the sight after each shot is fired.
Rifle scopes are conventionally mounted to a rifle support member by means of a Suhler hock mount, a swing mount, or a flip/slide mount. Each of these mounting systems provides releasable mounting of a rifle scope, but none of these mounts provides a quick release system that facilitates interchanging scopes during use in the field. In the mounting systems recited above, recoil is absorbed at a single location, at the front foot, the swing stud, or the front clamping, respectively. The rifle scope therefore tends to become misaligned after repeated firing, and substantial mechanical stresses may be sustained at the location where recoil is absorbed.
SUMMARY OF THE INVENTION
The present invention relates to a mounting system providing rapid, repeatable, precise, and releasable mounting of an optical device on a support member. The mounting system of the present invention includes one or more studs and rotating shafts, each having a groove provided therein, which interact to releasably lock the studs in a support member. Each stud is preferably mounted directly or indirectly on the optical device, and each rotating shaft is received in a support member mountable on the projectile firing apparatus, or the like. In an unlocked condition, the grooves on the studs and rotating shafts face one another and the studs and locking shafts are not in contact. As each rotating shaft is rotated, the shaft portion of each locking shaft engages the groove in each stud to releasably mount the optical device on the support member. This design permits rapid and precise releasable mounting, and additionally provides even distribution of recoil to each of the studs. The mounting system is therefore less prone to mechanical stresses and failures and provides precise, repeatable positioning of an optical device or similar mechanism over long periods of use.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and additional features of the present invention and the manner of obtaining them will become apparent, and the invention will be best understood by reference to the following more detailed description, read in conjunction with the accompanying drawings, in which:
FIG. 1 shows an isometric view of an optical device mountable on a support member employing the mounting system of the present invention, wherein the studs are mounted directly on an optical device;
FIG. 2 shows an isometric view of an optical device mountable on a support member employing the mounting system of the present invention, wherein the studs are mounted indirectly on the optical device;
FIG. 3 shows an isometric, partially broken-away view of a support member illustrating the position of the studs and rotating shafts in an unlocked condition;
FIG. 4 shows an isometric, partially broken-away view of a support member illustrating the position of the studs and rotating shafts in a locked condition;
FIG. 5 shows a top view illustrating the rotating shafts (shown in phantom) in an unlocked position; and
FIG. 6 shows a top view illustrating the rotating shafts (shown in phantom) in a locked position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, an optical device 10 is mountable on a support member 12 and may be releasably locked in its mounted position as a result of the interaction of studs 14 and rotating shafts 16. Any optical device suitable for mounting on a portable or stationary support member may be mounted in accordance with the mounting system of the present invention. Rifle scopes, such as the Fixed Power rifle scope series available from Leupold & Stevens, Inc., which includes 4X, 6X, 6x42 mm, 8X, 8x36 mm, and 12X scopes, are exemplary optical devices 10 releasably mountable on a support member in accordance with the present invention. Support member 12 is mountable on a projectile firing apparatus such as a rifle, by means of suitable fasteners passing through mounting bores 18 and fastening to the apparatus. Alternatively, support member 12 may be formed as a part of or integrally with the projectile firing apparatus or the like.
In the embodiment shown in FIG. 1, studs 14 are formed integrally with or operably connected to optical device 10, such that each stud 14 protrudes from a lower surface of optical device 10 A "lower" surface is defined as a surface of optical device 10 adjacent support member 12 when optical device 10 is oriented properly for use and mounted on support member 12. Studs 14 are preferably located generally symmetrically with respect to the ends of optical device 10 and preferably have a generally cylindrical configuration.
As shown in the preferred embodiment of FIG. 1, each stud 14 comprises an upper cylindrical portion 20 having a larger diameter than lower portion 22. During the mounting operation, lower portion 22 of each stud 14 is received in a stud receiving bore 24, and shoulder 26 rests on the upper surface of support member 12. The length of upper cylindrical portion 20 between optical device 10 and shoulder 26 therefore determines the distance between optical device 10 and support member 12 when the optical device is mounted thereon, and may be varied as conditions require.
Lower portion 22 of each stud 14 is provided with a groove 28, which is preferably curved in a generally symmetrical configuration. Groove 28 preferably has a configuration corresponding generally to the contour of rotating shaft 16, so that the shaft portion of rotating shaft 16 is slidably rotatable about its central longitudinal axis in groove 28. Where multiple studs are provided, grooves 28 on studs 14 are preferably oriented in the same direction, as shown in FIG. 1. In this configuration, each rotating shaft is rotated in the same direction to mount each stud, and the locking operation is the same for each stud 14.
Rotating shafts 16 are generally cylindrical and, as shown in FIG. 1, include a shaft portion 32 having a groove 34 provided therein. Additionally, rotating shafts 16 comprise an enlarged head 36 at one end having a locking lever 38 mounted thereon, and a threaded portion 40 provided on shaft portion 32 opposite enlarged head 36. Groove 34 provided in each rotating shaft 16 is preferably curved in a generally symmetrical configuration. Groove 34 preferably has a configuration corresponding generally to the contour of stud receiving bore 24. The innermost point along groove 34 is located at a position corresponding approximately to the central longitudinal axis of rotating shaft 16.
Support member 12 is provided with stud receiving bores 24 opening through its upper surface. Each stud receiving bore 24 is sized and located to receive lower portion 22 of stud 14 therein. Additionally, rotating shaft receiving bores 30 open through a front surface of support member 12. Rotating shaft receiving bores 30 are sized and configured to receive rotating shafts 16 therein, and are preferably provided with an internally threaded portion matching threaded portion 40 of rotating shaft 16, so that rotating shafts 16 may be rotatably mounted and retained in rotating shaft receiving bores 30.
The central axes of stud receiving bores 24 and rotating shaft receiving bores 30 are generally perpendicular to one another. Rotating shaft receiving bores 30 are offset from but intersect stud receiving bores 24. In a preferred embodiment, the central axis of each rotating shaft receiving bore 30 is preferably generally tangential to an outer wall of stud receiving bore 24. According to preferred embodiments, rotating shaft receiving bores 30 and shaft portions 32 have a smaller diameter than stud receiving bores 24 and lower portions 22 of studs 14, respectively.
An alternative embodiment of the mounting system of the present invention is illustrated in FIG. 2. Components that are substantially similar to those shown and described with reference to FIG. 1 have been labelled with the corresponding reference numerals, and only the alternative embodiments will be described in detail.
In the embodiment illustrated in FIG. 2, studs 14 are mounted indirectly, and thereby removably, on optical device 10. Studs 14 are mounted on or formed integrally with mount rings 44 adapted to encircle optical device 10. Mount rings 44 are removably mountable on optical device 10 by means of fasteners 46. A single fastening location may be provided, as shown in FIG. 2, with each mount ring 44 having a generally annular configuration, or two fastening locations may be provided when mount ring 44 is provided as two separate components, each having a generally semi-circular configuration. An enlarged mount 48 is mounted on or formed integrally with mount rings 44 and abuts the upper surface of support member 12 when optical device 10 is in a mounted position. Enlarged mounts 48 function similarly to upper portions 20 of studs 14 in the embodiment illustrated in FIG. 1.
Rotating shafts 16 are received in rotating shaft receiving bores 30 and may be rotatably retained therein by means of screw fasteners 54 threadedly engageable in an internally threaded bore 50 of rotating shaft 16. Enlarged head 36 provided at one end of rotating shaft 16 has a slot 52 to facilitate rotation of rotating shafts 16 during the mounting operation.
In operation, rotating shafts 16 interact with grooves 28 in studs 14 to releasably lock studs 14 in stud receiving bores 24. Rotating shafts 16 are rotatable about their central longitudinal axes in rotating shaft receiving bores 30 between an unlocked position wherein studs 14 (and thereby optical device 10) may be removed from or inserted into stud receiving bores 24, and a locked position wherein studs 14 are securely retained in support member 12. The locking and unlocking operations are accomplished by rotation of rotating shafts 16 approximately 180° about their central longitudinal axes.
FIG. 3 illustrates the relative positions of studs 14 and rotating shafts 16 in an unlocked configuration of the mounting system as studs 14 are being inserted into stud receiving bores 24, and FIG. 5 illustrates the position of rotating shafts 16 in their unlocked condition. In the unlocked configuration, groove 34 in each rotating shaft 16 is aligned with and forms part of the cylindrical wall of each stud receiving bore 24. Studs 14 are thus insertable in stud receiving bores 24, with grooves 28 facing grooves 34 of rotating shafts 16, as illustrated in FIG. 3. In this unlocked configuration, studs 14 are freely movable in an axial direction into and out from stud receiving bores 24.
After studs 14 have been positioned in stud receiving bores 24, the locking operation is achieved by rotation of rotating shafts 16. Upon rotation of each rotating shaft 16 approximately 180° about its central longitudinal axis, shaft portion 32 of each rotating shaft 16 is engaged in groove 28 of each stud 14 to securely mount each stud 14 in support member 12. FIG. 4 illustrates the relative positions of studs 14 and rotating shafts 16 in a locked configuration of the mounting system, and FIG. 6 illustrates the position of rotating shafts 16 in the locked position. In the locked position, grooves 34 in rotating shafts 16 face the wall of rotating shaft receiving bores 30, as shown in FIG. 6. Rotation of rotating shafts 16 to the locked configuration is facilitated by slot 52 or locking lever 38 on enlarged shaft head 36.
Rotating shafts 16 are preferably rotated in a direction whereby the uppermost shaft portion defining groove 34 contacts the uppermost portion of stud 14 defining groove 28. The "uppermost" rotating shaft and stud portions are defined, in the context of this mounting system, as those portions nearest optical device 10. Each stud 14 is thereby pulled downwardly and tightened in stud receiving bore 24 by the interaction of shaft portion 32 with groove 28, to secure each stud 14 in support member 12. In the embodiments illustrated in FIGS. 1-4, rotation of rotating shafts 16 in a counterclockwise locking direction is preferred.
To remove optical device 10 from support member 12, rotating shafts 16 are rotated 180° about their longitudinal axes from their locked position. The unlocking, or releasing direction of rotation is preferably opposite from the locking direction (i.e., clockwise in the embodiments of the present invention shown in FIGS. 1-4). To facilitate proper rotation during the unlocking operation, stops may be provided by threads (not shown) on rotating shafts 16 and within the rotating shaft receiving bores 30.
Two studs and rotating shafts are preferably employed to releasably mount optical device 10 to support member 12. This arrangement permits recoil to be absorbed at two spatially separated locations during operation of a gun, or the like. The amount of recoil absorbed at each mounting location is therefore reduced by 50%. The mounting system of the present invention is consequently less prone to loosening and misalignment. Obviously, a further reduction in recoil per recoil absorption location can be obtained using a higher number of mounting locations; however, spatial and other considerations suggest that two such locations are preferred.
As a result of the simplicity of the locking and unlocking operations involved in use of the mounting system of the present invention, optical devices 10 may be rapidly and easily mounted and released from a support member. Consequently, both the time required to instruct a user in the mounting and release operations and the time required for a user to perform such operations are reduced. Mounting or releasing an optical sighting device 10 from a projectile firing apparatus may be accomplished by an experienced user within seconds.
While the mounting system of the present invention has been shown and described with reference to optical devices such as rifle scopes, the mounting apparatus and methods of present invention are useful for mounting other optical devices, aiming devices and the like. Likewise, while the foregoing description relates to mounting devices on projectile firing apparatus such as rifles, pistols and the like, the mounting system of the present invention is useful for mounting optical or other devices on other types of apparatus, such as tripods and the like, that may be stationary or portable.
While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purposes of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein may be varied considerably without departing from the basic principles of the invention.
|
A method and apparatus for releasably mounting an optical device on a support member in a rapid, repeatable and precise manner is provided. The mounting system is especially suitable for releasably mounting an optical device such as a sighting scope on a projectile firing apparatus such as a rifle. The mounting system includes one or more studs, each having a groove provided therein, and a corresponding number of rotating shafts. Each rotating shaft interacts with the groove in the corresponding stud to releasably lock the studs in a support member. Each stud is mounted directly or indirectly on an optical device, and each rotating shaft is received in a support member mountable, for example, on a projectile firing apparatus.
| 5
|
RELATED PATENT APPLICATION
This is a continuation of U.S. application Ser. No. 08/020,969, filed Feb. 22, 1993, now abandoned, which is a continuation-in-part of application Ser. No. 07/858,797, filed Mar. 27, 1992, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to structural components such as sheet metal studs, ceiling grid, furring channel, etc., and particularly to a reinforcing of the web sections of such structural components.
Sheet metal studs, T-bars for ceiling grid systems, furring channels and other sheet metal structural members all have web sections, or the like, which are formed from a single, continuous, elongate, narrow portion of sheet metal. These web sections are normally located between elongate flanges, or the like, which provide substantial longitudinal stiffness to the structural member. The flexibility of sheet metal results in these web sections clearly lacking in lateral stiffness. Webs with improved lateral stiffness would contribute considerably in providing an improved, more rigid structural member, providing improved structural performance and/or cost reduction through reduced metal usage.
SUMMARY OF THE INVENTION
The present invention consists of a sheet metal elongate structural element including a web section which has a plurality of offset sections, formed by shearing along a pair of lines extending generally crosswise of the elongate web, and deforming the metal between the sheared lines to produce a plurality of spaced-apart short sections which have a cross section which is essentially reverse of the original web cross-sectional configuration. This reverse configuration can be a mirror image of the original configuration, a 180° rotated type of reverse, or just generally disposed on an opposite side of a median plane. The cross section of the original configuration and the reverse configuration must include a portion of the structural element which includes a longitudinal bend in the cross section. The portion of the structural element which is sheared and deformed may include more than just the web, particularly when the web to be reinforced includes no longitudinal bends.
It is an object of the present invention to provide laterally stiffened, elongate sheet metal structural elements.
It is a further object to provide a means for producing elongate structural elements using less material and thus reducing weight and costs.
It is a still further object to provide a method of forming an improved, elongate sheet metal structural element.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages will be more readily apparent when considered in relation to the preferred embodiments of the invention as set forth in the following specification and shown in the accompanying drawings in which:
FIG. 1 is an isometric view of a portion of an elevator shaft enclosure wall including only a portion of a horizontal stud thereof disposed between portions of two core boards.
FIG. 2 is an isometric view of a short action of a metal screw stud which has been sheared, preparatory to being deformed, in accordance with the invention.
FIG. 3 is an isometric view of the section of stud of FIG. 2 after being deformed.
FIGS. 4 and 5 are cross-sectional end views of two modifications of a screw stud embodying the invention.
FIGS. 6-9 are cross-sectional end views of four modifications of an I-stud all embodying the invention,
FIGS. 10 and 11 are cross-sectional end views of two modifications of a ceiling grid T-bar embodying the invention.
FIG. 12 is a cross-sectional end view of a furring channel embodying the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The several embodiments of the present invention described hereinbelow all relate to elongate structural sheet material members, a typical embodiment being a metal stud 324, which is a single, elongate, roll-formed product made of about 0.020-inch-thick, flexible sheet steel.
In a preferred embodiment, FIG. 1 shows horizontal studs 324 with two core boards 326, as used in an elevator shaft enclosure wall. The horizontal studs 324 and core boards 326 will typically be used by assembling them with corner posts, intermediate posts and door frame channels, none shown here, in a manner as fully disclosed in parent application, Ser. No. 07/858,797, which application is included herein by reference.
Horizontal stud 324 is an elongate, roll-formed sheet of metal with a cross section which includes an inner flange 328, a web 330 extending perpendicularly outwardly from the middle of inner flange 328 about 5/8 inch, forming a flat portion 332, whereat a major portion 334 of web 330 extends upwardly and outwardly about 5/8 inch to bend 336 and thence downwardly and outwardly to an upwardly extending outer flange 338. A minor portion 340 of web 330, about a 3-inch length of each foot of web, extends downwardly and outwardly about 5/8 inch to bend 342, thence downwardly to bend 344 and thence outwardly to upwardly extending outer flange 338.
Slits 346 were cut crosswise of web 330, during forming of horizontal stud 324, from the flat portion 332 to the outer flange 338. The slits 346 are preferably angled slightly to form minor portions 340 which have a shorter dimension along the outer flange bend 348 than along the bend 349, whereat the minor portion 340 is adjoined to the flat portion 332. By angling the slits 346, heat transfer through the stud, from one flange to the opposite flange is reduced, and, also, the studs are more easily stacked for warehousing and shipping.
The bend 336 divides the major portion 334 of web 330 into a ramp portion 350 and a connecting portion 352. The bends 342 and 344 divide the minor portion 340 into a bevel portion 354, a board holding portion 356 and a connecting portion 358.
Both ends of web major portion 334 and of web minor portion 340 are integrally connected to the stud; they have no free or dangling ends. Thus as shown in FIG. 1, web 330 has no tabs or any other part with a dangling or free end, all of which enhances the structural integrity of the web.
Inner flange 328 includes an upper double-thickness portion 360 and a lower single-thickness portion 362 which includes a lower hem 364 and a midway rib 366, both extending outwardly.
Horizontal stud 324 is mounted atop an upper edge portion 368 of one of the two core boards 326 in FIG. 1, and a lower edge portion 370 of the other core board 326 is disposed atop stud 324.
The upper edge portion 368 of the one core board 326 is held firmly between board holding portion 356 of web minor portion 340 and the hem 364 and rib 366 of single-thickness portion 362 of inner flange 328. Upper edge portion 368 has a flat top portion 372 and a bevelled portion 374 with an elongate corner therebetween of about 150°. Flat portion 372 abuts flat portion 332 of web 330. Bevelled portion 374 is parallel to and closely spaced from minor portion, bevel portion 354.
The lower edge portion 370 of the other core board 326 has a flat bottom portion 376, similar to flat top portion 372, and a bevelled portion 378 similar to bevelled portion 374. Flat bottom portion 376 is parallel to and closely spaced from flat portion 332 of web 330, and the junction of flat bottom portion 376 and bevelled portion 378 rests on ramp portion 350.
The core boards 326 are inserted onto each previously mounted horizontal stud 324 by merely sliding the bevelled portion 378 of lower edge portion 370 down the ramp portion 350 of the web 330 until the lower edge portion 370 abuts the double-thick portion 360 of inner flange 328. The lower edge portion 370 is held between the ramp portion 350 and inner flange 328 by the weight of the core board 326, plus the weight of all core boards 326 and horizontal studs 324 which are thereabove a part of the wall.
The horizontal studs 324 are forced onto the upper edge 368 of each core board 326 with the core board bevelled portion 374 guiding the stud web minor portion 340 so that upper edge 368 fits into the space between the inner flange 328 and the board holding portion 356.
Gypsum wide wallboard (not shown) is screw attached against the outer surfaces 380 of the outer flanges and to vertical posts (not shown).
In the preferred form of the invention, narrow, elongate slots 382 are arranged at spaced locations along the web 330, typically about three inches by 1/2 inch, spaced an inch apart, for reducing the heat conductivity through a wall, in case of fire on one or the other sides of the wall. Also, horizontal stud 324 could have 3/16-inch by 21/4-inch vent holes 384 added, with 3/4-inch spacing.
Referring next to FIG. 3, there is shown a modification of the invention, wherein a metal screw stud 10 has a web 12 and two spaced, parallel flanges 14. Web 12 includes two web halves 16, each angled upwardly from an adjacent flange 14 and joined along a ridge 18.
The web 12 also has a plurality of reversely directed, deformed portions 20, about a 3-inch length of each foot of web (only one deformed portion 20 being shown), extending downwardly from the generally upwardly directed web 12.
Referring to FIG. 2, stud 10 is shown unfinished, with slits 22 extending crosswise of web 12, defining a pre-bent portion 24 of web 12 to be bent downwardly to form a deformed portion 20. In the preferred form, deformed portion 20 includes two deformed portion halves 26, each angled downwardly and joined along a ridge 28. As will be seen in FIGS. 2 and 3, deformed portion 20 is the reverse of pre-bent portion 24.
As will also be seen in FIGS. 2 and 3, the bending to create deformed portion 20 results in two longitudinal bends 30, 32, which with the lateral slits 22, define the perimeter of the deformed portion. It is essential, in accordance with the invention, that the slits of any embodiment have a substantial lateral extent. An important consideration in regard to the amount of improvement to be provided by the present invention is in the extent to which the deformed portion is moved across an imaginary plane extending through the two longitudinal bends 30, 32. If only a minor portion of the deformed portion is on the opposite side of this imaginary plane, little or no stiffening will be effected, thus requiring that a major portion of the deformed portion of any embodiment of the invention be on the opposite side of this imaginary plane relative to the undeformed portion. Also, the degree of stiffening provided increases with the increase in the distance of the undeformed portion and the deformed portion from this imaginary plane.
In the embodiment of FIG. 3, the undeformed portions 34 of the web 12, that which remains with the original cross section, like the pre-bent portion 24, is the major portion of web 12, and only a minor portion, the deformed portion 20, has the reversed, deformed cross section. It is, however, contemplated that the deformed portions 20 could be the major portion and the undeformed portions 34 could be the minor portion, or the two portions could be equal.
Referring to FIG. 4, a stud 40 is shown, similar to stud 10, except that the deformed portion 42 extends completely across the web 44, reaching from one flange 46 to the other flange 48.
In FIG. 5, a stud 50 is shown having an undeformed portion 52 of web 54 which includes a raised, flat midsection 56, and a deformed portion 58 which includes a depressed, flat midsection 60.
FIG. 6 shows the cross section of an I-stud 70 with a web 72 and two flanges 74. Web 72 includes two upwardly inclined web halves 76, in an undeformed portion 78, and two downwardly inclined halves 80 in a deformed portion 82.
FIG. 7 shows the cross section of an I-stud with a web 92 and two flanges 94. Web 92 includes an undeformed portion 96 which is flat and extends from one flange 94 to the other flange 94. Web 92 also includes a deformed portion 98 which is displaced out of the plane of undeformed portion 96 to a parallel plane by folding back a small segment 100 of one flange 94, where the web 92 joins the one flange 94.
FIG. 8 shows the cross section of an I-stud 110, with a web 112 and two flanges 114. Web 112 includes an undeformed portion 116 which is flat and extends from one flange 114 to the other flange 114. Web 112 also includes a deformed portion 118 which is displaced out of the plane of undeformed portion 116 from the center of web 112 to one flange 114, by bending inwardly an inner layer 119 of the double-thickness part of the one flange 114.
FIG. 9 shows the cross section of a modified I-stud 120 with a web 122 and two flanges 124. Web 122 includes an undeformed portion 126 which includes three sections, a flat section 128 extending away from the center of one flange 124, an angled section 130 extending angularly away from the center of the opposite flange 124 and a mid-wall section 132, parallel to the flanges 124 connecting the flat section 128 and the angled section 130 and the center of the stud 120. Web 122 also includes a deformed portion 134 which also includes an angled section 136 and a mid-wall section 138, with the angled section 136 also extending angularly away from the center of the opposite flange 124, but in the opposite angular direction from that of angled section 130.
FIG. 10 shows the cross section of a ceiling grid T-bar 140 with a web 142, a bottom flange 144 and a top bulb 146. Web 142 includes an undeformed portion 148 which includes two outwardly angled halves 150 extending from flange 144 to bulb 146. Web 142 also includes a deformed portion 152 which includes two inwardly angled halves 154 extending from flange 144 to bulb 146.
FIG. 11 shows the cross section of a ceiling grid T-bar 160 with a web 162, a bottom flange 164 and a top bulb 166. Web 162 includes a vertical lower half 168, an undeformed outwardly formed ridge portion 170 and a deformed inwardly formed ridge portion 172.
FIG. 12 shows a furring channel 180, including two outwardly directed, horizontal bottom flanges 182, two undeformed upwardly and inwardly angled side wall portions 184 and an undeformed horizontal web 186. Furring channel 180 also includes two series of deformed portions 188, each of which includes a deformed side wall portion 190 and a deformed horizontal portion 192. Deformed portions 188 will be seen to be formed in a reverse cross-sectional shape relative to the cross sections of the undeformed portions 194 from which they were deformed.
In all of the above described embodiments, it is contemplated that the deformed portions will have been created by the method described relative to the embodiment of FIGS. 2 and 3, including shearing along crosswise lines and deforming the material between the sheared lines, creating a deformed section which is to a substantial degree a reverse cross-sectional configuration compared to undeformed cross-sectional configuration. It is further contemplated that, although the preferred embodiments will include about one deformed portion per elongate foot of structural element, that this may be varied to about one deformed portion per inch to about one deformed portion per two or three feet, with the lengths of the deformed portions and undeformed portions both being anywhere from about 1/2 inch to about 2 feet, alternating throughout the total length of the structural element.
Also, in all embodiments described, it will be noted that the deformed portions were all deformed to the opposite side of an imaginary plane through the bend lines as discussed relative to the embodiment of FIG. 3.
Also, in all embodiments, it will be noted that the deformed and undeformed portions were located in an elongate central portion, whether it be in a central web portion or a web portion plus part of an adjacent flange portion, which adjacent flange portion is in a sense part of a central portion since there is additional flange portions more remote from the embodiment's center. Described another way, the slits which partly define a deformed portion never extend to a lateral edge of the sheet material from which any embodiment is formed. Also, the deformed portions always include two bends which partly define the deformed portion, whereby the deformed portion is always integrally connected to the rest of the embodiment at both lateral ends.
Having completed a detailed description of the preferred embodiments of my invention so that those skilled in the art may practice the same, I contemplate that variations may be made without departing from the essence of the invention.
|
A laterally stiffened, elongate, roll-formed metal stud, or equivalent structural member having a central web with alternating deformed and undeformed portions.
| 4
|
FIELD OF THE INVENTION
The invention relates to electronic DC power supplies and more particularly to a DC power supply having a controlled slew rate limiting circuit to protect electronic loads from line voltage transients and a linearly adjustable set-point capability.
BACKGROUND OF THE INVENTION
Regulated D.C. power supplies provide predictable and reliable voltage sources for driving electronic circuitry. The conventional power supply design typically employs a power device for developing a D.C. voltage output and a regulating feedback loop. The regulation loop serves to maintain the power supply output voltage at a pre-selected set point by sensing the output voltage and increasing or decreasing the output relative to the desired set point.
To dampen the response of the feedback loop by changing the supply output voltage from 0 volts to a preselected set point voltage relatively slowly, rather than instantaneously, many power supply designs employ a slew rate limiting circuit. The slew rate circuit tends to reduce the stress on any loads developed by the sudden application of power to a deenergized electronic circuit.
The dampening effect of the slew rate circuit also reduces any transient voltage overshoot associated with the power supply regulation loop. Overshoots often develop from the fast feedback response of the system that produces a high initial error at start-up, causing saturation of the control loop with a corresponding overshoot above the desired set point.
Conventional slew rate limiting circuits typically fall into two categories: rampable set points and modulation limiters. Rampable set point circuits are constructed to change the desired output voltage from 0 volts to the desired value smoothly over time. U.S. Pat. No. 4,598,351 illustrates a typical rampable set point design that includes a reference capacitor coupled in parallel with a zener diode. A constant current source charges the capacitor at start-up to produce a ramping reference voltage fed to the input of an error amplifier. The reference voltage is clamped to a maximum value by the zener diode.
While the rampable set point design works well for its intended applications, the rate at which the capacitor charges to ramp the voltage up is not easily changed. This is because of the discrete component design that minimizes any controllable variation in the rate. Moreover, no provisions are included for changing the set point for the circuit in a predictable, linear manner.
In contrast to the rampable set point construction, modulation limiter designs generally include a grounded capacitor coupled to a forward-biased diode disposed at the input of an error amplifier. The error amplifier is employed in a feedback loop to effect voltage regulation. A second diode is disposed in parallel to the dioded capacitor and selectively couples a normal control signal to the amplifier input node.
In operation, the diode branch with the lowest input voltage to the amplifier sets the control signal. At start-up, the lowest voltage is at the dioded capacitor, which charges up to produce an increasing voltage until the capacitor diode reverse biases, at which time the second diode forward biases, enabling the normal control signal to set the output voltage.
Although modulation limiter circuits perform well for their intended applications, they suffer from many of the problems plaguing conventional rampable designs. Again, because of the arrangements of the discrete components, the slew rate is often non-adjustable. Additionally, typical modulation limiter circuits fail to include circuitry to vary the desired set points.
Therefore, the need exists for a power supply having a slew rate limiting circuit that provides control capability not only for the slew rate, but additionally offers the capability of adjusting the set point in a predictable linear manner. The power supply and method of the present invention satisfies these needs.
SUMMARY OF THE INVENTION
The power supply of the present invention provides a slew rate limiting circuit that offers control capability for the slew rate, and a variability feature for changing the set point of the power supply. These advantages give the present invention a wide flexibility in electronic D.C. power supply applications.
To realize the above advantages, in one form the invention comprises a power supply with a programmable voltage slew rate for generating a regulated voltage at a predetermined set-point. The power supply includes a programmable current source for generating a controllable level of current flow and a capacitive element coupled to the current source. The capacitive element is responsive to the current flow to establish a reference voltage that varies linearly with respect to variations in the current flow. The power supply additionally includes a power device having a control element disposed in sensed communication with the reference voltage and an output for driving a load. The output is operative to generate an output voltage following that of the reference voltage.
In another form, the invention comprises a method of controlling the slew rate of a regulated voltage power supply. The power supply includes a programmable current source, a capacitive element coupled to the power source, and a power device having a control element disposed in sensed communication with the capacitive element and an output. The method includes the steps of: charging the capacitive element to generate a reference voltage; sensing the reference voltage with the control element; and generating an output voltage at the power device output that follows the sensed reference voltage whereby changes in the charging adjust the reference voltage to correspondingly create a proportional change in the output voltage.
Other features and advantages of the present invention will be apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram schematic of a power supply according to one embodiment of the present invention;
FIG. 2 is a block diagram schematic of the present invention according to a second embodiment;
FIG. 3 is a block diagram schematic of the present invention according to a third embodiment; and
FIG. 4 is a block diagram schematic of a clamping circuit employed in the power supply of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, the power supply of the present invention according to a first embodiment, generally designated 10, includes a programmable current source 12 for charging a capacitive element C1 to develop a reference voltage Vref. A power device 16 disposed in sensed communication with the reference voltage produces an output that follows the reference voltage. By programmably varying the current through the capacitive element, the power supply output can be predictably adjusted in a linear fashion to drive a load L.
Further referring to FIG. 1, the programmable current source 12 comprises an operational amplifier (not shown) connected in the well-known "bi-polar current source for grounded load" configuration. An error amplifier 18 acts as a controller and produces a current source command signal Icmd and continuously compares the output voltage Vout with a predetermined setpoint signal SP.
The capacitive element C1 comprises a reference capacitor and is tied to a reference node N1 which in turn is connected to the output of the programmable current source 12. Preferably, the current source generates current within the range of approximately +/-0.1 to 1.0 milliamps while the reference capacitor has a capacitance of approximately 0.1 to 1.0 microfarads. These component values produce slew rates of approximately 100 V/s to 10,000 V/s (0.1V/ms to 10V/ms). The opposite end of the capacitor is left floating to define the negative output voltage terminal -Vout for the power supply 10. The negative terminal may then be tied to a negative power supply bus (not shown) for accessibility by one or more loads.
The power device 16 comprises a MOSFET transistor with its gate G connected to the reference node N1. The transistor is employed in a source-follower configuration with the source S providing a voltage output+Vout that closely follows the voltage generated at the node N1 by the capacitor. The output voltage+Vout is sampled by the error amplifier 18 via a feedback connection 17. The source lead may be tied to a positive power supply bus (not shown) in much the same manner as the negative output voltage lead. The drain D of the transistor is tied to a pre-regulated voltage source or pre-regulator 20 which supplies a regulated voltage Vin to power the MOSFET.
The pre-regulator 20 includes an input transformer 22 that receives AC voltage from an AC voltage source (not shown) and a plurality of silicon-controlled-relays (SCR's) 24, 25, 26, and 27 disposed in a well-known bridge configuration. The bridge filters the negative components of the AC waveform and feeds the converted output to a charging capacitor C2, which maintains the SCR bridge output at approximately the maximum AC voltage level to establish a regulated DC level for Vin.
Prior to operation, the desired slew rate of the power supply is preprogrammed into the error amplifier 18 to controllably activate the current source when the power supply is turned on. The programming also includes identifying a threshold set point for the power supply output voltage. The set point comprises the target level that the power supply regulates at.
During normal operation at start-up, the error amplifier 18 issues a maximum-positive control signal to the current source 12 due to the large error between the output voltage and the setpoint. In response, the current source drives current toward node N1. Because of the very high input impedance, virtually none of the current flows into the MOSFET gate G. Consequently, virtually all of the current flows through the reference capacitor C1. The injected current charges the capacitor at a linearly increasing voltage according to the well known equation:
V=1/C∫idt
The negative side of the capacitor provides the negative output potential -Vout for the power supply.
The power device 16, operating in a source-follower configuration, produces a positive output voltage at its source. The output voltage is the difference between the reference voltage Vref and the nominal gate-source voltage Vgs. When the output voltage is different than the setpoint, the error amplifier 18 generates the command signal Icmd at a level proportional to the determined difference. At ramp-up, however, the error is very large. The error amplifier saturates at the +/-12V floating supply rails (not shown), and the commanded current is a constant. The current remains constant until the output voltage is fairly close to the setpoint, at which time the error amplifier output comes out of saturation and the commanded current is reduced.
I have discovered that by incorporating the current source 12 into a "floating" power supply configuration 10, a wide range of output voltage is available with relatively inexpensive circuit components. For example, to realize a +/-15 volt power supply, the capacitor typically can charge only to about a reference voltage of +/-13 volts. If the +/-15 volt power supply is left floating, as I have discovered, and referenced to the MOSFET source S, then the capacitor voltage can range up to the value of the pre-regulator 20 voltage.
This discovery is especially advantageous in the aerospace industry wherein D.C. power supplies are often utilized to simulate solar cell batteries and the like. Many simulations involve output voltage s on the order of about 200 volts. I have found that at these high voltages, the output voltage regulation is very good. This is because the MOSFET gate to source voltage only increases from about 3 volts to 5 volts when the output current goes from no-load to full-load. Additionally, because the reference voltage developed by the capacitor C1 is essentially isolated from any loads, system response may be tailored independent of the load.
Referring now to FIG. 2, the present invention according to a second embodiment, generally designated 30, includes much of the circuitry described in the foregoing first embodiment, with like numerals indicating like components. The power supply includes a pre-regulator circuit 20, an error amplifier 18, a programmable current source 12, a reference capacitor C1, and a power device 16. In contrast to the power supply 10 described as the first embodiment, the second embodiment adds a multiplying digital-to-analog (DAC) converter 32 between the output of the error amplifier and the input to the current source. The multiplying DAC reduces the error signal to a preselected multiplicative constant. A separate digital controller 34 is connected to the DAC and loads a programmed scale factor into the DAC. The separate digital controller preferably comprises an 8-bit microcontroller with 1 k-2 k bytes of memory to load the scaling factor. Prior to operation, the desired slew rate of the power supply is preprogrammed into the error amplifier 18 to controllably activate the current source 12 when the power supply 30 is turned on. The programming for this embodiment of the present invention is conveniently carried out by the separate digital controller 34 that latches a digital value in to the multiplying digital-to-analog converter (DAC) 32 (FIG. 2). The output of the DAC 32 comprises the product of the analog input (error amplifier 18 output) and the digital scaling factor. In this way, the digital controller 34 can accurately set the maximum current out of the current source 12. This capability also changes the response of the power supply 30 to transient loads since all error amplifier signals are multiplied by the scale factor.
Referring now to FIGS. 3 and 4, the present invention according to a third embodiment, generally designated 40, employs the components described in the second embodiment, with like numerals indicating like components, and adds a well-known programmable voltage clamping circuit 41 disposed between the multiplying DAC 32 output and the current source 12 input. The clamping circuit cooperates with the multiplying DAC to further reduce the error signal to the preselected maximum value.
Referring more particularly to FIG. 4, the clamping circuit 41 includes an input buffer amplifier 42 that feeds the signal output from the multiplying DAC 32 to a diode bridge comprising diodes D1, D2, D3 and D4. The bridge is balanced by respective positive and negative clamping voltage sources 44 and 46 that include respective DACs 48 and 50 and resistors R1 and R2. The bridge output feeds an output buffer amplifier 52 that produces a clamped signal output. Alternatively, the clamping circuit is realized by an integrated circuit, such as that marketed under the trademark Clamp-Amp®
In operation, the clamping circuit 41 acts to set the maximum current to the input of the current source 12. The clamping levels for the clamping circuit are set by latching digital values from the digital controller 34 and into clamping-level DACs. If the input signal exceeds the positive clamping voltage, diodes D1 and D4 will be off, while diode D2 conducts current. Diode D3 then sets the output voltage to the clamping voltage (less one diode voltage drop of approximately 0.7 volts). If the signal is within a normal range, the voltage drops on diodes D1 and D3 will cancel and the output voltage will equal the input voltage.
Those skilled in the art will appreciate the many benefits and advantages offered by the present invention. Of significant importance is the feature of providing a programmable current source to linearly adjust the slew rate of the power supply. Moreover, the invention offers the capability of adjusting the set point of the power supply in a linear manner using relatively inexpensive discrete components.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
|
A power supply with a programmable voltage slew rate is disclosed for generating a regulated voltage at a predetermined set-point. The power supply includes a programmable current source for generating a controllable level of current flow and a capacitive element coupled to the current source. The capacitive element is responsive to the current flow to establish a reference voltage that varies linearly with respect to variations in the current flow. The power supply additionally includes a power device having a control element disposed in sensed communication with the reference voltage and an output for driving a load. The output is operative to generate an output voltage following that of the reference voltage.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is in the field of blood sample acquisition and testing. In particular, the invention is directed to a sensor strip used in a device that performs both a lancing operation to acquire a blood sample and a measurement operation on the sample in one user-initiated step. The strip is provided with a plurality of test sites, and may be wound on a supply wheel and fed through the device between the supply wheel and a take-up wheel, so that a single strip may be used to obtain a plurality of measurements.
2. Description of the Related Art
Self-monitoring of blood glucose generally requires the user to extract a volume of capillary blood and place it on a disposable element for analysis. Devices for lancing a subject at an extraction site to obtain a small quantity of blood for testing on a test strip are known in the prior art. For example, U.S. Pat. No. 6,558,402, which is incorporated by reference, discloses a lancer having suitable mechanisms for piercing a subject's skin and obtaining a sample.
Test strip sensing elements using amperometric and other techniques for determining the concentration of blood glucose in a blood sample are known in the prior art. U.S. Pat. Nos. 6,143,164, and 5,437,999, incorporated by reference herein, each disclose examples of test strip construction for electrochemical measurement of blood glucose.
The integration of lancing and sensing would be a desirable advance in the self-monitoring of blood glucose. U.S. patent application Ser. No. 12/502,594, filed Jul. 9, 2009, describes such a “two-in-one” device, wherein a single test strip contains a plurality of test sites, which can be advanced automatically through a testing device. In this context, it would be desirable to have a layout of electrodes and contact pads on a test strip to permit automatic advancement of the strip through the device, that would account for variations in alignment, and to eliminate transient signals as the strip is indexed through different stop points in the lancing/sensing process and on to the next test position on the strip.
SUMMARY OF THE INVENTION
According to the present invention, an elongated sensor strip for use in a blood sample test device is provided comprising a plurality of test sites arranged in series in a travel direction on the strip. Each test site includes a lancet hole, electrodes for determining a blood sample volume, and test electrodes for determining a blood sample characteristic. Each test site on the strip comprises a non-conductive substrate layer and a conductive layer, which is formed into electrodes and conductive pads (such as by etching non-conductive lines in the conductive layer). The conductive pads are aligned with device contacts in the blood sample test device. A non-conductive layer is superposed on the conductive layer and has a window exposing a plurality of the conductive pads.
The conductive pads of the sensor strip are preferably formed by depositing a conductive layer and etching lines to form conductive pads in columns aligned with device contacts in a blood test device. Rows of the conductive pads correspond to stop positions in the lancing/sensing operation during which a blood sample is accumulated on the strip and then moved to a position where a blood glucose measurement is taken. Horizontal traces in the sensor strip which connect the electrodes on the strip with the conductive pads (which are perpendicular to the travel direction of the strip) are covered by a non-conductive cover layer, so that the horizontal traces are not directly contacted by the device contacts as the strip advances through the device.
A blood sample acquisition and sensing system according to the invention comprises a housing containing device contacts and the elongated strip having a plurality of test sites arranged in series in a travel direction on the strip, as described above. Each test site includes a lancet hole, electrodes for determining a blood sample volume, test electrodes for determining a blood sample characteristic, and conductive pads aligned in columns with the contacts on the blood test device for making electrical contact between the strip and the device contacts. The system also comprises a lancet and lancet injector, a motor for advancing the strip, and a processor. The processor is adapted to process signals produced when the device contacts make electrical contact with the conductive pads on the strip at stop positions in the lancing/sensing process, and to communicate with the lancet injector, the test electrodes, and the motor. In a preferred embodiment, the elements of the system, including the strip, lancet and lancet injector, motor and processor are provided in a unitary housing which may be provided with user-operable controls and a display.
A method for performing a plurality of blood sample acquisition and testing procedures on a strip according to the invention comprises the steps of: providing an elongated strip, such as described above, having a plurality of test sites arranged in series in a travel direction on the strip, wherein each test site includes a lancet hole, electrodes for determining a blood sample volume, test electrodes for determining a blood sample characteristic, and conductive pads for making electrical contact with a blood test sensor device; injecting a lancet through the lancet hole at a first test site into a subject to obtain a blood sample contacting the strip; contacting the blood sample with the electrodes for determining a blood sample volume so that a signal is produced when a blood sample volume is detected; advancing the strip responsive to the signal produced when a blood sample is detected; contacting the blood sample with the test electrodes to obtain a blood sample characteristic signal; and advancing the strip to a second test site.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a test site on an elongated sensor strip according to an embodiment of the invention.
FIG. 2 depicts a matrix of showing the state of the electrodes at each stop position of the strip during the lancing/sensing process in an embodiment of the invention.
FIG. 3 depicts an embodiment of the system according to the invention, in which the sensor strip, lancet and processor are enclosed within a unitary housing.
FIGS. 4A , 4 B, 4 C and 4 D depict layers of the test strip, forming an exploded view of the structural features in a test site.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 schematically depicts a portion of an elongated sensor strip 20 according to an embodiment of the invention, including the elements found in a test site. A plurality of such test sites are provided in series along the travel direction 12 of the strip. Thus, each test site includes a lancet hole 30 , electrodes 41 , 42 for determining a blood sample volume, and test electrodes 43 , 44 for determining a blood sample characteristic, all of which are arranged on a non-conductive substrate layer 50 .
The material of the non-conductive substrate layer is not particularly limited and may be, for example, polyethylene terephthalate (PET) having a thickness in a range of about 5 mils to about 15 mils. The electrodes are preferably formed by sputtering a metal, such as gold, to form a conductive layer having a thickness in a range of about 50 Angstroms to about 2000 Angstroms, and etching a pattern to form the electrodes and conductive pads. Conductive pads, such as pad 45 , are preferably formed from the same conductive layer by etching non-conductive lines, such as line 35 . Other conductive materials and/or methods of depositing and/or patterning may be used. A non-conductive cover layer 90 forms a window, depicted by dotted line 52 , exposing the pads to the contacts in the device as the strip is indexed through the device.
In a preferred embodiment, the horizontal traces, such as trace 47 between conductive pad 45 and electrode 42 are protected by the non-conductive cover layer 90 so that they are not severed by the device contact, and to minimize noise signals.
In a preferred embodiment, the leading edge of a first conductive pad, which is defined by a non-conductive line, is in front of a leading edge of another pad in the same row. In this way, the order in which signals are collected from the pads can be controlled. Thus, in each of rows 22 , 23 and 24 (lance, detect, and acquire positions respectively); one contact has a shifted leading edge. For example, the leading edge of conductive pad 33 is behind the other pads in row 24 in respect of the travel direction, and is connected to the common ground. The leading edge of conductive pad 53 is behind pad 45 in row 23 and is connected to the common ground. Conductive pad 73 is behind the pressure switch pad PS in “lance” row 22 . Pads 33 , 53 and 73 are connected to a conductor at column 28 , which is contacted by a grounding contact in the device to provide a reference. Column 28 is always grounded in the lance, detect, and acquire states represented by rows 22 , 23 and 24 . All of the conductive pads preferably have a surface area in a range of about 1.0 mm 2 to about 3.0 mm 2 .
The structural layers of the test strip form features typical of an individual test strip, including a capillary channel and reagent wells. U.S. application Ser. Nos. 12/502,594 and 12/502,585, both filed Jul. 9, 2009 by the Assignee herein, and incorporated by reference herein, describe these details of the strip structure.
Referring to FIG. 4A through 4D , FIG. 4D shows non-conductive substrate layer 50 with a conductive pattern 69 of pads and traces formed thereon. FIG. 4C shows a non-conductive structural layer with the features of the reagent wells 92 , 94 aligned with corresponding electrodes. FIG. 4B depicts a spacer layer which forms a capillary channel between the lancet hole and the wells. Top layer 4 A forms vent 96 . The top layer, spacer layer and structural layer share a window 52 , which exposes conductive pads, but protects horizontal traces.
The conductive pads are arranged into columns 25 , 26 , 27 , and 28 , which are aligned with contacts in the device (not shown), which press against the sensor strip as it advances through the device. Rows of pads 21 , 22 , 23 , and 24 correspond to positions of the tape in the lancing/sensing process. Lancet hole 30 is provided so that a lancet in the device can be injected through the hole into a subject's body. Sprocket hole 32 is provided in the strip so that a motor can control the advancement of the strip through the device in precise increments using a sprocket mechanism.
In the course of using the sensor strip, a lancet is injected through lancet hole 30 to obtain a blood sample. The blood sample is collected in the space between electrodes 41 and 42 , which are connected by traces to conductive pads 49 and 45 , respectively. When sufficient blood sample is accumulated, an electrical short is detected between electrodes 41 and 42 , and a processor signals the motor to advance the strip in direction 12 . Moving the strip causes the blood sample to be conducted to the test electrodes 43 and 44 at the bottom of corresponding reagent wells. Data from the electrochemical measurement of the blood glucose content of the sample is collected from signals generated by electrical contact made between device contacts and associated conductive pads 34 and 37 . This information is routed to the processor for display, on the device housing or otherwise, and the sensor tape is thereafter advanced to the next test site on the strip so that the lancing/sensing process can be repeated.
FIG. 2 depicts a matrix which describes the state of the conductive pads at stop positions in the lancing/sensing process. The matrix comprises rows 10 , 14 , 16 , and 18 , and columns 11 , 21 , 31 , and 41 corresponding to the conductive pads in an exemplary embodiment of the invention.
FIG. 2 depicts three active states and a home position. At the home position, depicted as row 10 , first, third and fourth conductive pads are grounded and the second conductive pad is unused because it is not needed. This is the state of the device prior to conducting a lance operation. The device is not used in the home state. When the system is activated, the strip is positioned so that pressure sensor PS on the strip can be pressed against a subject's skin. This is the lance position of the strip, depicted as row 14 , so that when the strip is in this position, the third and fourth contacts are grounded and the second contact is unused. At the lance position, the second contact is unused due to the presence of the lancet hole 30 . At the detect position, in which a blood sample volume is detected, the second contact is grounded, the first contact is connected to the Top Detect Switch and the third contact is connected to the Bottom Detect Switch, represented in row 16 (i.e., the electrodes for determining a blood sample volume). When a blood sample creates an electrical short between electrodes 41 and 42 the switches in row 16 give the signal to the processor. At the acquire position, represented by row 18 , the first contact is grounded, the second contact is connected to the “Rear Capillary Switch” and the third contact is connected to the “Front Capillary Switch,” (i.e., the electrodes for determining a blood sample characteristic). The grounded contact is routed to the common ground in column 28 , to minimize false readings. The signal for glucose reading produced by electrodes 43 , 44 is sent to the processor through switches in row 18 . Preferably, at least one of the test electrodes is active so that a current can be passed through the sample to obtain a blood glucose measurement.
The advancement of the strip is driven by a motor in response to commands from a processor. A control system stops the motor when a selected contact encounters the edge of a grounded electrode. The sensor strip may be wound on a supply wheel and taken up by a take-up wheel as the strip advances through the device. Sprocket holes 32 in the strip ensure that the motor advances the strip in controlled increments.
As shown in an embodiment depicted in FIG. 3 , a blood sample acquisition and sensing system may combine the elements described above in a unitary housing 60 . Thus, an elongated sensor strip 84 , having the features described above, may be provided to the housing on a supply wheel 54 , and as the strip is advanced through the device, the sensor strip may be taken up on take-up wheel 56 . Processor 82 communicates with a motor (not shown) to advance the strip, preferably using sprocket on the strip, so that the incremental advancement of the sensor strip is accurately controlled and not affected by the variation in the thickness of the layers of sensor strip being wound around the take-up wheel 56 . The processor may communicate with user operable controls 64 , 66 , and a display 62 so that a user can conveniently control the system for self-monitoring of blood glucose. The elements are powered by any suitable power supply 80 , such as a battery. The processor 82 communicates with lancet injector 74 to inject lancet 72 through the lancet hole on the strip.
The above description of the preferred embodiments should not be deemed as limiting the invention, which is defined by the following claims. Features described in the dependent claims are further aspects of the preferred embodiments, which may be used in combination.
|
An improved electrode layout for a continuous strip sensor is provided which reduces misalignment of the electrodes with the contacts which read the position of the strip. Better contact with the electrodes reduces or eliminates transient signals between stop positions of the sensor strip.
| 0
|
BACKGROUND OF THE INVENTION
This invention relates to a method of manufacturing a semiconductor device involving the step of impurity ion implantation. When a semiconductor device is manufactured, the well-known process is one which involves the step of implanting impurity ions in a substrate to fabricate a layer of a prescribed conductivity type. In the case of, for example, a GaAs integrated circuit, an active layer is produced in a semiconductor substrate by ion implantation to provide source and drain regions of high impurity concentration. Due to the high integration and increased speed of operation of semiconductor devices, greater demand is made for the precise control of ion implantation.
When a layer of a prescribed conductivity type is formed by ion implantation, it sometimes happens that a channeling phenomenon appears, in which an impurity ion is implanted to a greater depth in a particular direction of implantation depending on the structure of a single crystal substrate. With a semiconductor single crystal substrate whose surface parallel to the (100) plane, it is known that when the implantation of an impurity is carried out perpendicularly to the substrate, an axial channeling takes place because crystal lattices are widely separated from each other. The phenomenon of channeling becomes more noticeable as the constituent atoms of the substrate, and ions to be implanted have a larger atomic number, and the acceleration voltage for ion implantation decreases. When, therefore, an activated layer is made thinner for higher integration, the channeling more readily takes place. The conventional practice to avoid such a drawback is to incline the main substrate plane by some degrees to the ion implantation direction in order to avoid axial channeling, and further, to rotate the substrate about the surface normal axis several or scores of degrees, thereby avoiding plane channeling.
The conventional method of manufacturing semiconductor devices mentioned before is also accompanied with the following drawbacks. Since ion beams enter obliquely into the substrate surface, the mask material gives rise to shades, causing the patterns to be asymmetric and resulting in variation in the properties of the element devices thus produced. Moreover, difficulties arise in estimating the area ion implantated from the mask size. The smaller the pattern becomes for high integration, the more the drawbacks increase. Since the respective positions on the substrate have different separations from the ion source, said positions are electrically charged to different degrees by an ion beam-accelerating electric field, thus causing ions to be implanted with different densities. Consequently variations appear in the properties of the element devices formed on the substrate. Moreover, some ion-implanting devices do not allow the substrate rotation angle to be freely defined. When, therefore, such an ion-implanting device is used, it is impossible to produce highly reliable semiconductor devices. Therefore, the rotation angle of the substrate plane has to be determined for each substrate, requiring a great deal of work.
The above-mentioned difficulties particularly arise in a semiconductor device having an extremely fine circuit arrangement, for example, a high speed digital IC or a high frequency analog IC fabricated by forming an MESFET on a GaAs single crystal substrate.
SUMMARY OF THE INVENTION
It is accordingly the object of this invention to provide a method of manufacturing a semiconductor device which suppresses the occurrence of channeling when a plurality of regions are simultaneously formed in a monocrystalline, semiconductor substrate; by implantation of an impurity; and which substantially equalizes the impurity concentrations of the respective regions, thus significantly facilitating the mask of ion implantation.
The semiconductor device-manufacturing method embodying this invention is characterized in that when an impurity is implanted in the main phase of the monocrystalline semiconductor substrate, and when the angle of ion implantation direction with respect to the main crystal orientation of said crystal is assumed to be expressed by Euler anglesλ, μ, θ), then the main crystal orientation is so determined as to satisfy the following conditions:
11°<λ<33°
7°<μ<24°
θ≈0°
If λ falls outside of the above-mentioned range, plane channeling appears, and if λ exceeds 33°, the subject semiconductor monocrystalline substrate will be undesirably reduced in machinability. If μ is displaced from the above-mentioned range, then axial channelling will appear. Also if μ rises above 24°, the monocrystalline semiconductor substrate will undesirably decrease in machinability.
The present invention offers the advantages that even when an impurity is perpendicularly implanted in a monocrystalline semiconductor substrate, no channeling occurs, dispensing with the troublesome task of defining the rotation angle of the substrate; when an ion implanter lacking a rotation angle-defining mechanism is applied, it is nonetheless possible to carry out ion implantation under a well-controlled condition; when an impurity is implanted perpendicularly to the main substrate plane, the implanted impurity does not present asymmetry and variations in the distribution within said substrate plane; an equal potential is preserved throughout the substrate plane; an impurity can be implanted under a well controlled condition; it is possible to provide a semiconductor device whose excellent elements indicate no variations in the properties on the substrate plane; and consequently a highly integrated semiconductor device can be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an ignot by way of indicating the relationship between the crystal orientation in which the substrate used in the embodiment of this invention is cut out and the direction in which an impurity is implanted in the substrate;
FIG. 2 is a chart setting forth the Euler angles;
FIGS. 3A to 3G show the sequential steps of manufacturing GaAs-MESFET embodying this invention; and
FIG. 4 indicates a comparison between the threshold voltage variations observed in a semiconductor device manufactured by the method utilized in this invention and those appearing in a semiconductor device obtained by the conventional manufacturing method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Description may now be made with reference to the accompanying drawings of the method of manufacturing a semiconductor device GaAs MESFET utilized in this invention.
FIG. 1 sets forth the relationship between the crystal orientation in which a gallium arsenide (GaAs) substrate is cut out in accordance with the method of this invention and the direction in which an impurity is implanted. Referring to FIG. 1, reference numeral 11 shows a GaAs ingot, and reference numeral 12 indicates an orientation flat formed on a (011) face. When an impurity is implanted in a GaAs substrate 13 cut out of said ingot 11 by the conventional method, as previously mentioned, ion implantation direction 14 is inclined to a (100) face at prescribed angle β (≈7°) in order to suppress the occurrence of axial channeling, and further the plane of said GaAs substrate 13 is rotated at angle α (≈20°) in order to avoid plane channeling.
Unlike the above-mentioned conventional method, the embodiment of this invention applies the method of cutting out semiconductor monocrystalline substrate 15 from GaAs ingot 11 in such a manner that the substrate's main plane is inclined to the indicated (100) face at a prescribed angle as later described. Namely, the main plane of said GaAs substrate is so defined as to suppress the occurrence of axial and plane channelings in ion implantation direction 14.
Concrete description may now be made by the Euler angles of the range within which angle inclination to the (100) face of the GaAs substrate is defined by the embodiment of this invention. The Euler angles (λ, μ, θ) are generally indicated as shown in FIG. 2. Namely, angles (0°,0°,0°) represented by the equation λ=μ=θ=0° are plotted on axes X, Y, Z. It was assumed that under the above-mentioned conditions, the ion implantation direction was represented by axis Z, and the angles defined by the ion implantation direction with the main crystal axis were denoted by λ, μ, θ. Further, it was assumed that the size of an atom at a crystal lattice point was represented by 1/10 of the lattice spacing. First, the plane involving said λ, μ and θ is rotated counterclockwise about the Z axis by an angle of λ. At this time, line X is shifted to X 1 , and line Y is moved to Y 1 . Thereafter, said plane is rotated counterclockwise about line X 1 by an angle of μ. As a result, line Y 1 is shifted to Y 2 , and line Z is moved to Z 2 . Further, said plane is rotated counterclockwise about line Z 2 by an angle of θ. At this time, line X 1 is shifted to X 3 , and line Y 2 is moved to Y 3 . Computation was made as to the pattern which would be presented by a crystal lattice. Measurement was made of the angles which would not cause the lattice points to overlap each other three-dimentionally. As a result, the following conditions were ascertained.
11°<λ<33°
7°<μ<24°
θ≈0°.
In actuality, a GaAs substrate was prepared whose main plane represented the aforesaid crystal orientation. A silicon (Si + ) impurity ion was implanted under the conditions:
Acceleration voltage: 150 keV.
Impurity doping concentration: 3×10 12 /cm 2 .
Thus, numerous diode alleys were formed and determination was made of the manner in which the peak carrier concentration was distributed. As a result, it was found that said concentration fell within the range of 3%. When Euler angle λ ranged between 21° and 26°, and Euler angle μ ranged from 10° to 11°, said peak carrier concentration was less than 1%. Electronic line analysis clarified that the above-mentioned ranges represented the ion implantation direction in which the occurrence of defect of ion implantation was minimized.
When a GaAs substrate whose Euler angles were defined to fall within the aforementioned range was cut out of an ingot, it was found that axial and plane channeling were effectively prevented when an impurity was implanted perpendicularly to the main plane of said GaAs substrate. The present invention offers further advantages that since an impurity can be implanted perpendicularly to the main substrate plane, the impurity implanting process is simplified and can be carried out under tightly controlled conditions; though the cleavage plane constituted by (110) face of the GaAs monocrystalline is susceptible to impacts and fractures readily, yet the main plane of said GaAs crystal is shifted from said (100) face at a prescribed angle in order to suppress the occurrence of channeling, said cleavage plane is not rendered perpendicular to the substrate main plane, thereby improving the impact strength of the subject GaAs-MESFET.
Description may now be made with reference to FIGS. 3A to 3G of the method of manufacturing the GaAs-MESFET utilized in this invention. Throughout the figures, reference numeral 31 represents a monocrystalline semiconductor substrate prepared from gallium arsenide (GaAs). The substrate is cut out of an ingot in such a manner that the main plane of said substrate represents a crystal orientation in which Euler angles λ, μ and θ respectively denote 21°, 11° and 0°, and thereafter said main plane is polished. An ion implantation mask is provided on said main plane of GaAs substrate 31 by means of a first photoresist layer 32a. Next, a silicon (Si + ) impurity is implanted perpendicularly into the main plane of the substrate under the conditions:
Acceleration Voltage: 150 keV.
Doping concentration: 3×10 12 /cm 2 .
As a result, an n type conductivity layer 33 is deposited on the main plane of the substrate. Thereafter, the first resist layer 32a is removed from the main plane of the substrate. Heat treatment is continued at 850° C. for 15 minutes to activate said n-type conductivity layer 33. Thereafter tungsten nitride layer 34 is deposited with a thickness of 1000 Å over the phase surface of substrate 31 as indicated in FIG. 3B. A second photoresist layer 32b is formed on said tungsten nitride layer 34. A gate electrode-forming mask is provided by etching said second photoresist layer 32b except for that portion thereof which lies on the central portion of said n-type layer 33. Later as shown in FIG. 3C, gate electrode 34 is mounted on the n-type conductivity layer by reactive ion etching (RIE) by means of the aforementioned mask. Then said second photoresist layer 32b is removed from gate electrode 34. Then third photoresist layer 32c is formed all over the fabricated mass. That portion of said photoresist layer 32c which is mounted on said n-type layer is eliminated to provide a mask open to the MESFET forming region. Thereafter as shown in FIG. 3D, silicon is ion implanted by means of said mask perpendicularly to the main plane of the substrate under the conditions:
Acceleration voltage: 180 keV.
Doping concentration: 2×10 13 /cm 2 .
to provide source and drain regions 35, 36 both of n + -type. Later said third photoresist layer 32c is eliminated, and silicon oxide (SiO 2 ) layer 37 is deposited with a thickness of about 5000 Å by chemical vapor deposition (CVD) all over the fabricated mass (FIG. 3E). The whole mass is heat treated at 800° C. for 15 minutes to activate the silicon constituting the source and drain regions. Later SiO 2 layer 37 is removed from the substrate. A fourth resist layer 32d is formed on that part of the substrate which is now rendered vacant by the removed of said SiO 2 layer 37. Those portions of said fourth resist layer 32d which were deposited on said source and drain regions are eliminated to form a mask open to the region for drawing out the source and drain electrodes. Later, as shown in FIG. 3F, a gold germanium alloy (AuGe) layer of 1500 Å thick is formed, and then gold (Au) is thermally deposited on said AuGe layer. Thus an AuGe/Au layer is formed all over the fabricated layer. Later, fourth photoresist layer 32d, together with that portion of said AuGe/Au layer which is deposited thereon, is removed (lift off step). Last, heat treatment is applied at 400° C. for 2 minutes to provide source and drain ohmic electrodes, thereby finishing the GaAs-MESFET method used in this invention.
The foregoing description was made of the process seemingly for manufacturing a single FET unit. In fact, however, a large number of FETs are formed on the substrate at the same time, as can be easily inferred.
Measurement was made of threshold voltages Vth of the numerous GaAs-MESFETs of this invention simultaneously fabricated on the same substrate, the results being set forth in the coordinate system of FIG. 4. The ordinate represents the threshold voltages Vth and the abscissa denotes the diameter of the wafer. The circular plotted points () show the measured threshold voltages of the MESFET representing the invention, and the cross-shaped plotted points (×) represent the threshould voltages of an FET unit fabricated by including the wafer by 7 degrees in the ion implantation direction and further rotating the wafer lane by 210 degrees (corresponding to the conventional process). The pattern of the coordinate system of FIG. 4 clearly indicates that the threshould voltage of all the MESFETs manufactured by the method of this invention substantially stands at -4.0 volts, whereas noticeable variations appear in the threshold voltage of the MESFETs provided by the conventional process. The above-mentioned noticeable merit of the present invention arises from the fact that the source and drain regions of the elements fabricated by the method of this invention have a substantially uniform impurity concentration, no matter where said regions are formed in the substrate wafer.
In the foregoing embodiment, the MESFET was prepared from a monocrystalline GaAs substrate having the structure of sphalerite. However, the present invention is not limited to this instance. Namely, the same effect can be ensured by fabricating any monocrystalline substrate having a diamond structure such as that prepared from Si, Ge or InP. Further, not only silicon, but also any other impurities known to this particular field, for example, S, Se, Mg, are adapted for ion implantation.
|
A method of manufacturing a semiconductor device involves the step of carrying out the implantation of an impurity in the main plane of a GaAs substrate for the simultaneous formation of a plurality of regions. When the angles formed with the perpendicular implantation of silicon ions in the GaAs main plane and the main orientations of GaAs substrate are expressed by the Euler angles (λ,μ,θ), then the crystal orientation is so prescribed as to satisfy the following conditions:
11°<λ<33°
7°<μ<24°
θ≈0°,
thereby suppressing the occurrence of channeling in the implantation of ions in the substrate main plane and consequently ensuring substantially uniform impurity concentration in the plural regions.
| 8
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Applicant claims priority under 35 U.S.C. §119 of Japanese Patent Application No. JP2009-093204 filed on Apr. 7, 2009.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a connector for a backlight in a liquid crystal panel, a monitor, or the like.
[0003] For example, this type of connector is disclosed in JP-A 2008-34330, the contents of which are incorporated herein by reference. In the connector disclosed in JP-A 2008-34330, unexpected stress may be applied to a portion connected to a circuit board (e.g., a solder portion) due to thermal contraction or thermal expansion of a cold cathode fluorescent lamp (CCFL) or the like that is held by the connector.
[0004] Meanwhile, in a case of a connector disclosed in JP-A 2007-95672, even if thermal contraction or thermal expansion of a CCFL or the like occurs, the flexibility of contacts absorbs such thermal contraction or thermal expansion. Therefore, there is no problem that stress is concentrated at a solder portion or the like.
[0005] However, in the connector disclosed in JP-A 2007-95672, contacting areas of the contacts (portions supporting the CCFL or the like) have excessively high flexibility of movement. Therefore, the connector cannot be formed only by the contacts, and a housing is required separately from the contacts. Assuming that a housing is removed from the connector disclosed in JP-A 2007-95672, the strength of the connector is too weak. In other words, the number of parts is increased in order to maintain the strength with the structure disclosed in JP-A 2007-95672.
SUMMARY OF THE INVENTION
[0006] It is, therefore, an object of the present invention to provide a connector capable of avoiding problems caused by thermal contraction or thermal expansion of a CCFL or the like with a technique different than that disclosed in JP-A 2007-95672.
[0007] One aspect of the present invention provides a connector having a first member connectable to a first object and a second member connectable to a second object. The second member is arranged so as to restrict movement of the first member in a first horizontal direction. The connector also has a connection member configured to connect the first member and the second member to each other so that the first member is movable relative to the second member in a second horizontal direction perpendicular to the first horizontal direction.
[0008] An appreciation of the objectives of the present invention and a more complete understanding of its structure may be had by studying the following description of the preferred embodiment and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view showing a mounted state of a connector according to an embodiment of the present invention, in which only part of cold cathode fluorescent lamps and a circuit board is illustrated.
[0010] FIG. 2 is an enlarged view of the connector shown in FIG. 1 .
[0011] FIG. 3 is a perspective view of the connector shown in FIG. 2 as viewed from above a front side of the connector.
[0012] FIG. 4 is a perspective view of the connector shown in FIG. 2 as viewed from above a rear side of the connector.
[0013] FIG. 5 is another perspective view of the connector shown in FIG. 4 as viewed from above the rear side of the connector, in which a second member is omitted from the illustration.
[0014] FIG. 6 is a sectional view of the connector shown in FIG. 3 which is cut by the YZ-plane passing line VI-VI.
[0015] FIG. 7 is a perspective view showing a variation of a regulation portion of a base according to the embodiment of the present invention.
[0016] FIG. 8 is another perspective view showing a variation of the regulation portion of the base according to the embodiment of the present invention.
[0017] FIG. 9 is another perspective view showing a variation of the regulation portion of the base according to the embodiment of the present invention.
[0018] FIG. 10 is a perspective view of the connector shown in FIG. 2 as viewed from below the connector.
[0019] FIG. 11 is an enlarged perspective view showing a variation of a meander portion according to the embodiment of the present invention.
[0020] FIG. 12 is another enlarged perspective view showing a variation of the meander portion according to the embodiment of the present invention.
[0021] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] As shown in FIGS. 1 and 2 , a connector 10 according to an embodiment of the present invention is used to connect a cold cathode fluorescent lamp 20 and a circuit board 30 to each other. In FIG. 1 , the cold cathode fluorescent lamps 20 and the circuit board 30 are illustrated only with their connecting portions to the connector 10 .
[0023] As shown in FIGS. 2 to 4 and FIG. 10 , the connector 10 according to the present embodiment has a first member (first section) 100 , a second member (second section) 200 , and a connection member (connection section) 300 . The first member 100 is connected to a cold cathode fluorescent lamp 20 , and the second member 200 is connected to the circuit board 30 . The connection member 300 connects the first member 100 and the second member 200 to each other. The first member 100 , the second member 200 , and the connection member 300 of the present embodiment are formed integrally by pressing or the like.
[0024] The first member 100 includes a holder 110 for holding a terminal 22 of the cold cathode fluorescent lamp 20 , a support 120 for defining the bottom dead center of the cold cathode fluorescent lamp 20 (the lowermost position of the cold cathode fluorescent lamp 20 in the Z-direction), and a base 130 connecting the holder 110 and the support 120 to each other.
[0025] The holder 110 is formed by a pair of spring portions 111 a and 111 b , which partially contact each other in the X-direction. The spring portions 111 a and 111 b include tip potions 112 a and 112 b , detachment prevention portions 113 a and 113 b produced by making an incision in part of the spring portions 111 a and 111 b and then bending the incised portion downward in the Z-direction, protrusions 115 a and 115 b projecting so as to separate from each other in the X-direction, and bent portions 116 a and 116 b.
[0026] Preloads are applied to the spring portions 111 a and 111 b so that the spring portions 111 a and 111 b push against each other in the X-direction under the normal conditions shown in FIGS. 3 and 4 . In the present embodiment, the terminal 22 of the cold cathode fluorescent lamp 20 is passed between the detachment prevention portions 113 a and 113 b downward in the Z-direction and then held by the holder 110 .
[0027] The tip portions 112 a and 112 b are bent so as to extend upward in the Z-direction and separate from each other in the X-direction. The tip portions 112 a and 112 b serve to guide the terminal 22 of the cold cathode fluorescent lamp 20 .
[0028] The detachment prevention portions 113 a and 113 b extend downward in the Z-direction from contacts of the spring portions 111 a and 111 b and contact each other without any space. Thus, even if the terminal 22 of the cold cathode fluorescent lamp 20 held by the holder 110 moves upward in the Z-direction, it strikes lower ends of the detachment prevention portions 113 a and 113 b . Therefore, the terminal 22 is prevented from being detached upward in the Z-direction from the holder 110 .
[0029] The bent portions 116 a and 116 b are produced by bending the spring portions 111 a and 111 b so as to curve downward in the Z-direction and then bending the spring portions 111 a and 111 b so as to curve upward in the Z-direction. As a result, each of the bent portions 116 a and 116 b has an S-shaped cross-section on the XZ-plane as can be seen from FIG. 5 .
[0030] As shown in FIGS. 5 and 6 , each of the protrusions 115 a and 115 b projects outward in the X-direction. This arrangement can reduce contact areas between the spring portions 111 a and 111 b and the terminal 22 of the cold cathode fluorescent lamp 20 as shown in FIG. 2 and can thus prevent wear due to movement of the terminal 22 .
[0031] As shown in FIGS. 3 and 4 , the support 120 has a U-shaped edge 122 formed for supporting the terminal 22 of the cold cathode fluorescent lamp 20 . The U-shaped edge 122 defines the bottom dead center of the terminal 22 .
[0032] The base 130 has a roughly rectangular shape as viewed downward in the Z-direction. The bent portions 116 a and 116 b of the holder 110 extend from side surfaces of the base 130 facing each other in the X-direction, which is hereinafter referred to as X-side surfaces. The support 120 extends upward from a front side surface of the base 130 in the Y-direction. As shown in FIG. 5 , the base 130 has guide portions 132 formed respectively in the X-side surfaces. In the present embodiment, each of the guide portions 132 is formed by a slit extending in the Y-direction.
[0033] Protrusions 134 are formed near opposite ends of each guide portion 132 in the Y-direction. Each of the protrusions 134 projects along the X-direction from the side surface. The first member 100 is connected to the connection member 300 , which will be described later, via a lower edge 140 of the base 130 .
[0034] As shown in FIGS. 3 and 4 , the second member 200 includes an outer frame 210 and fixing portions 220 extending from the outer frame 210 . The outer frame 210 is formed so as to surround three side surfaces of the base 130 of the first member 100 other than the front surface of the base 130 in the Y-direction. The fixing portions 220 extend from lower portions of the X-side surfaces of the base 130 so as to separate from each other in the X-direction. The fixing portions 220 are electrically connected to a circuit (not shown) of the circuit board 30 (see FIG. 2 ). Furthermore, the outer frame 210 has a lower edge 240 with a recessed portion 240 a , which is recessed partially in the Z-direction. The second member 200 is connected to the connection member 300 , which will be described later, via the recessed portion 240 a . The lower edge 140 of the first member 100 is located at the same height in the Z-direction as the recessed portion 240 a of the second member 200 .
[0035] As shown in FIGS. 4 and 5 , the protrusions 134 formed on the base 130 of the first member 100 are provided in order to reduce clearances in the X-direction between the base 130 and the outer frame 210 of the second member 200 . Thus, the protrusions 134 abut the second member 200 . With this configuration, movement of the first member 100 is restricted relative to the second member 200 in the X-direction.
[0036] In the present embodiment, the second member 200 has regulation portions 214 formed on both side surfaces in the X-direction. Each of the regulation portions 214 includes a portion extending upward and a portion extending toward the first member 100 . As can be seen from FIG. 6 , each of the regulation portions 214 has an end 216 received within the corresponding guide portion 132 . In the present embodiment, the end 216 of each regulation portion 214 has a Y-direction width smaller than that of the corresponding guide portion 132 . With this configuration, the end 216 can move in the Y-direction within a range of the Y-direction width of the guide portion 132 . Meanwhile, the Z-direction thickness of the end 216 of each regulation portion 214 is slightly smaller than the Z-direction height of the corresponding guide portion 132 . Thus, the end 216 can hardly move in the Z-direction within the guide portion 132 . With this arrangement, the first member 100 can move within a certain range in the Y-direction relative to the second member 200 and can hardly move in the Z-direction.
[0037] The guide portions 132 and the regulation portions 214 are not limited to the aforementioned structures. For example, as shown in FIG. 7 , regulation portions 214 a may be configured such that the regulation portions 214 shown FIG. 4 are turned upside down. Specifically, each regulation portion 214 a may be formed so as to have a portion extending downward and a portion extending toward the first member 100 . Furthermore, as shown in FIG. 8 , part of upper edges of the outer frame 210 may be extended so as to form regulation portions 214 b . Alternatively, as shown in FIG. 9 , each regulation portion 214 c may be formed so as to have a portion extending frontward in the Y-direction and a portion extending toward the first member 100 . In any case of FIGS. 7 to 9 , the first member 100 is arranged such that the first member 100 can move within a certain range in the Y-direction relative to the second member 200 and can hardly move in the Z-direction. The structures of the guide portions and the regulation portions are not limited to the aforementioned structures as long as they regulate movement of the first member 100 as described above.
[0038] As shown in FIGS. 3 and 10 , the connection member 300 includes first connection ends 310 connected to the first member 100 , second connection ends 320 connected to the second member 200 , and a meander portion 330 connecting the first connection ends 310 and the second connection ends 320 to each other. The meander portion 330 is formed so as to be expandable and contractible in the Y-direction. Thus, as shown in FIG. 2 , the first member 100 is supported in a floating state via the connection member 300 by the second member 200 fixed to the circuit board 20 . Considering this structure of the connection member 300 , the aforementioned operations of the guide portions 132 and the regulation portions 214 (see FIG. 6 ), and the role of the protrusions 134 ( FIG. 5 ), the first member 100 to which the cold cathode fluorescent lamp 20 is connected is movable within a certain range in the Y-direction (the direction in which the cold cathode fluorescent lamp 20 expands or contracts) relative to the second member 200 connected and fixed to the circuit board 30 . Meanwhile, movement of the first member 100 is restricted relative to the second member 200 in the X-direction and the Z-direction, so that the first member 100 can hardly move in the X-direction and the Z-direction. This arrangement can absorb thermal expansion and thermal contraction of the cold cathode fluorescent lamp 20 in the Y-direction. Therefore, the connector 10 according to the present embodiment does not suffer from any problem caused by thermal expansion and thermal contraction of the cold cathode fluorescent lamp 20 .
[0039] In the present embodiment, the first connection ends 310 and the second connection ends 320 are connected to the lower edge 140 of the first member 100 and the lower edge 240 of the second member 200 , respectively, at two locations as shown in FIG. 10 . With this configuration, the strength can be enhanced against stress applied to the first connection ends 310 and the second connection ends 320 during a pressing process. Moreover, the first member 100 , the second member 200 , and the connection member 300 can be stabilized without distortion by the connections at two locations. Furthermore, one meander portion 330 is provided to connect between the first connection ends 310 and the second connection ends 320 . This configuration increases the spring length of the meander portion 330 , thereby providing high spring characteristics.
[0040] In order to enhance the strength and the spring characteristics of the connection member 300 , the connection member 300 of the present embodiment is arranged as described above. However, the connection member 300 may be configured to enhance only one of the strength and the spring characteristics of the connection member 300 . For example, as shown in FIG. 11 , one first connection end 310 a and one second connection end 320 a may be connected to the lower edge 140 of the first member 100 and the lower edge 240 of the second member 200 , respectively. This configuration can increase the spring length of a meander portion 330 a . However, the first member 100 may twist relative to the second member 200 on the XZ-plane. Alternatively, as shown in FIG. 12 , two meander portions 330 b each including a first connection end 310 b and a second connection end 320 b may be used to form two springs. With this configuration, the first member 100 and the second member 200 are connected to the connection member 300 at two locations. Therefore, the stability can be enhanced as with the meander portion 330 shown in FIG. 10 . However, since two springs are used, the spring length of each spring cannot be increased as compared to the meander portion 330 shown in FIG. 10 . Accordingly, it is preferable to use the connection member 330 as shown in FIG. 10 in order to achieve improvement of both of the stability and high spring characteristics.
[0041] According to the present invention, two members are connected to each other in such a manner that the member connected to one connection target, such as a CCFL, is movable relative to the member connected and fixed to another connection target, such as a circuit board. Therefore, thermal contraction of the CCFL can be absorbed by relative movement between the two members. Accordingly, a connector according to the present invention does not suffer from any problem caused by thermal contraction.
[0042] The present application is based on a Japanese patent application of JP2009-093204 filed before the Japan Patent Office on Apr. 7, 2009, the contents of which are incorporated herein by reference.
[0043] While there has been described what is believed to be the preferred embodiment of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such embodiments that fall within the true scope of the invention.
|
A connector has a first member connectable to a first object and a second member connectable to a second object. The second member is arranged so as to restrict movement of the first member in a first horizontal direction. The connector also has a connection member configured to connect the first member and the second member to each other so that the first member is movable relative to the second member in a second horizontal direction perpendicular to the first horizontal direction.
| 7
|
BACKGROUND OF THE INVENTION
Magneto ignition systems are based upon the electrical principle that a voltage is generated in any conductor which is subjected to a change in magnetic flux through the conductor. More specifically, a sudden change of the magnetic flux in the core upon which a conductor is mounted will induce a high voltage which can be applied to a spark gap for fuel ignition.
The conventional ignition systems for internal combustion engines have used cam actuated breaker points. The breaker points physically break the magneto coil circuit to induce a high voltage at the proper time in the engine cycle to cause sparking action at the spark plug. With the advent of solid-state switching circuits, many designers in the ignition art recognized the advantages of substituting such circuits for the breaker points. Various electronic circuits, including transistors and silicon controlled rectifiers (SCR), were used in place of the breaker points to interrupt the current to the magneto or primary winding. The use of an auxiliary pick-off coil to trigger the switching action of the electronic circuit also was implemented as an appropriate means to control the timing of the switching action.
In U.S. Ser. No. 790,704, now U.S. Pat. No. 4,120,277 filed May 25, 1977 there is described a breakerless magneto device which utilizes primary and trigger windings mounted on separate cores. The core upon which the auxiliary trigger coil is mounted is located close to the main magneto core for reasons of spark timing, but is operationally substantially isolated magnetically therefrom. A thyristor and a semiconductor circuit such as Darlington connected transistors act as switching elements for interrupting the current in the primary winding of the magneto.
SUMMARY OF THE INVENTION
The present invention provides an improved magneto ignition system comprised of a first core having a first winding mounted thereon, a second core adjacent the first core and having a second winding mounted thereon, and a rotor structure having a permanent magnet which produces a varying flux field in the first and second cores. A third winding is mounted on the first core. A primary circuit including semiconductor devices is provided for current buildup in the first winding. The voltage pulse generated in the second winding due to the varying flux field of the rotating permanent magnet is applied as a trigger signal to a solid-state device such as a silicon controlled rectifier which interrupts the current in the primary circuit at or near its maximum value thereby changing the flux field. A biasing voltage is provided from the third winding to the switching element, the semiconductor circuit, to enhance and facilitate the interruption of current in the primary circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, FIG. 1 is a circuit diagram of a preferred embodiment of the present invention.
FIG. 2A is a circuit diagram of another preferred embodiment of the present invention.
FIG. 2B is a circuit diagram of another preferred embodiment of the present invention.
FIG. 3 is a cross-sectional representation of the core and coil structures of an embodiment of the present invention.
FIG. 4 is a sectional view of FIG. 3, showing the placement of the windings on the cores.
FIG. 5A is a graphical representation of the emitter to base voltage during switching in a circuit without the improvement of the present invention.
FIG. 5B is a graphical representation of the emitter to collector voltage rise during switching in a circuit without the improvement of the present invention.
FIG. 5C is a graphical representation of the emitter to base voltage during switching in a circuit showing the improved switching time using the present invention.
FIG. 5D is a graphical representation of the emitter to collector voltage rise during switching in a circuit with the improvement of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.
Referring to FIG. 1, there is shown a circuit diagram for the breakerless ignition system of this invention. In accordance with the invention a semiconductor circuit 10 is connected across the terminals of a first winding, primary winding 12, of magneto coil 14. Preferably semiconductor device 10 has first, second and third terminals 16, 18 and 20 respectively which, for instance, can be the collector, base and emitter of circuit 10.
As here embodied, semiconductor circuit 10 includes first and second transistors 22 and 24 respectively, connected in a Darlington arrangement. The collector and base of first transistor 22 serve as the first and second terminal 16 and 18 respectively of semiconductor circuit 10. The emitter of first transistor 22 is connected to the base of second transistor 24 and to one end of resistance 26. The other end of resistance 26 is connected to the emitter of second transistor 24 which also serves as third terminal 20 of semiconductor circuit 10. Resistance 27 is connected between base and emitter of transistor 22.
Preferably the semiconductor circuit 10 further includes a diode 29 connected across the collector and the emitter of second transistor 24. Diode 29 serves to bypass the reverse direction current which is generated in the primary winding 12.
According to the invention, means responsive to a voltage to switch from a nonconductive to a conductive state is connected in series with a section of a winding 28 across terminals 18 and 20 of semiconductor circuit 10. Such means can be a thyristor, and as herein embodied, is a silicon controlled rectifier (SCR) 32. Silicon controlled rectifier 32 has a gate 34 connected through resistance 35 to one end of a second winding, trigger coil 36, which is mounted on core 37. The other end of second winding 36 is connected to the cathode 33 of silicon controlled rectifier 32.
As herein embodied, base terminal 18 of semiconductor circuit 10 is connected to one side 48 of a third winding, bias supply winding 28, through resistance 30. The other side 44 of third winding 28 is connected to the cathode 33 of silicon controlled rectifier 32 and a tap 46 on third winding 28 is connected to terminal 20 of semiconductor circuit 10. As herein embodied core 40 is provided on which the first winding, primary winding 12, and the third winding, bias supply winding 28, are mounted.
Preferably means is provided for completing a circuit through primary winding 12 which can include semiconductor circuit 10 with collector and emitter terminals 16 and 20 respectively of semiconductor circuit 10 connected to the ends of primary winding 12.
With reference to FIG. 1 and as herein embodied, switch 50 connects one end of first winding 12 to ground. When switch 50 is closed, primary winding 12 is shorted out and the circuit is shut off.
As shown in FIG. 1 secondary winding 42 is provided with a high voltage output which is typically connected to an engine fuel ignition means such as a spark plug (not shown). The current generated in the first winding, primary winding 12, and switched through semiconductor circuit 10 produces a magnetic field affecting the common core 40 of the primary and secondary windings 12 and 42 inducing the high voltage output in the secondary winding.
In accordance with the invention, means responsive to the varying flux through core 40, here embodied as third winding 28, provides a reverse bias voltage to semiconductor circuit 10 to facilitate the interruption of current therethrough. As herein embodied in FIG. 1, a portion of third winding 28 is connected in series between the cathode of silicon controlled rectifier 32 and emitter terminal 20 of semiconductor circuit 10. The cathode of silicon controlled rectifier 32 is connected to a first terminal 44 of third winding 28. A second terminal, tap terminal 46 is connected to terminal 20 of the semiconductor circuit 10. Second terminal 46 of third winding 28 is intermediate to first terminal 44 and a third terminal 48 of third winding 28. The terminal 46 is connected to third winding 28 to provide a reverse voltage responsive to the varying flux in core 40 which is greater than the forward voltage drop of the silicon controlled rectifier under all conditions of operation.
Third winding 28 can be constructed as two separate windings or can be a single winding with a tap terminal as in FIG. 1 which produces two simultaneous voltages. A forward bias voltage developed on a first section between terminals 46, 48 is applied across terminals 18 and 20 of semiconductor circuit 10 for turning on and driving the circuit. Simultaneously and in phase opposition to the forward bias voltage, a reverse bias voltage is produced on a second section between terminals 46 and 44 which is applied in series between silicon controlled rectifier 32 and semiconductor circuit 10. The reverse bias voltage is chosen to exceed the forward voltage drop of controlled rectifier 32 to provide a reverse bias voltage on the emitter to base junction of the semiconductor circuit 10 when rectifier 32 is turned on.
The breakerless ignition system of the present invention operates as follows: A forward bias voltage generated across the portion of third winding 28 defined between terminals 46 and 48 is applied to semiconductor circuit 10, and the Darlington arrangement is turned on and current is conducted in the primary circuit. When a trigger signal is applied from second winding 36 to the gate of silicon controlled rectifier 32, the forward voltage drop of rectifier 32 will be less than the opposing bias voltage and the voltage between emitter 20 and base terminal 18 of semiconductor circuit 10 will swing negative turning semiconductor circuit 10 off. The negative value of the base emitter voltage is determined by the voltage generated in the tap portion of third winding 28 between terminals 44 and 46.
Second and third preferred embodiments of the breakerless ignition system of the present invention are depicted in FIGS. 2A and 2B. Like elements of the circuit as shown in FIG. 1 have been identified by the same symbols. In FIG. 2A the circuit has been modified to eliminate a portion of third winding 28 and thereby to simplify the circuit. Further, resistance 30, which is the base current limiting resistor, is connected to first winding, primary winding 12, rather than to third winding 28. Primary winding 12 provides the forward bias voltage through resistance 30 to turn on and drive semiconductor circuit 10. The voltage generated by first winding 12 provides an ample forward bias to turn semiconductor circuit 10 on and thereby eliminates the need for a major portion of third winding 28.
The breakerless ignition system according to FIG. 2A is simpler to manufacture since third winding 28 has been decreased in size. However, the forward bias voltage for turning on semiconductor circuit 10 is only available from the fixed number of turns in first winding 12 and the voltage can not be independently varied from that value. With the circuit as shown in FIG. 1 the portion of the third winding between terminals 46 and 48 controls the forward bias for turning on and driving semiconductor circuit 10. Consequently, the power and voltage for driving semiconductor circuit 10 can be regulated independently of the primary winding. Nonetheless, in the usual applications the circuit of FIG. 2A provides ample power capability from first winding 12 for driving semiconductor circuit 10.
A preferred embodiment in which a third winding is not required is shown in FIG. 2B. A first section of first winding 12 between terminals 11 and 13 is connected in series with resistance 30 across terminals 18 and 20 to drive semiconductor circuit 10. The voltage generated between terminals 11 and 13 of first winding 12 provides a forward bias drive to semiconductor circuit 10 as was done in the embodiment of FIG. 2A.
A second section of first winding 12 which is tapped off between terminals 11 and 15 is connected in series between cathode 33 of the silicon controlled rectifier 32 and terminal 20 of semiconductor circuit 10. The voltage across the second section of first winding 12 is selected to be greater in magnitude than the forward voltage of silicon controlled rectifier 32 and is connected to oppose such forward voltage so that the voltage across terminals 18 and 20 is reversed during current interruption.
It will be appreciated that multiple magnets in the rotor and distributor means can be provided where a multiple cylinder internal combustion engine is used for any of the embodiments of FIGS. 1, 2A and 2B. The voltage produced in the secondary winding 42 can then selectively be applied to each spark plug corresponding to the respective cylinders of the internal combustion engine.
The construction of the first and second cores 40 and 37, the magneto and trigger cores respectively, and their respective windings is shown in FIGS. 3 and 4. As herein embodied the rotor 52 of a nonmagnetic material has a permanent magnet 54 embedded in its periphery for providing a rotating field or source of flux for the magneto system. It will be appreciated that variations can be made in the configuration of the magnet 54 and rotor 52 without varying from the concept taught in this invention.
Rotor 52 is usually mounted directly on the shaft of the internal combustion engine, and as shown here, rotates in a counterclockwise direction in synchronism with the engine. The air gap between first core 40 and rotor 52 is minimized so that the total reluctance of the magnetic circuit, when the poles of magnet 54 are aligned respectively with the legs of core 40, is small. When the poles of magnet 54 are aligned with the end portions of legs 56 and 58 of core 40, most of the flux from the rotating field member passes through first core 40.
Preferably and as herein embodied, the second core 37 having second winding 36 mounted thereon is positioned next adjacent and spaced from first core 40. This can be achieved by placement of an insulating spacer 60 between the second winding 36 and first core 40.
As herein embodied the first winding, primary winding 12, is mounted on leg 58 of core 40 to encompass both second core 37 and second winding 36. Preferably second core 37 is positioned parallel to and adjacent leg 58 of core 40.
Third winding 28 is preferably mounted on the first winding, primary winding 12, as shown in FIG. 3. Third winding 28 is wound coaxially with primary winding 12. Secondary winding 42 as here shown in mounted on third winding 28. Each of the respective windings, first winding 12, third winding 28 and secondary winding 42 are mounted concentric with leg 58 of core 40. Insulating spacers such as 60 are used to position the respective windings in proper relationship to one another and to core 40.
Second core 37 and second winding 36 are positioned inside and adjacent first leg 58 so that a voltage pulse is generated in second winding 36 at the time that the current in primary winding 12 is substantially at its maximum value. The trigger voltage pulse is applied to gate terminal 34 of silicon controlled rectifier 32 placing it in a conductive state. The flow of current through primary winding 12 is thereby interrupted.
At the instant that switching occurs, base terminal 18 of semiconductor circuit 10 goes from a forward bias voltage to a reverse bias voltage with respect to emitter terminal 20. This causes semiconductor circuit 10 to rapidly switch off because the charge carriers are driven by the reverse bias. The result is a switching time which is a fraction of the switching time achieved when a forward bias level remains on semiconductor circuit 10 after switching. Additionally the reverse bias between base 18 and emitter 20 momentarily raises the hold off voltage or the break over voltage of the emitter collector simultaneously with the arrival of increasing voltage from the first winding, primary winding 12, immediately after switching has occurred. Rather than the emitter collector breaking over, it is now held off to a higher voltage and the circuit is allowed to oscillate slightly between the emitter and base providing essentially an oscillating bias in unison with the voltage applied from primary winding 12 to the emitter collector of semiconductor circuit 10. This causes a ringing in the secondary output voltage which enhances the operation of the device.
The improvement in operation of the magneto ignition system is best shown by comparing FIGS. 5A and 5B with FIGS. 5C and 5D. In FIGS. 5A and 5B the emitter to base voltage and emitter to collector voltage respectively are shown for a device which does not provide a reverse bias voltage to semiconductor circuit 10 during turn off. The voltage generated in third winding 28 that is applied across base terminal 18 and emitter terminal 20 of semiconductor circuit 10 is shown to increase to a typical value of 1.8 volts. When triggering occurs at time T 1 , silicon controlled rectifier 32 turns on and the emitter to base voltage drops to about 0.9 volts positive in a time T 1 to T 2 . The relative switching time is shown in FIG. 5B by plotting the emitter to collector voltage rise. The emitter to collector voltage of semiconductor circuit 10 goes from a low value in the on condition at time T 1 to a maximum voltage at time T 2 determined by circuit conditions imposed upon the emitter collector of the Darlington arrangement. The switching time (T 1 to T 2 ) is typically of the order of 2 to 3 microseconds.
In FIGS. 5C and 5D there is shown the emitter to base voltage and the emitter to collector voltage respectively for a circuit according to the present invention utilizing means to provide a reverse bias voltage to semiconductor circuit 10 during turn off. The emitter to base voltage rises during the on condition of the circuit to a typical value of 1.8 volts. When triggering occurs at time T 1 , silicon controlled rectifier 32 turns on and the emitter to base voltage is driven negative by an amount that is determined by the number of turns of third winding 28 between terminals 44 and 46 as shown in FIG. 1.
The rise time of the emitter to collector voltage of semiconductor circuit 10 shown in FIG. 5D is decreased appreciably by the use of reverse biasing. Whereas the rise time (T 2 -T 1 ) shown in FIG. 5B typically is between two and three microseconds, when switching is accomplished in a circuit according to that of FIGS. 1, 2A or 2B it can be accomplished in less than one microsecond, typically 0.8 microsecond. The faster switching time results in lower switching losses and less heating. A greater output from the secondary due to lower power losses and the faster rate of current change in the primary winding 12 is thereby achieved.
If an increased reverse bias is applied across the emitter to base junction of semiconductor circuit 10, the break-over voltage between the emitter and collector increases. The circuits according to either FIGS. 1, 2A or 2B allow a reverse bias voltage to be applied to the base to emitter junction of semiconductor circuit 10 at the rate of application of emitter to collector voltage after semiconductor circuit 10 is shutoff. Accordingly it is possible to achieve hold off voltages with this circuit under momentary biasing conditions that are substantially higher than the voltage ratings of the transistors.
The reverse biasing of the base to emitter junction of semiconductor circuit 10, as described above, occurs because of the structure of the windings. Third winding 28 is wound concentric with first winding 12 which produces the voltage which appears across the emitter collector terminals of semiconductor circuit 10. When a voltage is generated in first winding 12, a voltage is also generated in third winding 28 since they are wound coaxially on the same core 40.
|
The several embodiments of the self-generating breakerless ignition system disclosed herein are each comprised of a rotor structure with a permanent magnet which induces voltages in a plurality of windings, three cascaded semi-conductor switching elements to control the current in the windings, a trigger signal which is provided by one of the windings and which activates the switching elements at a predetermined time, and means which simultaneously supply positive and negative biasing to the switching elements to enhance the switching procedure.
| 5
|
This is a continuation of copending application Ser. No. 07/925,890, filed on Aug. 6, 1992, now abandoned, which is a continuation of Ser. No. 07/583,889, filed on Sep. 17, 1990, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to the field of coated cutting tools.
In the past, cemented carbide cutting tools have been used in both a coated and an uncoated condition to machine metals and alloys. The application of a coating having one or more layers of a refractory material to a tungsten carbide-cobalt cemented carbide substrate has been used to improve the wear resistance and application range of cemented carbide cutting tools. In the past, refractory coatings, such as TiC, TiCN, TiN, and Al 2 O 3 , have been applied by CVD (chemical vapor deposition) techniques. In addition, TiN coatings have been applied by PVD (physical vapor deposition) techniques. Such CVD coatings deposited on cemented carbide substrates are characterized by thermal cracks, and residual tensile stresses. PVD TiN coatings are characterized by a dense, pore free structure without thermal cracks, and may have residual compressive stresses. The application of CVD coatings to cemented carbide substrates results in a reduction in the transverse rupture strength of the insert and, therefore, produces a greater susceptibility to chipping and breakage during use.
SUMMARY OF THE INVENTION
Applicants have now discovered that the transverse rupture strength of CVD coated cemented carbide may be improved by applying a PVD layer to the CVD coated substrate. In order to provide the aforementioned improvements, it is believed that the PVD coating must contain residual compressive stresses.
Therefore, in accordance with the present invention, improved cutting tools are provided having a substrate coated with one or more CVD layers and one or more PVD layers. The outermost layer of the CVD and PVD layers preferably is a PVD layer having residual compressive stresses. The substrate is a composite material having hard refractory grains (e.g., WC) bonded together by a binder material, preferably, metallic (e.g., Co).
These and other aspects of the present invention will become more apparent upon review of the detailed specification in conjunction with the FIGURE which is briefly described below:
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE shows an isometric view of an embodiment of a cutting tool in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, the FIGURE shows a preferred embodiment of an indexable cutting insert 10 having cutting edges 12 at the junction of rake face 14 with flank faces 16. The cutting insert 10 shown in the FIGURE is an SPGN-433 (ANSI B212.4-1986) which may be in a sharp, or preferably, honed cutting edge condition.
In a preferred embodiment, the substrate is a WC based cemented carbide substrate containing at least 70 weight percent WC, and more preferably, at least 80 weight percent WC. The binder is preferably cobalt or a cobalt alloy and, preferably, has a bulk concentration of 5 to 15 weight percent. More preferably, the bulk cobalt content is about 7 to about 13 weight percent, and most preferably, about 8 to about 12 weight percent. The substrate may also preferably contain solid solution carbide forming elements such as Ti, Hf, Zr, Nb, Ta, V, preferably selected from Ti, Nb and Ta alone or in combination with each other. These elements preferably may be added to the mix as an element, alloy, carbide, nitride or carbonitride. Preferably, the concentration of these elements is as follows: Ta 0-12 w/o; Ti 0-10 w/o and Nb 0-6 w/o. More preferably, the sum of Ta plus Nb is between about 3 to about 7 w/o and the titanium content is between about 0.5 to 10 w/o. Most preferably, the titanium content is about 1.5 to 4.0 w/o.
These elements form solid solution carbides with the WC in the substrate. Chromium, preferably as Cr 3 C 2 , may also be added in small amounts.
Bonded on to the substrate is a hard refractory coating having at least two layers, a CVD layer and a PVD layer, with the last PVD layer preferably being outside the last CVD layer. Applicants have found that, when the PVD layer also has a compressive residual stress, that the transverse rupture strength of the CVD coated article is improved.
In a preferred embodiment, the inner CVD layer is preferably a hard nitride, such as the nitrides of Ti, Hf, Zr, their alloys with each other and their alloys with other elements, and more preferably Ti, Zr or Hf nitride. Nitrides are preferred over refractory carbides or carbonitrides for the inner layer adjacent to the substrate in order to minimize the formation of eta phase (Co 3 W 3 C and/or Co 6 W 6 C) at the cemented tungsten carbide based substrate peripheral boundary. Eta phase is a brittle phase which may make the cutting edge more susceptible to chipping. A second layer in the coating is preferably a CVD hard carbonitride, or carbide, such as Ti, Zr or Hf carbonitride or carbide, because of the higher hardness and abrasion resistance of the carbides and carbonitrides of Ti, Zr and Hf compared to their nitrides. Carbonitrides of the alloys of Ti, Hf and Zr with each other and their alloys with other elements may also be utilized. The CVD second layer and any additional CVD layers may include, for example, alumina, either as a single layer or multiple layers separated from each other by a layer of another refractory material, such as a nitride, carbonitride or carbide of Ti, Hf or Zr, preferably, Ti.
Where it is desired to have an Al 2 O 3 CVD layer next to the outer PVD layer, it is preferred, in order to improve the bond strength between the Al 2 O 3 and the PVD layer that a CVD nitride, carbonitride or carbide layer of Ti, Hf or Zr is deposited between the alumina CVD layer and the PVD layer.
The final and outermost layer of the coating is preferably a hard refractory PVD layer, such as a nitride, carbonitride of Ti, Zr or Hf, their alloys with each other, and their alloys with other elements. This outermost layer is characterized by residual compressive stresses.
The present invention is further illustrated by the following examples which are provided purely for illustration and not limitation.
The effect of coatings on the transverse rupture strength of cemented carbide substrate was demonstrated by applying the following coatings on a conventional WC-6 weight percent cobalt-0.5 weight percent Cr 3 C 2 cemented carbide substrate.
Coatings
1. CVD {TiN (1 μm)/TiCN (3 μm)/TiN (4 μm)}
2. CVD {TiN (1 μm)/TiCN (3 μm)}/PVD TiN (4 μm)
3. PVD TiN (8 μm)
The CVD coatings were applied by conventional CVD techniques at about 950 to 1000 cegrees Centigrade. The PVD TiN coating was applied with a Balzers BAI-830 (Balzers AG, Liechtenstein) ion plating PVD coating unit at about 500 degrees Centigrade using a titanium source and a nitrogen atmosphere (see U.S. Pat. No. 4,448,802). As is common practice during the initial stages of coating a very thin layer (detectable by high resolution TEM) of titanium was deposited on the CVD TiCN layer to provide improved adhesion between it and the PVD-TiN layer. The PVD layer produced by this technique has compressive residual stresses.
The transverse rupture strength of transverse rupture bars coated as described above and in an uncoated condition were measured using the ASTM standard B406 transverse rupture test procedure. The transverse rupture strength data are given below in Table I.
TABLE I______________________________________ Average Standard TRS (Ksi) Deviation (Ksi)______________________________________Uncoated 559 27Coating 1 (CVD) 193 12Coating 2 (CVD + PVD) 281 11Coating 3 (PVD) 566 58______________________________________
As shown by the examples, the application of CVD layers to a cemented carbide substrate results in a drastic decrease in transverse rupture strength. This reduction is believed to be due to: (a) the high temperature annealing effect of the CVD deposition temperature (950-1000 degrees Centigrade) which reduces beneficial compressive residual stresses in the surface due to grinding of the cemented carbide substrate; and (b) the presence of thermal cracks and residual tensile stresses in the CVD layers caused by thermal expansion mismatch between the coating and the cemented carbide substrate.
The deposition of PVD TiN over the CVD {TiN/TiCN} partially restores the loss in TRS observed with CVD coating alone. This improvement (about 45 percent) in TRS is believed to be due to the presence of compressive residual stresses and the absence of thermal cracks within the outer PVD TiN layer.
It, therefore, follows that a coating of solely PVD should not degrade transverse rupture properties. This is shown by the results of the samples coated with coating 3.
It is the applicants' belief that, in view of the above results, combinations of CVD and PVD coatings may be applied to a variety of cemented carbide substrates to obtain improvements in the overall properties and performance of the material. It is contemplated that this invention may be used to its best advantage where the cobalt content of the substrate is 7 to 13 weight percent and, more preferably, 8 to 12 weight percent. Specific examples of substrates where the present invention may be applied are as follows:
Substrate 1 11.5 w/o Co, 2.5 w/o Ta (Nb)C, 86 w/o WC - 89.8 R A , Hc 160 Oe, A and/or B porosity
Substrate 2 6.0 w/o Co, 0.5 w/o Cr 3 C 2 , 93.5 w/o WC - 93 R A , Hc 300 Oe, A and/or B porosity (used in Table I examples)
Substrate 3 9.75 w/o Co, 90.25 w/o WC - 91 R A , Hc 200 Oe, A and/or B porosity
Substrate 4 10 w/o Co, 90 w/o WC - 89 R A , Hc 120 Oe, A and/or B porosity
Substrate 5 10.5 w/o Co, 10 w/o Ta(Nb)C, 7 w/o TiC, 72.5 w/o WC - 91.4 R A , Hc 180 Oe, A and/or B porosity
Substrate 6 8.5 w/o Co, 11 w/o Ta(Nb)C, 7.5 w/o TiC, 73 w/o WC - 91.2 R A , Hc 140 Oe, A and/or B porosity
CVD and PVD coated binder enriched substrates and other embodiments of the present invention are described in copending application U.S. Ser. No. 07/583,544 entitled "Binder Enriched CVD and PVD Coated Cutting Tool," filed on the same date as the present application, now U.S. Pat. No. 5,250,367. This copending application describes the application of these cutting inserts to milling of steel and shows the superiority of binder enriched grades over nonenriched grades in the severe milling applications described therein. The present applicants believe that, for less severe milling applications and turning applications, the application of CVD+PVD coatings to nonenriched substrates as described in the present application should be sufficient to provide improved chipping resistance.
All applications, patents and other documents referred to herein are hereby incorporated by reference.
Other embodiments of the invention will be apparent to those skilled in the art from a consideration of this specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims.
|
Provided is a coated cutting tool having a coating and a substrate. The coating includes at least one chemical vapor deposited (CVD) layer and at least one physical vapor deposited (PVD) layer. The outermost layer of the coating is a PVD layer, containing residual compressive stresses. The substrate is a composite having hard refractory grains bonded together by a binder material.
| 2
|
BACKGROUND
[0001] The present disclosure relates to multi-projectile toy guns. The disclosure more particularly, although not exclusively, relates to toy guns in which air is used to propel a succession of soft projectiles.
[0002] It is known to propel soft projectiles from toy guns using air as the propellant. In some toy guns, air is rapidly compressed behind a projectile to force the projectile to fire from the toy gun. For some toy guns, a method is required to prime the gun prior to pulling a trigger to cause firing. Priming might be by pump-action to load a piston against a compression spring for example. The trigger would release the piston so as to move rapidly forward—compressing air behind the projectile. In other toy guns, there is no separate priming action. Instead, two handles are provided for grasping by separate hands. One handle is fixed with respect to the body of the gun whereas the other is fixed with respect to a piston. The two handles are reciprocated toward and away from each other and during the forward stroke air is compressed behind the projectile to cause it to be ejected.
[0003] In multi-projectile toy guns of the type described above, some means is required to present the projectiles in succession to the firing position. For example, a barrel, magazine or “ammunition chain” might be loaded with projectiles. After one projectile is fired, a cylinder or ammunition chain must be advanced one position. With a gravity-feed magazine extending above the firing position, the next projectile might simply fall into position, but some means of mechanically advancing projectiles in a side or bottom-mounted magazine would be required.
[0004] Toy guns with projectile advancing mechanisms are disclosed in U.S. Pat. Nos. 5,186,156 and 5,680,853 but each of these has a complex mechanism to cause advancement of the projectiles during a cocking operation of the toy gun. Moreover, complex systems of levers, ratchets and pawls are designed to cause the advancing mechanism to function during a reverse stroke of a plunger and then some further means is required to maintain alignment of the parts during the firing stroke. This is unnecessarily complex and expensive to manufacture.
SUMMARY
[0005] Briefly stated, there is disclosed herein a toy gun, comprising:
[0006] a body;
[0007] a piston adapted to move relative to the body between an extended position and a retracted position and to be moved rapidly toward the retracted position during a firing stroke;
[0008] a plurality of firing chambers each adapted to receive a projectile and to receive air compressed by the piston during a said firing stroke to fire the projectile from the toy gun, and
[0009] an air delivery mechanism adapted to convey the compressed air to one of the firing chambers and co-operating with the piston to advance as a result of piston movement to a configuration whereat it can convey compressed air to another of the chambers.
[0010] Preferably, the toy gun further comprises a first handle extending from the body to be grasped by one hand and a second handle extending from the piston to be grasped by another hand.
[0011] The toy gun can further comprise a trigger associated with the first handle for releasing the piston.
[0012] Preferably, each firing chamber further comprises an ejection nozzle via which air compressed by the piston is delivered to a projectile during the firing stroke.
[0013] Preferably, the toy gun further comprises a pressure chamber situated between the firing chambers and the piston and via which the compressed air is conveyed to the firing chambers.
[0014] Preferably, said plurality of said firing chambers is in a circular array.
[0015] Preferably, the air delivery mechanism comprises a disc rotatable within the pressure chamber, the disc having a port aligned with one of the firing chambers, and means for rotatably indexing the disc to align the port with another one of the firing chambers.
[0016] Preferably, the port has a check valve across it.
[0017] Alternatively, the port can include a tube extending into the pressure chamber.
[0018] Preferably, the toy gun further comprises a seal for sealing the port against each firing chamber.
[0019] Preferably, the disc is adapted to move linearly within the pressure chamber.
[0020] Preferably, said means for rotatably indexing the disc comprises a substantially cylindrical hub fixed with respect to the body and a ring attached to or formed integrally with the disc and surrounding the hub, the hub having an array of indexing fingers, the ring having one or more cams which engage upon linear movement of the disc with one or more of the fingers to rotate the disc.
[0021] Preferably, the disc is biased by a spring toward the firing chambers.
[0022] Alternatively, the air delivery mechanism comprises a conduit extending from the pressure chamber to one of the firing chambers, and means for rotatably advancing the conduit to align the conduit with another one of the firing chambers.
[0023] The means for rotatably advancing the conduit can comprise a substantially cylindrical hub fixed with respect to the conduit and a cam attached to the piston, the hub having an array of indexing fingers, the cam engage upon movement of the piston with one or more of the indexing fingers to rotate the hub and conduit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] With reference to the drawings:
[0025] FIGS. 1 , 2 and 3 are schematic cross-sectional elevations of toy guns having different air delivery advancing mechanisms;
[0026] FIGS. 4A to 9A are schematic end elevations of a toy gun barrel having multiple firing chambers and soft projectiles located within some of the firing chambers. The number of and position of the projectiles corresponds figure-to-figure with FIGS. 4B to 9B alongside these figures respectively;
[0027] FIGS. 4B to 9B are schematic cross-sectional elevations of a toy gun showing a sequence of configurations of internal compartments during priming and firing of the toy gun;
[0028] FIGS. 10 to 14 are schematic elevations of an air delivery advancing mechanism of the toy gun depicted in FIGS. 4B to 9B ;
[0029] FIG. 15 is a schematic perspective illustration of an advancing ring forming part of the advancing mechanism;
[0030] FIG. 16A is a schematic illustration of a check valve seal;
[0031] FIG. 16B is a schematic cross-sectional elevation of a portion of a disc having a check valve installed thereon and the seal of FIG. 16A in an open configuration;
[0032] FIG. 16C is a schematic cross-sectional elevation similar to FIG. 16B , but showing the check valve seal in a closed configuration;
[0033] FIG. 17A is a schematic illustration of an alternative check valve seal;
[0034] FIG. 17B is a schematic cross-sectional elevation of a portion of a disc having a check valve installed thereon and the seal of FIG. 17A in an open configuration;
[0035] FIG. 17C is a schematic cross-sectional elevation similar to FIG. 17B , but showing the check valve seal in a closed configuration;
[0036] FIG. 18A is a schematic illustration of another alternative check valve seal;
[0037] FIG. 18B is a schematic cross-sectional elevation of a portion of a disc having a check valve installed thereon and a floating plug in an open configuration away from the seal of FIG. 18A ; and
[0038] FIG. 18C is a schematic cross-sectional elevation similar to FIG. 18B , but showing the floating plug in a closed configuration pressed against to the seal.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] FIGS. 1 to 3 of the accompanying drawings depict toy guns of similar construction, although each comprises a different means of indexing the delivery of compressed air from one firing chamber to the next.
[0040] In FIG. 1 there is depicted schematically a toy gun 10 a including a body 11 and a cylinder 12 extending rearwardly from the body 11 . The cylinder 12 could alternatively be housed inside the body 11 . A piston 13 having an O-ring 15 slides linearly within the cylinder 12 . A stopper 32 prevents over-extension of the piston. The body 11 has a first handle 25 and the piston 13 has a second handle 14 . In use, the first handle is grasped by one hand and the second handle is grasped by the other. The handles are pumped in and out with respect to one another to fire projectiles in succession.
[0041] At the forward end of the body 11 , there is provided a barrel 17 . The barrel 17 is fixed with respect to the body 11 and comprises a plurality of projectile chambers 24 in a circular evenly-spaced array. Within each chamber 24 there is provided a nozzle 37 . Individual soft projectiles 18 have hollow tail portions into which a nozzle 37 extends when the projectile is loaded within a firing chamber 24 .
[0042] Located behind the barrel 17 is a cylindrical pressure chamber 16 . At the back of the pressure chamber 16 vent holes 22 are provided via which air can pass back and forth between the pressure chamber 16 in the area immediately forward of the piston 13 .
[0043] The pressure chamber 16 communicates with each of the firing chambers 24 . Moreover, the nozzles 24 have air passages through them which extend to the pressure chamber 16 .
[0044] Located within the pressure chamber 16 is a disc 19 which divides the pressure chamber into a pair of variable volume chambers. The disc 19 can move linearly within the pressure chamber 16 and can also rotate about its central axis. A guide pin 26 extends from the disc 19 and through an aperture in the rear wall of the pressure chamber and enables the disc to rotate as well as reciprocate. A disc return spring 23 surrounds the guide pin and serves to bias the disc 19 toward the barrel 17 . There is a small air gap 34 between the periphery of the disc 19 and the internal surface of the pressure chamber 16 to allow a small amount of air to pass around the periphery of the disc. There is also a vent 33 forward of the disc 19 through which air can pass from the general interior of body 11 to the pressure chamber 16 forward of the disc 19 . There is an airflow port 46 through the disc 19 . A check valve 21 a is located upon the disc 19 across the airflow port 46 . The check valve is described in detail below with reference to FIGS. 16A , 16 B and 16 C. Aligned with and immediately in front of the check valve 21 a is a seal 45 which surrounds the airflow port 46 and bears against the back of the barrel 17 when the disc 19 is in the fully forward position. Air passing through the airflow port 46 from the pressure chamber 16 via the check valve 21 a therefore passes directly into nozzle 37 of one of the firing chambers 24 .
[0045] The embodiment 10 b of FIG. 2 is the same as that of FIG. 1 , except that instead of providing a check valve 21 a across the airflow port 46 , an elongate tube 21 b is provided which extends rearwardly of the disc 19 into the rear portion of the pressure chamber. The diameter and length of the tube is chosen to control air flow rate through the tube cause correct movement of the disc 19 .
[0046] Fixed with respect to and extending from the back of the barrel 17 is an indexing hub 20 . The indexing hub 20 extends into a central recess of the disc 19 and co-operates with the disc to cause rotation of the disc between successive projectile firings. Pressure fluctuations caused by the piston 13 within the pressure chamber 16 cause the disc 19 to move back and forth along the axis of the guide pin 26 . The indexing hub 20 translates this linear movement of the disc into indexed rotation of the disc 19 to thereby sequentially align airflow port 46 with respective ones of the nozzles 37 between successive firings. The structure and operation of the indexing hub 20 will be described later with reference to FIGS. 10 to 15 .
[0047] The embodiment 10 c of FIG. 3 does not include a disc 19 , but instead provides a rotating conduit 30 rotatably sealed to the pressure chamber in front of the piston 13 by a seal 31 . The conduit has a radial segment at the forward end 21 c at which an airflow port 46 is provided. Instead of the indexing hub 20 being affixed with respect to the back of the barrel 17 in this version, the indexing hub 20 is fixed about the axial portion of conduit 30 . A metal rod 27 is fixed to and extends from the piston 13 through a seal 28 and has at its forward end a cam 29 which engages with ramped fingers which are spaced around the indexing hub 20 . Upon retraction of handle 14 , the rod 27 draws the cam 29 backward to bear upon the ramped leading edges of one of the fingers to cause the hub 20 and conduit 30 to rotate in unison, thereby indexing the airflow port 46 with the next firing chamber 24 .
[0048] FIGS. 4A to 9B depict an embodiment of a toy gun 10 d in which a trigger 36 is activated to release the energy of a piston spring 35 . In this embodiment, the handle 25 is grasped by one hand and the other hand is used to activate the priming handle 14 . Priming handle 14 is attached directly to the piston 13 to drawing back against the piston spring 35 whereupon a catch 38 retains the piston in a primed position. Activation of the trigger 36 releases the catch 38 so that the piston 13 moves rapidly forward to create projectile-firing pressure at the pressure chamber 16 . The forward portion of the toy gun 10 d is for all intents and purposes the same as that of FIG. 1 and these figures are intended to illustrate the operation of the disc 19 and the indexing mechanism. Reference will be made to FIGS. 10 to 15 in the description to follow.
[0049] In the rest position as depicted in FIGS. 4A and 4B , the piston 13 is in the forward position and the barrel 17 has five of its six firing chambers 24 loaded with projectiles 18 . The barrel 17 can hold six projectiles although five are shown to indicate the loading state after the first projectile has been dispatched from the toy gun. Priming handle 14 is drawn backward as indicated by the arrow in FIG. 5B to commence compression of piston spring 35 . During this action, diminished air pressure behind in the disc 19 draws the disc backward and air is allowed into the forward portion of chamber 16 via vent 33 etc. Air also passes from the pressure chamber 16 through the vents 22 into the area immediately in front of piston 13 .
[0050] After the priming handle 14 is released from the position depicted in FIG. 6B it is drawn forward by a spring as shown by the arrow in FIG. 7B . Coincidentally, spring 23 biases disc 19 forward so that the seal 45 at port 46 seals the pressure chamber 16 with one of the nozzles 37 . The catch 38 retains the piston until the trigger 36 is activated as indicated in FIG. 8B . The piston moves rapidly forward under the force of piston spring 35 and air rushes through the vents 22 and via the pressure chamber 16 and airflow port 46 into nozzle 37 causing projectile 18 to fire out of the toy gun. The piston comes to rest at the position depicted in FIG. 9B .
[0051] During the above procedure, the indexing mechanism is operative to rotate the disc 19 such that port 46 comes into alignment with successive firing chambers 24 . FIGS. 10 to 14 illustrate the detail of the indexing mechanism.
[0052] The indexing mechanism includes a cylindrical drum 20 which is affixed to or formed integrally with the back of barrel 17 . There is a spindle 47 over which the disc 19 can slide and rotate. This is not essential however.
[0053] At the forward portion of the drum 20 , there is an array of fingers 41 each having a rear-facing ramp 42 . At the rear portion of the drum 20 there is another array of fingers 43 each having a forward-facing ramp 44 . The fingers are spaced peripherally about the drum 20 and are separated by grooves 48 .
[0054] Surrounding the drum 20 is a ring 39 . The ring 39 is formed integrally with or attached to the disc 19 within the central recess of the disc 19 . The ring 39 is fixed with respect to the disc so as to rotate as one therewith. Formed on the internal surface of the ring 39 is a pair of diametrically opposed cams 40 . The cams 40 fit within the grooves 48 . To enable the drum 20 to be fitted into the ring 39 , two of the grooves open at 49 to the end of the drum.
[0055] As noted earlier, pressure fluctuations within the pressure chamber 16 cause the disc 19 to reciprocate linearly. During this linear movement the cams 40 bear against the ramps 42 and 44 . Relative linear motion in either direction will thereby cause rotation of the ring in one direction only as indicated by the arrows in FIGS. 11 and 13 thereby indexing the airflow port 46 as described.
[0056] FIGS. 16A , B and C depict the check valve 21 a in more detail. Attached to or formed integrally with the disc 19 behind the airflow port 46 and seal 45 is cylindrical body 50 . A circular cap 51 fits over the cylindrical body 50 and includes a port 55 . A flexible seal 52 a is held in place against the end of the cylindrical body by the cap 51 . The flexible seal 52 a has a number of apertures 53 in a circular array. The diameter of the circular array is larger than the diameter of the port 55 in the cap 51 . This allows the central portion of the flexible seal 52 a to lift away from the port 55 to allow air to flow in the direction indicated by the arrow in FIG. 16A , but the central portion presses against the port 55 to prevent air from flowing in the direction indicated by the arrow in FIG. 16C .
[0057] An alternative flexible seal 52 b associated with a slightly different check valve 21 d is shown in FIGS. 17A , B and C. The seal 52 b includes a central portion 56 partly surrounded by a C-shaped aperture 54 . The central portion 56 can hinge away from the port 55 as depicted in FIG. 17B to allow air to flow in the direction indicated by the arrow is in that figure. The central portion seals against the port 55 to prevent air from flowing in the direction indicated by the arrow in FIG. 17C .
[0058] A further option is depicted in FIGS. 18A to 18C . In this embodiment the cylindrical body 50 of a variation of the check valve 21 e has internal guide ribs 58 . A floating plug 57 resides within the cylindrical body 50 and can move longitudinally within it. The longitudinal airflow ribs 58 at the internal surface of the cylindrical body 50 enable air to flow around the plug 57 . The plug 57 moves away from the cap 51 to allow air to flow through the port 55 and around the plug 57 via the slots between ribs 58 as indicated by the arrows in FIG. 18B . The plug 57 seals against the port 55 to prevent the back-flow of air in the direction indicated by the arrow in FIG. 18C .
[0059] It should be appreciated that modifications and alterations obvious to those skilled in the art are not to be considered as beyond the scope of the present invention.
|
A toy gun includes a body, a piston adapted to move relative to the body between an extended position and a retracted position and to be moved rapidly toward the retracted position during a firing stroke. A number of firing chambers each receive a projectile and air compressed by the piston during a firing stroke to fire the projectile from the toy gun. An air delivery mechanism conveys the compressed air to one of the firing chambers and co-operates with the piston to advance as a result of piston movement to a configuration whereat it can convey compressed air to another of the chambers.
| 5
|
BACKGROUND
[0001] Field
[0002] The present invention provides for improved bonding compositions where the bonding composition includes a film former component. In particular, the present invention provides for improved bonding compositions useful in bonding polymers to substrates such as metals, glass or other hydroxylated substrates and in particular elastomer to substrate bonding compositions. Of particular interest are compositions comprising at least one non-halogenated polymer. The compositions of the invention display good bonding properties under various testing conditions, such as initial and pre-bakes tests. Such properties are of particular interest in vulcanisation processes.
[0003] Brief Description of Related Technology
[0004] Reinforced composite materials play a critical role in the manufacture of high-performance products that need to be lightweight, yet strong enough to take harsh loading and operating conditions. Popular reinforcing materials included wood, glass, metals, quartz and carbon fibres. Composites reinforced with these types of substrate may find utility in the manufacture of a number of structural materials such as aerospace components and racing car bodies.
[0005] Polymer to metal substrate and, in particular rubber, to metal bonding has been practised for many years. There are many applications for formulations which achieve polymer or rubber to metal bonding. Rubber to metal bonding is widely used to bond different metals to a natural or synthetic rubber so as to combine the structural strength of the metal with the elastomeric properties of the rubber.
[0006] Accordingly, metal and polymers such as rubber are often bonded to each other for impact absorption applications, such as in bearings, wheels, shock absorbers, moving arms, etc. Such components can be utilised on a very small scale, for example in PC components or on a very large scale for example in constructions such as bridges and buildings. Noise reduction may also be achieved by utilising metal to rubber bonding. It is accepted that tremendous forces can be experienced by any component that comprises metal and rubber bonded together. Thus, it is desirable to provide metal to rubber bonding, which can withstand significant forces, such as compressive or extensive pressures including shocks without having the metal or the rubber separate from each other. There are many other rubber to metal bonding applications, including tyre production where internal wire reinforcements for the tyre are bonded to the rubber of the tyre. Prior art compositions are discussed below.
[0007] Glass fibre reinforced composite materials consist of high strength glass fibres embedded in a matrix. For example, Glass Fibre Reinforced Concrete comprises glass fibres embedded in cement-based matrix and may find utility in buildings and other structural edifices. Similarly, Glass Reinforced Plastic comprises glass fibres embedded in a plastic material. Glass Reinforced Plastics are immensely versatile materials which combine to provide lightweight materials with high strength performance. Glass reinforced plastics find utility in a number of different areas from structural engineering to telecommunications.
[0008] Elastomer to glass bonding provides an attractive means by which the structural strength of glass can be combined with the elastomeric properties of the elastomer/rubber. Reinforcing fibres such as glass fibres have been used as a reinforcing material for rubber articles such as in rubber belts, tyres and hoses. In particular, glass fibres have been employed to reinforce automotive timing belts, where there is a need for synchronous transfer of power from crankshaft to overhead camshaft without loss of inertia.
[0009] Traditionally, such glass cord composites are manufactured by coating individual filaments of glass yarn with specialised coatings, such as resorcinol formaldehyde latex (“RFL”) formulations. Conventional rubber to metal bonding products are then employed to bond the RFL latex to the rubber via a vulcanisation step.
[0010] Traditional rubber-to-metal bonding technology incorporates a two-step system, where in a first step a primer is applied and thereafter in a second step an improved curable, for example, adhesive composition is applied. The primer ordinarily consists of solutions or suspensions of chlorinated rubber and phenolic resins containing reactive groups, and also pigments such as titanium dioxide, zinc oxide, carbon black, etc. The primer is generally applied as a thin layer onto a treated (cleaned) surface of a metallic component such as treated steel component for example a component that has been grit blasted or chemically treated.
[0011] The improved curable composition ordinarily consists of a large range of rubber materials and cross-linkers. These include, but are not restricted to, chlorinated and bromochlorinated rubbers, aromatic nitrosobenzene compounds and bismaleimide as cross-linkers, xylene, perchloroethylene and ethylbenzene as solvents, and also some lead or zinc salts. The improved curable composition layer is generally the link between the primed metal and the rubber. Other cross-linkers that have been employed in rubber-to-metal bonding technology are aromatic nitroso compounds, such as p-dinitrosobenzene.
[0012] Many formulations for rubber to metal bonding exist. For example silanes have been used as corrosion inhibitors and as rubber-to-metal bonding adhesion promoters. U.S. Patent Application Publication No. 2009/0181248 discloses substantially hydrolysed silane solutions, for example bis(trimethoxypropyl)amine and bis(triethoxypropyl)tetrasulfide, for use in a rubber to metal bonding composition. The amino silane and sulphide silane are formulated in a ratio of 1:3 respectively, in an ethanol/water solution.
[0013] International Patent Publication No. WO2004/078867 to Lord Corporation describes a single coat solvent-based improved curable composition designed to bond thermoplastic elastomers containing an alkoxy silane/urethane adduct and a chlorinated polymer. Methods of synthesis and formulation are described within this patent document. U.S. Pat. No. 4,031,120 to Lord Corporation describes a composition comprising an isocyanate functional organosilane, in combination with a polyisocyanate and an aromatic nitroso compound. The resulting system is described as a one-coat improved curable composition for bonding a variety of elastomeric materials to metals and other substrates.
[0014] Canadian Patent No. 1,087,774 describes a composition for use in the production of composite rubber materials. The composition discloses a one-part composition comprising a vulcanisable polymer, a discrete aromatic nitroso compound and a discrete organic phosphonic acids (and partial esters thereof). Problematically, the toxic nitrosobenzene component is freely formulated within the composition.
[0015] Generally, it is desirable that bonding is achieved during a vulcanisation step like compression moulding, transfer moulding, injection moulding and autoclave heating, for example with steam or hot air. For example, semi-solid rubber can be injected into a mould. The semi-solid rubber is then cross-linked into a fully cured rubber and the bond with the substrate is formed at the same time.
[0016] Certain requirements of the curing system are desirable. These include, ease of processing, stability (for example avoiding sedimentation), ease of application, fast drying (to allow handling without fouling), good wetting properties, and good curing strengths. Curing should be achieved independently of the type of elastomer (rubber) employed and also independently of the type of substrate. It will be appreciated that some rubbers are blended materials and accordingly it is desirable that good curing is achieved with such blended materials. Suitably consistent curing is achieved under various process parameters.
[0017] Certain elastomer to substrate adhesive compositions have typically comprised a film former component. Often the film former component includes a halogenated polymer (such as chlorinated isoprene, bromo/chloro butadiene) and a crosslinking agent (such as dinitrosobenzene or nitrososilane). The purpose of the film former is to allow the bonding composition to be applied (by spraying, rolling or dipping from solvent based adhesive composition) to the bonding substrate (usually a metal) as a dry tack free film. The coated part can then be bonded immediately or more usually after a desired period of time which conveniently allows for transportation to different facilities or allows for storage before bonding is carried out. The applied film needs to be robust and withstand typical chipping or scratching which can occur during transport or storage. The film former component should also not full react or cross-link too quickly at the vulcanisation temperature, otherwise poor bonding may occur (as evidenced by short pre-bake resistance, where the films react too quickly giving poor bonding). The film also needs be robust enough to resist being swept from the metal surface (sweep resistance) during for example, a rubber injection vulcanisation process. Therefore, the film must remain solid and have sweep resistance at the vulcanisation temperatures (normally 150-180° C.). The film former must not be so cross-linked or solid at the vulcanisation temperatures as to restrict the mobility or reactivity of nitroso moieties within with the rubber, otherwise poor bonding will result.
[0018] Notwithstanding the state of the art it would be desirable to provide improved compositions to bond polymeric substrates to a variety of substrates (such as metals, glass, quartz, etc.) that remedy some or all of the known deficiencies and/or provide alternatives to the existing technologies so that consumers have more possibilities from which to choose.
SUMMARY
[0019] The present invention provides improved curiable compositions, such as those forming bonds, and methods of bonding of polymers or polymeric materials to various substrates which may including metal, glass or other hydroxylated surfaces, using the improved composition of the invention. The improved composition of the invention may also be used in bonding in materials in which reactions in which sulfur can participate such as those mentioned above and for example in vulcanisation.
[0020] Accordingly, in a first aspect of the invention, there is provided a curable composition comprising one or more reactive components that cure upon exposure to suitable conditions, the curable composition comprising:
(i) at least one aromatic nitroso or at least one aromatic nitroso precursor compound or combinations thereof; and (ii) a film former component comprising at least one non-halogenated hydroxy group-containing resin together with at least one crosslinking agent.
[0023] Advantageously, the film former of the invention have tailorable reactivity that can be adjusted to deliver the correct level of robustness, and at the same time, allow excellent bonding to the rubber. The film former of the invention gives better control than the chlorinated olefin film formers (a number of the examples of the present invention herein should show excellent pre-bake resistance i.e. up to 10 minutes).
[0024] The term “reactive components that cure upon exposure to suitable conditions” as used herein refers to monomers, oligomers, or polymers made from natural or synthetic, modified or unmodified resins which are not fully cured and/or crosslinked, e.g., which are capable of being further cured and/or crosslinked by exposing said reactive components to suitable conditions, such as heat.
[0025] In a preferred embodiment the “reactive components that cure upon exposure to suitable conditions” means crosslinkable polymer components (for example, an elastomeric material, such as uncured rubber), that cure on exposure to heat, whereby application of heat results in increased crosslinking, which has the effect of increasing the molecular weight of the polymer. Preferably, these components crosslink at temperatures greater than about 50° C.
[0026] Said reactive components can be used in combination with additive components which facilitate the curing or crosslinking reaction of said reactive components. Examples of additive components include alkoxy silanes and aromatic nitroso compounds or precursor compounds (examples of these components and compositions are disclosed in International publication WO 2011/029752, the contents of which are incorporated herein by reference). Such nitroso structures are recognised in the art to assist in the formation of desirable bonds to polymeric substrates, such as elastomeric substrates. Suitable nitrososilanes are also disclosed above herein and in U.S. patent application Ser. No. 12/055,908, the disclosure of which is hereby incorporated herein by reference. Cure conditions for these compounds are described herein.
[0027] It is also to be appreciated that oligomers are also encompassed by this definition.
[0028] Desirably, the non-halogenated hydroxyl group-containing resin has the general structure:
[0000]
[0000] wherein each of n, o and p is at least 5, and the combined % wt of the m, o and p components in the non-halogenated hydroxyl group-containing resin is 100%.
[0029] Suitably, a preferred polycellulose acetate butyrate polymer has the general structure:
[0000]
[0000] wherein R 1 , R 2 , R 3 are independently selected from acetyl, butyryl or H, and n is an integer great than 10.
[0030] The non-halogenated hydroxy group-containing resin may be present in the composition of the invention in a range of from about 0.5 to 10% wt/wt of the total weight of the curable composition. Suitably, the non-halogenated hydroxy group-containing resin may be present in the composition of the invention in a range of from about 1 to 3% wt/wt of the total weight of the curable composition, as this range gives particular good film properties.
[0031] Suitably, the non-halogenated hydroxy group-containing resin may have a hydroxy content of from about 5 to 35% wt/wt of the total weight of the non-halogenated hydroxy group-containing resin. More suitably, the non-halogenated hydroxy group-containing resin may have a hydroxy content of from about 7 to 30% wt/wt of the total weight of the non-halogenated hydroxy group-containing resin, to provide optimum crosslinking.
[0032] In the compositions of the invention, the at least one crosslinking agent may be a compound having at least two reactive moieties, each of which can undergo a crosslinking reaction with a hydroxy group of the at least one non-halogenated hydroxy group-containing resin.
[0033] By the term “crosslinking”, it is meant that the crosslinking agent reacts with the non-halogenated hydroxy group-containing resin resulting in a cross-linked molecule with an molecular weight greater than that of the non-halogenated hydroxy group-containing resin starting component.
[0034] The crosslinking agent may be selected from the group consisting of: epoxy resins, phenolic resins, melamines, isocyanates, anhydrides, aldehydes, each of which resins having at least two reactive moieties, and mixtures thereof. Examples of such crosslinking agents are shown below.
[0000]
[0000] wherein R are a linking group which may be made of single moieties or repeating units or intermediate chains onto which the functional groups are located at opposing terminating ends. The skilled person will appreciate that such chains R may contain repeating aliphatic or aromatic groups, or combinations thereof, and that these groups can be substituted or unsubstituted with further groups, for example, branched or unbranched alkyl groups having from 1 to 6 carbons.
[0035] Preferred crosslinking agents comprising functional groups which form chemical bonds with the OH groups of the non-halogenated hydroxyl-containing resin. Examples of such crosslinking agents are phenol formaldehyde resins, polyfunctional aldehydes, polyfunctional epoxides, melamine resins (such as melamine formaldehyde resins) and polyfunctional isocyanates.
[0036] Suitable epoxy resins may vary in chemical identity. Preferred epoxy resins may be selected from (a) epoxy resins comprised mainly of the monomeric diglycidyl ether of bisphenol-A; (b) epoxy resins comprised mainly of the monomeric diglycidyl ether of bisphenol-F; (c) epoxy resins comprised mainly of the hydrogenated diglycidyl ether of bisphenol-A; (d) polyepoxidized phenol novolacs; (e) diepoxides of polyglycols, alternatively known as an epoxy terminated polyether; or (f) a mixture of any of the foregoing epoxy resins of (a) through (e). To save unnecessarily detailed description, further information on these classes is in the Encyclopedia of Polymer Science and Technology, Volume 6, 1967, Interscience Publishers, N.Y., pages 209-271, which is incorporated herein by reference.
[0037] Particularly preferred crosslinking agents are selected from epoxy resins having at least two oxirane ring systems and/or phenolic resins. Desirably, the crosslinking agent is a phenolic resin. Phenolic resins are well known in the art.
[0038] It will be understood that depending on the nature of the compound having at least two reactive moieties, the crosslinking reaction may be for example a condensation reaction with a hydroxy group of the linear non-halogenated hydroxy groups containing resin (eliminating water or other small molecule). In the case where the at least one crosslinking agent is an epoxide with at least two epoxide groups, such as a diepoxide, each epoxide group can undergo a nucleophilic substitution or epoxide ring opening reaction with the hydroxy group of the linear non-halogenated hydroxy groups containing resin.
[0039] Preferably, the curable composition of the invention may comprise at least one aromatic nitroso or at least one aromatic nitroso precursor compound which may comprises at least one alkoxy silane moiety and at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor or combinations thereof.
[0040] In one aspect, the curable composition of the invention may further comprise a sulfur impregnated particulate solid which acts as a release agent for sulfur during the cure process. Desirably. the curable composition comprises
a) one or more reactive components that cure upon exposure to suitable conditions, and b) a sulfur impregnated particulate solid which acts as a release agent for sulfur during the cure process; and c) optionally a solvent.
[0043] Reactive components that cure are described above.
[0044] The solvent is a preferred example of a suitable carrier vehicle may be utilised with any of the various improved composition of the invention described herein. It is desirable that the carrier vehicle, for example, solvent is environmentally friendly. For example, the solvent may be an aqueous-based solvent. The solvent may further comprise an organic solvent. Desirably, the organic solvent is miscible with water. This allows for efficient dissolution of and hydrolysis of the nitrososilane. The organic solvent may be selected from the group consisting of alcohols, carboxylic acids, acetone, acetonitrile, and tetrahydrofuran. The organic solvent may be an alcohol. Suitable alcohols include, without limitation, methanol, ethanol, propanol and isomers thereof, butanol and isomers thereof, and pentanol and isomers thereof.
[0045] Use of a sulfur-impregnated particulate solid in curing applications or curable compositions acts as an effective source of sulfur which can be released under application of suitable conditions to participate in the curing process. The sulfur-impregnated particulate solid improves the bond durability and resistance in many applications, and such as, under harsh conditions for example those where moisture is present and/or elevated pressures or temperatures. The increased durability and bond resistance can be imparted to existing curable compositions to further improve the effectiveness of bonding for example during the various bonding processes and including vulcanisation processes. It is to be appreciated that the solid is not itself solid sulfur or particulate sulfur materials. Rather, the particulate solid material acts as a carrier material for the sulfur, which is impregnated therein. By solid, it is meant that the material is solid at a temperature of 22° C., and preferably solid at 50° C., 60° C., 70° C. 80° C. or 100° C. It should also be appreciated that impregnated sulfur means that the sulfur is releasably trapped within the particulate solid by means of, for example, dispersion, adsorption, trapping or immobilisation. It is preferred that the sulfur is impregnated within the particulate solid material by adsorption. Furthermore, impregnated means that the sulfur is dispersed throughout the particulate solid material, i.e., a substantial proportion of the sulfur is located within (inside) the particulate solid, and that amounts of sulfur may be located on the surface of the particulate solid. The It is also important to appreciate that sulfur release from the sulfur impregnated particulate solid is latent. The latency is thermal latency meaning that at room temperature (approx. 22° C.) the sulfur impregnated particulate solid does not release sufficient quantities of sulfur, but on heating the sulfur is released from the particulate solid material. It is to be appreciated that for sulfur release, there is no requirement for rupture or breakage of the particulate solid material to effect such release, application of sufficient heat is required to release the trapped sulfur. It should be appreciated at temperatures of above 50° C. a small amount of sulfur is released. Suitably, at temperatures of above 60° C., a greater quantity of sulfur is released. More suitably still, at temperatures of above 70° C., a greater quantity still of sulfur is released. It is to be appreciated that temperatures of above 80° C., provide an optimum quantity of sulfur is released. Selection of appropriate temperature allows the rate of release of sulfur to be controlled. The sulfur may be released by a diffusion process whereby the sulfur is released from its association with the particulate solid. Alternatively, sulfur may be released by a vaporisation process in which sulfur is typically sublimated at sufficiently elevated temperatures.
[0046] Desirably, the sulfur impregnated particulate solid used in the compositions of the invention are latent sulfur releasing particulate solid. Typically, at room temperature little or no sulfur is released, whereby the sulfur releasing ability desirably increases at elevated temperatures, typically through a sublimation process. The particulate solid may be a solid, such as a granular solid, such as a powder. The particulate solid may be an amorphous solid.
[0047] Suitably, the sulfur content of the particulate solid used is in the range of from about 0.5 to about 20% w/w of the sulfur impregnated particulate solid, more preferably, from about 1.0 to about 15% w/w of the sulfur impregnated particulate solid. Suitably the sulfur content of the sulfur impregnated particulate solid used in the various improved compositions of the invention is about 1.5 to about 12% w/w. A particularly preferred sulfur content is about 12% w/w of the sulfur impregnated particulate solid.
[0048] Suitably, the sulfur impregnated particulate solid used is in the range of from about 0.5 to about 10% w/w of (the total weight of) the curable composition, more preferably from about 1 to about 5% w/w of (the total weight of) the curable composition. Suitably, the sulfur impregnated particulate solid used in the various improved compositions of the invention is about 2.5% w/w (the total weight of) the curable composition.
[0049] The sulfur impregnated particulate solid of the invention has an average particle size of from about 1 to 200 μm. Suitably, the average particle size is less than 10 μm.
[0050] As used herein, the term “average particle size” refers to the Do value of the cumulative volume distribution curve at which 50% by volume of the particles have a diameter less than said value. The average particle size or D 50 value is measured in the present invention through laser diffractometry preferably using a Malvern Mastersizer 2000 available from Malvern Instruments Ltd. In this technique, the size of particles in suspensions or emulsions is measured using the diffraction of a laser beam, based on application of either Fraunhofer or Mie theory. In the present invention, Mie theory or a modified Mie theory for non-spherical particles is applied and the average particle sizes or D 50 values relate to scattering measurements at an angle from 0.02 to 135 degrees relative to the incident laser beam.
[0051] Desirably, the sulfur impregnated particulate solid used in the improved composition of the invention have a BET surface area of from about 500 m 2 /g to 1200 m 2 /g, more suitably from about 600 m 2 /g to 1100 m 2 /g, more suitably still from about 700 m 2 /g to 1000 m 2 /g, as determined by the ASTM method D6556-10. Particularly good bond durability and bond resistance may be achieved with sulfur impregnated particulate solid having BET surface area of 700 m 2 /g and 1000 m 2 /g as determined by the ASTM method D6556-10.
[0052] Example of sulfur impregnated particulate solids include sulfur-impregnated clays, silicates, aluminates, charcoals or carbon materials such as carbon black. Desirably, the sulfur-impregnated particulate solid is a sulfur impregnated carbon black or a sulfur impregnated charcoal. Preferably, the sulfur-impregnated particulate solid is at least one sulfur impregnated charcoal. The sulfur-impregnated particulate solid may be formed by burning a suitable raw material, for example, coal or biomaterials, such as coconut husks, thereby forming a carbonaceous particulate material that has a suitable sulfur loading for the purposes of the present invention.
[0053] It should also be appreciated that a single grade of sulfur impregnated particulate solid or mixtures of at least two grades sulfur impregnated particulate solid (as discussed above for particle sizes, sulfur contents, surfaces areas) can be used in the improved compositions of the invention.
[0054] The provision of heat to the improved compositions of the invention may aid in the controllable release of the sulfur from the particles or particular of the improved curable compositions of the invention. Suitably, the composition may be cured at a temperature greater than 100° C., and suitably, between 120-200° C. Suitably, the composition may be heated to a temperature between 150-190° C. The composition may be heated to 180° C., which is a reasonably cost effective process temperature that gives excellent cure and cure rates.
[0055] The composition may be heated for up to 5 hours, depending on the type of bonding application and conditions necessary for cure (for example, higher temperatures and pressures require less curing time). Suitably, the composition may be heated for up to 3 hours, for example, under conditions involving mid range temperature and/or pressures. Desirably, the composition may be heated for up to 30 minutes, for example, where high temperatures and/or pressures are used. It will be appreciated that the improved curable compositions comprising the aforementioned film formers, may also comprise any conventional curing components or mixtures of components, such as alkoxy silanes and aromatic nitroso compounds or precursor compounds (examples of these components and compositions are disclosed in International publication WO 2011/029752, the contents of which are incorporated herein by reference). Such nitroso structures are recognised in the art to assist in the formation of desirable bonds to polymeric substrates, such as elastomeric substrates. These conventional components are known to form good quality bonds, the durability and resistance of which, in certain applications, is increase by inclusion of the aforementioned sulfur impregnated particulate solid.
[0056] It will also be appreciated that where the improved compositions of the invention also comprise compounds having both alkoxy silane moiety and aromatic nitroso or an aromatic nitroso precursor moieties in the same molecule, as such compositions will assist in the formation of excellent polymer to substrate bonds, and in particular, the formation of rubber to metal bonds. Advantageously, inclusion of such dual moiety compounds (known as nitrososilanes) in the improved composition of the invention, particularly when used together with sulfur impregnated particulate solid, assist in development of particularly durable and resistance bonds during the curing process. Suitable nitrososilanes are also disclosed above herein and in U.S. patent application Ser. No. 12/055,908, the disclosure of which is hereby incorporated herein by reference. One advantage arising from use of nitrososilanes in curing compositions is that the compositions may be less toxic compared to conventional dinitrosobenzenes formulations (no free or untethered nitrosobenzene compounds are formulated within the composition). Furthermore, inclusion of these nitrososilane compounds may also facilitate formulation of one part improved curable composition systems via conventional application techniques, such as spraying and dipping. One part systems can be readily applied to substrates in a single step using these convenient and conventional techniques. Compositions of the present invention may also be two-part compositions.
[0057] A number of the improved compositions of the present invention possess a number of advantages. For example, an improved curable composition absent conventional dinitrosobenzene may be formulated and stored. Such formulations are easily and conveniently applied to substrates in a standard manner. Furthermore, the improved compositions as so provided can also achieve, on curing, excellent bond strengths to polymeric materials, such as elastomers, for example rubbers (natural or synthetic). For example, in rubber to metal bonding tests to determine the bond strength of the compositions of the present invention, up to 80% rubber failure may be observed. Furthermore, the resultant bonds may have hot water resistance.
[0058] As used herein, the terms “elastomer”, “elastomeric substrate” or “elastomeric material” are used interchangeably in the present invention. The terms preferably refer to a material that can undergo a substantial elongation and then returns to its approximately original dimensions upon release of the stress elongating the material. More preferably the elastomeric substrate has a permanent set of less than 50%, such as less than 30% or less than 10% after one minute when recovering from a strain of 100% applied for one minute at a temperature of 22° C. In one embodiment the elastomer or elastomeric substrate may be selected from natural or synthetic rubbers, wherein the improved curable compositions of the present invention are particularly suitable for bonding polar rubbers, like nitrile butadiene rubbers (NBR), hydrogenated nitrile butadiene rubbers (HNBR) and/or ethylene acrylic elastomers to rigid substrates, such as metallic substrates. The synthetic rubber may be a nitrile butadiene rubber (HNBR). The polymer may be a C 2 -C 1,000,000 polymer, such as a C 2 -C 10,000 polymer. Other suitable polymers, include those capable of reacting with nitroso groups so as to provide cross-links therebetween. Such a reaction produces a variety of cross-links, for example between the nitroso group and a rubber material. The materials of the invention are thought to reduce free nitroso groups as the nitroso group is within a molecular structure.
[0059] Suitably, the improved compositions of the invention may also be used in vulcanisation application as well as bonding of polymeric substrates, such as elastomeric substrates to any of a wide variety of useful materials, including for example other elastomers, non-elastomeric but flexible materials such as for example fabrics or films, and rigid materials such as plastics, engineering plastics, wood, metal, glass or other hydroxylated substrates. In embodiment having sulfur releasing particulate solids as part of the composition, the improved compositions of the invention improve the adhesion provided by known compositions whereby durability of the bond between substrate is improved as a result of the presence of sulfur releasing particulate solid in the improved composition.
[0060] In examples utilising an elastomeric, such as a rubber substrate, the elastomer may be vulcanised or crosslinked prior to bonding to the second substrate. Alternatively, the elastomeric substrate may be vulcanised or crosslinked concurrently with bonding to the second substrate. The second substrate may be a metal. The nitroso aromatic compound of the composition of the present invention may become anchored to the elastomeric substrate. On polymerisation, the nitroso groups of the compounds of the composition can react with polymers, in particular a polymer with diene or allylic functionality within the polymer chain. Reaction of a nitroso group and an allylic group on the polymer occurs via an alder-ene reaction. Such a reaction produces a variety of cross-links, for example between the nitroso group and a elastomeric material.
[0061] Suitably, the improved composition of the invention may be preferably used for bonding polar elastomeric materials, such as nitrile butadiene rubbers (NBR), hydrogenated nitrile butadiene rubbers (HNBR) and/or ethylene acrylic elastomers to metallic substrates.
[0062] In contrast to conventional systems, the improved compositions of the present invention can be applied to the unvulcanised rubber (as distinct from a metal or glass substrate), prior to vulcanisation and bond formation, and upon subsequent vulcanization a bond results. This means that the improved compositions may be applied to either the rubber or the metal or the hydroxylated surface. Conventional systems do not form a bond if applied in this manner. Alternatively, the improved compositions may be applied to a metal or a hydroxylated surface. This means that application to either the polymeric substrate such as a rubber or a metal or glass substrate or unvulcanised rubbers are both possible. Thus a rubber substrate may be vulcanised or crosslinked prior to bonding to the metal or hydroxylated surface. The rubber substrate may be vulcanised or crosslinked concurrently with bonding to the metal surface.
[0063] The compositions of the present invention are coated in the range of 10 to 60 μm, and more preferably in the range of 20 to 30 μm.
[0064] Generally, it is desirable that bonding is achieved during a vulcanisation step. Suitable vulcanisation methods include compression moulding, transfer moulding, injection moulding and autoclave heating, for example with steam or hot air. For example semi-solid rubber can be injected into a mould. The semi-solid rubber is then cross-linked into a fully cured rubber and the bond with the substrate is formed at the same time.
[0065] Certain requirements must be fulfilled by a curing system in order to allow it to be successfully employed in a production environment. For example, the curing system must be easy to process. This means that it should be stable for use. Issues with the prior compositions have included a tendency to sediment. Accordingly, it is desirable that the curing system has a low tendency to sediment.
[0066] Furthermore, the curing system should be easy to apply. For example, it should be convenient to apply by any suitable dispensing system. It is also desirable that it dries quickly so that components can be handled without applied material running off and/or fouling production equipment. It is also desirable that the curing system shows good wetting properties for ease of application and spreading, for instance.
[0067] It is also desirable to have good curing strengths. This curing should be achieved independently of the type of elastomer (rubber) employed and also independently of the type of substrate. It will be appreciated that some rubbers are blended materials and accordingly it is desirable that good curing is achieved with such blended materials. Suitably consistent curing is achieved under various process parameters.
[0068] It is desirable that the bonds and in particular the substrate/metal bond, such as rubber/metal joint, are durable under high pressure and even if exposed to an aggressive atmosphere, for example, a hot liquid such as oil. The bonds must also be durable against relatively high mechanical stress, under conditions involving any of high pressure, temperature and/or moisture. Advantageously, inclusion of the sulfur releasing particulate solid in the compositions of the invention increases bond durability and in particular under conditions of moisture and/or elevated temperatures or pressures.
[0069] The improved compositions of the invention can be easily applied at the interface between the polymer and the substrate and may assist in developing strong and durable bonds during the curing process.
[0070] Desirably, in the improved compositions of the invention, the composition may further comprise a carrier, for example, a solvent, for the above mentioned compounds. It will be appreciated that any suitable carrier vehicle may be utilised with any of the various improved composition of the invention described herein. It is desirable that the carrier vehicle is environmentally friendly. For example, the carrier vehicle may be an aqueous-based vehicle.
[0071] It will be appreciated, that, as described above, the presence of water in the improved composition of the present invention facilitates substantial hydrolysis of the nitrososilane. At least one alkoxy moiety in the compound may be hydrolysed to ensure good bonding. The carrier may further comprise an organic solvent. Desirably, the organic solvent is miscible with water. This allows for efficient dissolution of and hydrolysis of the nitrososilane. The organic solvent may be selected from the group consisting of alcohols, carboxylic acids, acetone, acetonitrile, and tetrahydrofuran. The organic solvent may be an alcohol. Suitable alcohols include, without limitation, methanol, ethanol, propanol and isomers thereof, butanol and isomers thereof, and pentanol and isomers thereof.
[0072] In the relevant embodiments, the solvent, of the improved compositions of the present invention may comprise between from 0.1-100% w/w water. The solvent of the improved composition of the present invention may comprise between 0.5-50% w/w water. The solvent of the improved composition of the present invention may comprise between 1-20% w/w water. Suitably, a solvent comprising about 5% w/w water is suitably to substantially hydrolyse the nitrososilanes.
[0073] Desirably, the solvent consists of water and an alcohol. An alcohol:water solvent provides for dissolution of the nitrososilane in the carrier, thereby enabling uniform application of the compound as a film or coating to a target substrate. Uniform application of the nitrososilane compound as part of a composition may result in improved bonding.
[0074] The composition of the present invention may further comprise an acid. Suitable acids include organic acids. For example, acetic acid, oxalic acid, formic acid, and propionic acid.
[0075] Suitably, the solvent of the composition may comprise between 0.1-100% w/w water. The solvent of the composition may comprise between 0.5-50% w/w water. The solvent may comprise between 1-20% w/w water. Suitably, a solvent comprising about 5% w/w water may substantially hydrolyse the nitrososilanes.
[0076] Hydrolysis of alkoxy silanes (formation of silanol groups, i.e. SiOH) will generally occur efficiently within the pH range of 3-7. At a pH above or below this range, silane condensation may occur by a process where the silanol self-condenses to form a siloxane. During this process the hydroxyl molecules of the adjacent molecules react with one another to eliminate molecules of water and form a cross-linked siloxane structure containing —Si—O—Si—O—Si— functionality. To accelerate silane hydrolysis and inhibit silane condensation during the hydrolysis step, the pH of the silane solution may be maintained below about 7 and preferably in the mildly acidic range from about 4 to 6.5.
[0077] In a preferred second embodiment, in additional to the aforementioned film former, the improved curable compositions may further comprise a solvent comprising at least 0.1% water. Examples of such compositions (but without the film former of the present invention) may be found in International publication WO 2011/029752, the contents of which are incorporated herein by reference.
[0078] Such compositions are particularly useful in bonding polymers to metal or hydroxylated surfaces. The solvent comprising at least 0.1% w/w water may allow for hydrolysis of the compound comprising the at least one alkoxy silane moiety.
[0079] As used herein hydrolysis of the compound refers to hydrolysis of the alkoxy silane moiety, i.e., hydrolysis of any alkoxy moiety to yield a hydroxy moiety. At least one alkoxy moiety in the compound may be hydrolysed to ensure good bonding. Advantageously, hydrolysis of the compound prior to bonding may result in improved adhesion. Hydrolysis of the compound prior to bonding may result in improved bond strengths. Hydrolysis of the compound prior to bonding may result in improved bond strengths in bonding a polymeric substrate having diene and or allylic functionality within the polymer chain to a metal or hydroxylated surface.
[0080] It should be appreciated that, as used herein the term hydroxylated surface refers to any substrate with a surface comprising an atom bonded to a hydroxy group. Suitable non-limiting examples include, a hydrous metal oxide, glass substrates comprising surface Si—OH bonds or clay substrates comprising surface Al—OH bonds. Suitable hydroxylated surfaces include those of silicates, aluminates, germanates and combinations thereof. The hydroxylated surface may be a silicate, an aluminate or combinations thereof. As used herein, the term silicate refers to substrates comprising Si—OH bonds. The term aluminate refers to substrates having Al—OH bonds and the term germinate refers to substrates having Ge—OH bonds. As used herein, hydroxylated surface also comprises substrates primed with hydroxylated materials, for example primed with a silicate, aluminate, germanate and combinations thereof. For example, the hydroxylated surface may be one of glass such as glass fibres, quartz, clays, talcs, zeolites, porcelains, ceramics, and silicon substrates such as silicon wafers and combinations thereof.
[0081] The various improved compositions of the present invention may be utilised to bond a polymeric substrate as defined above to a second substrate, which may be an elastomer, a metal, glass or other hydroxylated surface as defined above. The compositions having carrier and water, are particularly useful for bonding a polymeric substrate to a metal or hydroxylated surface.
[0082] Many different metals may be treated with the various improved compositions of the present invention. Suitable metals include, but are not limited to, zinc and zinc alloys such as zinc-nickel and zinc-cobalt alloys, metal substrates having zinc-containing coatings, steel and in particular cold rolled and carbon steel, aluminium and aluminium alloys, copper and copper alloys such as brass, and tin and tin alloys including metal substrates having tin-containing coatings.
[0083] Within the context of this specification, it is to be appreciated that the term aromatic nitroso moiety refers to an aromatic moiety having at least one nitroso group. Similarly, the term aromatic nitroso precursor moiety refers to any compound that is capable of being transformed into an aromatic nitroso moiety with at least one nitroso group. Preferred aromatic nitroso precursors are oximes. The term aromatic comprises both fused and non-fused aromatic rings. For example, a non-limiting selection of fused and non-fused aromatic nitroso moieties embraced by the present invention are detailed below:
[0000]
[0084] As will be appreciated by a person skilled in the art, the nitroso compounds or structures disclosed above may optionally be substituted one or more times, for example with at least one of C 1 -C 20 alkyl, C 1 -C 20 cycloalkyl, C 1 -C 20 alkoxy, C 7 -C 20 aralkyl, C 7 -C 20 alkaryl, C 6 -C 20 arylamine, C 6 -C 20 arylnitroso, cyano, amino, hydroxy, halogen and combinations thereof. Such substitutions are possible provided there is no interference with effective bonding or curing of the compositions.
[0085] The at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof may be selected from a nitrosobenzene or a nitrosobenzene precursor and combinations thereof.
[0086] The nitrosobenzene compound may be a mononitrosobenzene compound, a dinitrosobenzene compound, or combinations thereof.
[0087] Desirably compositions of the present invention may find utility in bonding a substrate to a natural or synthetic rubber. For example, the compositions may be used for applications where bonding metal to natural or synthetic rubber is required. In particular, the improved compositions of the present invention will provide for in-situ generation of a nitrosobenzene moiety or a dinitrosobenzene moiety. For example, to achieve good bonding it may be desirable for the compound to react in-situ to form a nitroso aromatic moiety comprising a hydroxy group. The nitroso aromatic moiety comprising a hydroxy group may be a para-nitrosophenol moiety. The phenolic moiety present may help to anchor the para-nitrosophenol moiety to a metal surface. para-Nitrosophenol may be generated in-situ from the oxidation of quinone mono-oxime as shown below for information purposes:
[0000]
[0088] As will be appreciated by a person skilled in the art, references to nitrosobenzene and nitrosobenzene precursor moieties include nitrosobenzene and nitrosobenzene precursor moieties that may optionally be substituted one or more times with at least one of C 1 -C 20 alkyl, C 3 -C 20 cycloalkyl, C 1 -C 20 alkoxy, C 7 -C 20 aralkyl, C 7 -C 20 alkaryl, C 6 -C 20 arylamine, C 6 -C 20 arylnitroso, cyano, amino, hydroxy, halogen and combinations thereof. Such substitutions are possible provided there is no interference with effective bonding or curing of the compositions. For example, provided there is no interference with the generation of a nitrosobenzene moiety in-situ.
[0089] It will be appreciated that the nitrosobenzene precursor may form a nitrosobenzene structure in-situ. The nitrosobenzene precursor may be an aromatic oxime, for example at least one of a quinone dioxime or a quinone oxime or combinations thereof. Desirably, the aromatic nitroso compound precursor is selected from the group consisting of p-benzoquinone dioxime (QDO), naphthoquinone dioxime, toluquinone dioxime, diphenoquinone dioxime, diquinoyl dioxime, dibenzoyl dioxime and combinations thereof. The above list serves as a generalised example only and other aryl oximes and dioximes are possible and embraced by the present invention. Desirably, the nitrosobenzene precursor comprises p-benzoquinone oxime or p-benzoquinone dioxime (QDO). QDO is generally used as a vulcanizing agent for EPDM (ethylene-propylene diene monomer) to improve heat resistance. It is also used as a rubber to metal adhesion promoter and as a curing agent. It has been found that such structures assist in the formation of desirable bonds.
[0090] Suitably, the aromatic nitroso compound is selected from the group consisting of m-dinitrosobenzene, p-dinitrosobenzene, m-dinitrosonaphthalene, p-dinitrosonaphthalene, 2,5-dinitroso-p-cymeme, 2-methyl-1,4-dinitrosobenzene, 2-methyl-5-chloro-1,4-dinitrosobenzene, 2-fluoro-1,4-dinitrosobenzene, 2-methoxy-1-3-dinitrosobenzene, 5-chloro-1,3-dinitrosobenzene, 2-benzyl-1,4-dinitrosobenzene, 2-cyclohexyl-1,4-dinitrosobenzene and combinations thereof.
[0091] A general scheme for the oxidation of quinone dioxime to the dinitrosobenzene species using an oxidant, such as benzoyl peroxide (BPO), is shown below, for information purposes:
[0000]
[0092] The at least one aromatic nitroso compound precursor may be present in an amount of 1 to 20% w/w of the total composition. Suitably, the at least one aromatic nitroso compound precursor may be present in an amount of 1 to 10% w/w, for example 2 to 7% w/w. The at least one aromatic nitroso compound precursor may be present in 3% w/w of the total composition.
[0093] For example, the aromatic nitroso precursor moiety may be the mono- or dioxime of a compound selected from:
[0000]
[0094] As will be appreciated by a person skilled in the art, the diketone structures disclosed above may optionally be substituted one or more times, for example with at least one of C 1 -C 20 alkyl, C 3 -C 20 cycloalkyl, C 1 -C 20 alkoxy, C 7 -C 20 aralkyl, C 7 -C 20 alkaryl, C 6 -C 20 arylamine, C 6 -C 20 arylnitroso, cyano, amino, hydroxy, halogen and combinations thereof. Such substitutions are possible provided there is no interference with effective bonding or curing of the compositions, for example, with the generation of an aromatic nitroso compound in-situ.
[0095] As will be appreciated by a person skilled in the art, references to nitrosobenzene and nitrosobenzene precursor moieties include nitrosobenzene and nitrosobenzene precursor moieties that may optionally be substituted one or more times with at least one of C 1 -C 20 alkyl, C 3 -C 20 cycloalkyl, C 1 -C 20 alkoxy, C 7 -C 20 aralkyl, C 7 -C 20 alkaryl, C 6 -C 20 arylamine, C 6 -C 20 arylnitroso, cyano, amino, hydroxy, halogen and combinations thereof. Such substitutions are possible provided there is no interference with effective bonding or curing of the compositions. For example, provided there is no interference with the generation of a nitrosobenzene moiety in-situ.
[0096] Suitably, in the improved composition of the invention, the above mentioned nitrososilane compounds may have an alkoxy silane moiety of the general structure:
[0000]
[0097] wherein a is from 1 to 3, b is from 0 to 2, with the proviso that a+b=3; each R 1 is independently selected from the group consisting of H, C 1 -C 24 alkyl, and C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl and wherein when a≧1 at least one R 1 is not hydrogen; and each R 2 is independently selected from the group consisting of C 1 -C 24 alkyl and C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl.
[0098] In one embodiment, a is 3 and R 1 is C 1 -C 24 alkyl. R 1 may be C 1 -C 4 alkyl and a may be 3.
[0099] The compounds may be reaction products derived from an isocyanate or isothiocyanate and an active hydrogen compound, such as —NH x (where x=1 or 2), —SH, or —OH. In this manner the so-described compounds should contain at least one linkage described by:
[0000]
[0000] where X can be S or O, and Y includes —NH x (where x=1 or 2), —S, or —O.
[0100] The general structure for the compounds is shown below:
[0000]
[0000] wherein n is from 1 to 20; a is from 1 to 3, b is from 0 to 2, with the proviso that a+b=3; each R 1 is independently selected from the group consisting of H, C 1 -C 24 alkyl, and C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl and wherein when a≧1 at least one R 1 is not hydrogen; each R 2 is independently selected from the group consisting of C 1 -C 24 alkyl and C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl; X is O or S; Y is O, S, or N(R 3 ); and R 3 is a moiety comprising nitrosobenzene, quinone oxime or quinone dioxime.
[0101] Desirably, R 3 may be a moiety comprising nitrosobenzene, quinone dioxime or quinone oxime.
[0102] R 1 may be selected from C 1 -C 24 alkyl, C 3 -C 24 acyl. R 1 may be selected from C 1 -C 24 alkyl, C 3 -C 24 acyl and ‘a’ may be 3. X may be O. Y may be O or —NH x (where x=1). Y may be O. X and Y may be O. R 1 may be selected from C 1 -C 4 alkyl, X may be O and ‘a’ is 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O and ‘a’ may be 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be —NH x (where x=1) and ‘a’ may be 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O, ‘a’ may be 3 and R 3 may be a moiety comprising nitrosobenzene.
[0103] Structures for R 3 , showing the linkage through ‘Y’, can include:
[0000]
[0000] where R 4 can be C 1 to C 10 ; and
Z indicates that the rings of the above structures can optionally be mono-, di-, tri- or tetrasubstituted with the group consisting of C 1 -C 20 alkyl, C 3 -C 20 cycloalkyl, C 1 -C 20 alkoxy, C 7 -C 20 aralkyl, C 7 -C 20 alkaryl, C 5 -C 20 arylamine, C 5 -C 20 arylnitroso, amino, hydroxy, halogen and combinations thereof, and further where the substituents can either be the same or different on each carbon atom of the ring. Such substitutions may be possible provided there is no interference with effective bonding or curing of the compositions. For example, provided there is no interference with the generation of a nitrosobenzene compound in-situ.
[0104] One exemplary, the compound utilised one composition of the present invention may have the general structure:
[0000]
[0000] where ‘a’ can be 1-3 and ‘b’ can be 0-2; wherein a+b=3 and at least one alkoxy group is present;
R 1 can be selected from H, C 1 -C 24 alkyl, C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl and where when a≧1 at least one R 1 is not hydrogen; and
R 2 can be selected from C 1 -C 24 alkyl and C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl;
m and n can be the same or different and can be 1-10;
X can be O or S;
Y can be —O, —S, or —NH;
[0105] R 4 can be C 1 to C 10 ; and
Z indicates that the rings of the above structures can optionally be mono-, di-, tri- or tetrasubstituted with the group consisting of C 1 -C 20 alkyl, C 3 -C 20 cycloalkyl, C 1 -C 20 alkoxy, C 7 -C 20 aralkyl, C 7 -C 20 alkaryl, C 5 -C 20 arylamine, C 5 -C 20 arylnitroso, amino, hydroxy, halogen and combinations thereof, and further wherein the substituents can either be the same or different on each carbon atom of the ring. Such substitutions may be possible provided there is no interference with effective bonding or curing of a bonding composition comprising the compound.
R 1 may be selected from C 1 -C 24 alkyl or C 3 -C 24 acyl. R 1 may be selected from C 1 -C 24 alkyl, C 3 -C 24 acyl and ‘a’ may be 3. X may be O. Y may be O or NH. Y may be O. X and Y may be O. n may be C 2 -C 5 alkyl. m may be C 2 -C 5 alkyl. R 1 may be selected from C 1 -C 4 alkyl, X may be O and ‘a’ is 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O and ‘a’ may be 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be NH and ‘a’ may be 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O, ‘a’ may be 3 and R 4 may be C 1 to C 10 .
[0106] Desirably, the compounds in the above-mentioned composition of the present invention may have the general structure:
[0000]
[0000] where n can be 1-10;
‘a’ can be 1-3 and ‘b’ can be 0-2; wherein a+b=3 and at least one alkoxy group is present;
c can be ‘a’ or 1 to 3; d can be ‘b’ or 1 to 3;
R 1 can be selected from H, C 1 -C 24 alkyl, C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl and where when a≧1 at least one R 1 is not hydrogen;
R 2 can be selected from C 1 -C 24 alkyl and C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl;
X can be O or S; and
[0107] Y can be —O, —S, or —NH x (where x=1 or 2).
[0108] R 1 may be selected from C 1 -C 24 alkyl, C 3 -C 24 acyl. R 1 may be selected from C 1 -C 24 alkyl, C 3 -C 24 acyl and ‘a’ may be 3. X may be O. Y may be O or —NH x (where x=1). Y may be O. X and Y may be O. R 1 may be selected from C 1 -C 4 alkyl, X may be O and ‘a’ is 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O and ‘a’ may be 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be —NH x (where x=1) and ‘a’ may be 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O, n may be 3 and ‘a’ may be 3.
[0109] In a further embodiment, the above described compound of the above improved composition of the present invention may be an oligomeric or co-oligomeric compound of the general structure:
[0000]
[0000] where m can be 1-100; n can be 1-10; p can be 1-10; q can be 0-50; and if q=0, m≧2;
R 1 can be selected from H, C 1 -C 24 alkyl, C 3 -C 24 acyl, and preferably from C 1 -C 4 alkyl;
R 2 can be selected from OR 1 , C 1 -C 24 alkyl and C 3 -C 24 acyl, and where when R 2 ═OR 1 at least one R 1 is not hydrogen;
R 4 can be selected from acrylate, aldehyde, amino, anhydride, azide, maleimide, carboxylate, sulphonate, epoxide, ester functional, halogens, hydroxyl, isocyanate or blocked isocyanate, sulfur functional, vinyl and olefin functional, or polymeric structures;
X can be O or S;
[0110] Y can be —O, —S, or —NH x (where x=1 or 2); and
R 3 may be a moiety comprising nitrosoaromatic, or a nitrosoaromatic precursor as defined herein.
[0111] R 3 may be a moiety comprising nitrosobenzene, quinone dioxime or quinone oxime.
[0112] R 1 may be selected from C 1 -C 24 alkyl, C 3 -C 24 acyl. R 1 may be selected from C 1 -C 24 alkyl, C 3 -C 24 acyl and R 2 may be OR 1 . X may be O. Y may be O or —NH x (where x=1). Y may be O. X and Y may be O. R 1 may be selected from C 1 -C 4 alkyl, X may be O and R 2 may be OR 1 . R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O and R 2 may be OR 1 . R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be —NH x (where x=1) and R 2 may be OR 1 . R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O, n may be 3, R 2 may be OR 1 and R 3 may be a moiety comprising nitrosobenzene. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O, n may be 3, R 2 may be OR 1 , R 3 may be a moiety comprising nitrosobenzene, q may be O, and m may be ≧2. R′ may be selected from C 1 -C 4 alkyl, X may be O, Y may be O, n may be 3, R 2 may be OR 1 , R 3 may be a moiety comprising nitrosobenzene, q may be O, m may be and R 4 may be vinyl or ester.
[0113] Specific examples of the above mentioned nitrososilane compounds used in the improved compositions of the first embodiment of the present invention may include the following:
[0000]
[0114] Desirably, the improved compositions of the present invention may comprise the following compound:
[0000]
[0000] In the improved composition of the invention described above, the compound comprising the at least one alkoxy silane moiety and the at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor (also referred to as a nitrososilane) may be present in an amount of 1 to 20% w/w of the total composition. Suitably, the at least one aromatic nitroso compound precursor may be present in an amount of 1 to 15% w/w, for example, from 4 to 12% w/w. Desirably, the at least one aromatic nitroso compound precursor may be present in 6% w/w of the total composition.
[0115] It will be appreciated by a person skilled in the art that the various improved curable compositions of the present invention may additionally comprise conventional additives such as fillers, pigments, stabilisers, and moisture scavengers, provided that the additives do not interfere with effective curing of the compositions. The composition may comprise regular carbon blacks, which are not sulfur impregnated. Such carbon blacks may be acidic or basic. These include reinforcing carbon blacks; inactive fillers such as calcium carbonates, chalks, talcs, or metal oxides; accelerator systems; vulcanization retarders; promoters such as zinc oxide or stearic acid; plasticizers such as aromatic, paraffinic, naphthenic and synthetic mineral oils; ageing, light-protecting ozone-protecting, fatigue, coloration, and processing auxiliaries; and sulfur. Commonly these additives may be present at a quantity of about 0.1 parts to about 80 parts per 100 parts by weight of the rubber composition.
[0116] The composition may comprise silica.
[0117] Suitably, certain improved compositions of the present invention may comprise additional silanes. Suitably silane compounds and composition comprising same (but without the film formers of the present invention) are disclosed in International publication WO 2011/029752, the contents of which are incorporated herein by reference. Exemplary silanes may be of the general formula:
[0000]
[0000] where:
n is either 1 or 2;
y=(2−n)
each R 1 can be selected from C 1 -C 24 alkyl or C 2 -C 24 acyl;
each R 2 can be selected from C 1 -C 30 aliphatic groups, or substituted or unsubstituted C 6 -C 30 aromatic groups;
R 5 can be selected from hydrogen, C 1 -C 10 alkylene, C 1 -C 10 alkylene substituted with one or more amino groups, C 2 -C 10 alkenylene substituted with one or more amino groups, C 6 -C 10 arylene, or C 7 -C 20 alkarlyene;
X—R 5 is optional and X is either:
[0000]
[0000] where each R 3 can be selected from hydrogen, C 1 -C 30 aliphatic groups, or C 6 -C 30 aromatic groups;
and
R 4 can be selected from C 1 -C 30 aliphatic groups, or C 6 -C 30 aromatic groups; and
where when n=1, at least one of R 3 and R 5 is not hydrogen.
[0118] In one embodiment, X—R 5 is present. R 1 can be selected from C 1 -C 24 alkyl, R 2 can be selected from C 1 -C 30 aliphatic groups, X can be N—R 3 and R 5 can be selected from hydrogen or C 1 -C 10 alkylene. As will be appreciated, when X—R 5 is absent the silane may be of the general formula (wherein R 1 and R 2 are as defined above):
[0000]
[0119] Preferred silanes include bis-silyl silanes such as those having two trisubstituted silyl groups. The substituents may be individually chosen from C 1 -C 20 alkoxy, C 6 -C 30 aryloxy and C 2 -C 30 acyloxy. Suitable bis-silyl silanes for use in the improved compositions of the invention include:
[0000]
[0000] where:
each R 1 can be selected from C 1 -C 24 alkyl or C 2 -C 24 acyl;
each R 2 can be selected from C 1 -C 20 aliphatic groups or C 6 -C 30 aromatic groups;
X is optional and is either:
[0000]
[0000] where each R 3 can be selected from hydrogen, C 1 -C 20 aliphatic groups, or C 6 -C 30 aromatic groups;
and
[0120] R 4 can be selected from C 1 -C 20 aliphatic groups or C 6 -C 30 aromatic groups.
[0121] In one embodiment, X is present. R 1 can be selected from C 1 -C 24 alkyl, R 2 can be selected from C 1 -C 30 aliphatic groups, and X can be N— R 3 . As will be appreciated, when X is absent the bis-silane may be of the general formula (wherein R 1 and R 2 are as defined above):
[0000]
[0122] Examples of some bis-silyl aminosilanes used in the improved composition of the invention include: bis-(trimethoxysilylpropyl)amine, bis-(triethoxysilylpropyl)amine, bis-(triethoxysilylpropyl) ethylene diamine, N-[2-(vinylbenzylamino)ethyl]-3-aminopropyltrimethoxy silane, and aminoethyl-aminopropyltrimethoxy silane.
[0123] Such silanes may be included in the range from 1:3 to 3:1 relative to the nitrososilane compounds (stoichiometrically). As understood in the art, such mixing of silanes and nitrososilanes can result in excellent bonding to rubber substrates.
[0124] The silane may be present in an amount of 1 to 10% w/w of the total composition. Suitably, the silane may be present in an amount of 1 to 5% w/w, for example 1 to 3% w/w. The silane may be present in about 3% w/w of the total composition.
[0125] In particular, the inclusion of the amino bis(propyltrimethoxysilane) in addition to the nitrososilane significantly enhances the bond strength to rubber. It is thought that the amino bis(propyltrimethoxysilane) has multiple functions within the formulation. This includes aiding the film forming and “wetting” of the metal surface.
[0126] Generally, the final solution applied to the target substrate may vary in the total silane concentration and ratio (silane to nitrososilane) over a wide range and still provide beneficial results. The final solution should contain a total silane concentration of at least approximately 0.1% by volume, i.e., the concentration of the combination of silanes and nitrososilanes in the final solution. Solutions having a total silane concentration of between about 0.1% and about 10% by volume generally provide strong bonding without waste of valuable silanes.
[0127] Desirably, in an embodiment, in addition to the above described film former, the composition of the invention may further comprise a compound comprising:
(a) at least one phosphonate moiety; or (b) at least one phosphinate moiety; and (c) at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof, as defined above.
[0131] Examples of these phorphorus compounds and composition comprising same (but without the film former of the invention) may be found in International publication WO 2011/032998, the contents of which are incorporated herein by reference. During curing, in the reaction of the nitroso group and the phosphonate/phosphinate, the nitroso may react with allylic functionality within a natural rubber while the phosphonate/phosphinate forms a bond with the second substrate, such as a hydroxylated surface or metal.
[0132] Suitably, the phosphonate moiety may be of the structure:
[0000]
[0000] where R 1 and R 2 are the same or different and are selected from H, C 1 -C 24 alkyl, and C 3 -C 24 acyl.
[0133] R 1 and R 2 may be the same or different and may be selected from C 1 -C 4 alkyl.
[0134] Suitably, the phosphinate moiety may be of the structure:
[0000]
[0000] where R 1 is selected from H, C 1 -C 24 alkyl, and C 3 -C 24 acyl; and
[0135] R 2 is selected from C 1 -C 24 alkyl, and C 3 -C 24 acyl; and
[0136] R 1 and R 2 may be selected from C 1 -C 4 alkyl.
[0137] In each of the above structures the squiggle indicates attachment to a moiety comprising an aromatic nitroso, an aromatic nitroso precursor or combinations thereof, as defined above.
[0138] Suitably, a compound for use in the improved composition of the invention may be of the general structure:
[0000]
[0139] wherein u is from 0 to 20; A is a direct bond, O, or S; R 4 is selected from the group consisting of H, C 1 -C 24 alkyl, and C 3 -C 4 acyl, preferably from C 1 -C 4 alkyl; R 5 is selected from the group consisting of C 1 -C 24 alkyl, C 1 -C 24 alkoxyl and C 3 -C 24 acyl; and R 6 is a moiety comprising nitrosobenzene, quinone oxime or quinone dioxime.
[0140] R 1 , R 2 and R 3 can be the same or different and may be selected from C 1 -C 4 alkyl. n may be 0 to 5. n may be 1 to 4. R 4 may be a moiety comprising nitrosobenzene, quinone dioxime or quinone oxime, as defined above. X may be C, O or N. X may be C or O. X may be C. X may be O.
[0141] Structures for R 4 above may be selected from (showing linkage through X):
[0000]
[0000] where R 5 can be C 1 to C 10 alkyl; and
Z indicates that the rings of the above structures can optionally be substituting mono-, di-, tri- or tetrasubstituted with the group consisting of C 1 -C 20 alkyl, C 3 -C 20 cycloalkyl, C 1 -C 20 alkoxy, C 7 -C 20 aralkyl, C 7 -C 20 alkaryl, C 5 -C 20 arylamine, C 5 -C 20 arylnitroso, amino, hydroxy, halogen and combinations thereof, and further wherein the substituents can either be the same or different on each carbon atom of the ring. Such substitutions may be possible provided there is no interference with effective bonding or curing of the compositions. For example, provided there is no interference with the generation of a nitrosobenzene compound in-situ.
[0142] In an improved composition a suitable compound may be of the general formula:
[0000]
[0000] where R 3 can be C 1 -C 24 alkyl, C 3 -C 24 acyl or OR 2 ;
R 1 and R 2 can be the same or different and are selected from H, C 1 -C 24 alkyl, and C 3 -C 24 acyl.
[0143] R 1 , R 2 and R 3 can be the same or different and may be selected from C 1 -C 4 alkyl.
[0144] Further suitably compound may be of the following general structure;
[0000]
[0000] where R 3 can be C 1 -C 24 alkyl, C 3 -C 24 acyl or OR 2 ;
[0145] R 1 and R 2 can be the same or different and are selected from H, C 1 -C 24 alkyl, and C 3 -C 24 acyl.
[0146] R 1 , R 2 and R 3 can be the same or different and may be selected from C 1 -C 4 alkyl.
[0147] The invention provides for a polymer or co-polymer of a compound according to the present invention.
[0148] In another example of the invention, the improved composition of the invention may further comprise an oligomer or a co-oligomer comprising:
(a) at least one phosphonate moiety; (b) at least one phosphinate moiety; and (c) at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof,
where a co-oligomeric compound is composed of different monomers.
[0152] The oligomer or a co-oligomer may have the following general structural formula:
[0000]
[0000] where m can be 1-100; n can be 0-20; p can be 1-10; q can be 0-50; and if q=0, m≧2;
R 3 and R 6 can be the same or different and may be selected from C 1 -C 24 alkyl, C 3 -C 24 acyl or OR 2 ;
R 2 can be selected from H, C 1 -C 24 alkyl, and C 3 -C 24 acyl; X can be C, O, N, or S;
R 4 may be a moiety comprising nitrosoaromatic, or a nitrosoaromatic precursor (defined above); and
R 7 can be selected from acrylate, aldehyde, amino, anhydride, azide, maleimide, carboxylate, sulfonate, epoxide, ester functional, halogens, hydroxyl, isocyanate or blocked isocyanate, sulfur functional, vinyl and olefin functional, or polymeric structures.
[0153] R 2 , R 3 and R 6 can be the same or different and may be selected from C 1 -C 4 alkyl. n may be 0 to 5. n may be 1 to 4. p may be 1 to 5. q may be 1 to 5. R 4 may be a moiety comprising nitrosobenzene, quinone dioxime or quinone oxime. X may be C, O or N. X may be C or O. X may be C. X may be O.
[0154] A preferred compound (also referred to as a nitrosophosphonate or a nitrosophosphinate) forming part of the improved composition of the invention may be present in an amount of 1 to 20% w/w of the total composition. Suitably, the compound may be present in an amount of 1 to 15% w/w, for example 4 to 12% w/w. The compound may be present in 6% w/w of the total composition.
[0155] The compound of the present invention may be substantially hydrolysed in the composition of the present invention. As described above, a carrier comprising water may allow for hydrolysis of the compound comprising the at least one phosphonate or phosphinate moiety.
[0156] As used herein hydrolysis of the compound refers to hydrolysis of an alkoxy (or acyloxy) group of the phosphonate or phosphinate moiety, i.e. hydrolysis of any alkoxy moiety to yield a hydroxy moiety. At least one alkoxy moiety in the compound may be hydrolysed to ensure good bonding. Advantageously, hydrolysis of the compound prior to bonding may result in improved adhesion. Hydrolysis of the compound prior to bonding may result in improved bond strengths. Hydrolysis of the compound prior to bonding may result in improved bond strengths in bonding a polymeric substrate having diene and or allylic functionality within the polymer chain to a metal or hydroxylated surface.
[0157] The provision of heat may aid in the hydrolysis of the phosphonate/phosphinate moiety of the compound of the present invention. The composition may be heated to a temperature between 30-100° C. Suitably, the composition may be heated to a temperature between 40-60° C. The composition may be heated to 50° C. The composition may be heated for between 1-2 hours. The composition may be heated for up to 2 hours. The composition may be applied directly to the target substrate. The composition may be cooled prior to application to the target substrate.
[0158] The step of substantially hydrolysing the compound of the present invention may comprise heating the composition to encourage hydrolysis of the phosphonate/phosphinate moiety of the compound of the present invention. The composition may be heated to a temperature between 30-100° C. Suitably, the composition may be heated to a temperature between 40-60° C. The composition may be heated to 50° C. The composition may be heated for between 1-2 hours. The composition may be heated for up to 2 hours. The composition may be applied directly to the target substrate. The composition may be cooled prior to application to the target substrate.
[0159] In bonding, the phosphinate/phosphonate moiety of the compound will anchor to the surface of the metal or the hydroxylated surface. The moiety selected from an aromatic nitroso or an aromatic nitroso precursor will generally become anchored to the polymer, for example a rubber material. Accordingly, each end of the molecule is functionalised and assists in bonding the materials together with a strong and durable bond.
[0160] Desirably, in an embodiment of the invention, in addition to the above described film former described above, the composition of the invention may further comprise a compound comprising:
(a) at least one copper compound; and (b) at least one aromatic nitroso compound precursor.
[0163] The copper compound may oxidise the at least one aromatic nitroso compound precursor (defined above) to generate an aromatic nitroso compound in-situ.
[0164] As will be appreciated by a person skilled in the art, compositions of the present invention may further comprise adhesion promoting agents. The adhesion promoting agent may promote crosslinking between the aromatic nitroso compound and the elastomer substrate or may provide for improved adhesion to a substrate. For example, the adhesion promoting agent may be a silane, as defined above.
[0165] In the improved compositions of this embodiment of the present invention the oxidant is a copper compound. A general scheme for the oxidation of quinone dioxime to the dinitrosobenzene species using a copper oxidant is shown below, for information:
[0000]
[0166] For example, the copper compound may be a Cu(I) or Cu(II) compound. The copper compound may be a Cu(O) compound which may oxidise in situ to a
[0000] Cu(I) or Cu(II) compound. Suitable copper compounds are disclosed in International publication WO2010/106030, the contents of which are incorporated by reference. The copper compound may be metallic copper, copper salts, copper oxides or combinations thereof. Suitable copper compounds may be selected from the group consisting of copper nanopowder, CuO, Cu 2 O, CuSCN, Cu(SCN) 2 and combinations thereof. The copper compound may be CuSCN, Cu(SCN) 2 or combinations thereof. The copper may be CuSCN. The oxidant may be copper thiocyanate. Accordingly, improved compositions suitable for bonding metal to rubber may be formulated, together with the film former as described above, utilising appropriate amounts of a copper oxidant according to the present invention.
[0167] The copper compound may be present in an amount of 1 to 20% w/w of the total composition. Suitably, the copper compound may be present in an amount of 1 to 10% w/w, for example 2 to 7% w/w. The copper compound may be present in 4% w/w.
[0168] Desirably, the copper compound (or oxidant) may be encapsulated.
[0169] The compositions of the present invention may further comprise a suitable carrier vehicle for the aromatic nitroso compound precursor and or copper salt.
[0170] Compositions comprising an aromatic nitroso compound precursor with a copper oxidant may also overcome the problems associated with the prior art discussed above. Furthermore, the compositions of the invention may be less toxic. This is particularly important prior to vulcanisation applications.
[0171] In a further aspect the present invention provides an improved curable composition, as described above, for bonding substrates together, the composition comprising:
i) at least one compound according to the present invention as defined herein.
[0173] The improved composition of the present invention may further comprise:
i) a suitable carrier vehicle for the compound.
[0175] As mentioned above, it will be appreciated that any suitable carrier vehicle may be utilised, for example, a solvent or solvent combination. It is particularly desirable that the carrier vehicle should be environmentally friendly.
[0176] Desirably, in an embodiment, in addition to the above described film former, the composition of the invention may comprise at least one encapsulated aromatic nitroso compound.
[0177] The invention further provides for an improved bonding composition comprising at least one encapsulated aromatic nitroso compound precursor.
[0178] In a further aspect, the invention provides for an improved bonding composition comprising at least one aromatic nitroso compound precursor and at least one oxidant for the aromatic nitroso compound precursor, wherein at least one of the precursor and the oxidant are encapsulated. The oxidant may be encapsulated. Alternatively, both the precursor and the oxidant may be encapsulated.
[0179] An encapsulated aromatic nitroso compound may be present in an amount of 1 to 20% w/w of the total composition. Suitably, the encapsulated aromatic nitroso compound may be present in an amount of 1 to 10% w/w, for example 1 to 6% w/w. The encapsulated aromatic nitroso compound may be present in 2% w/w of the total composition.
[0180] An encapsulated aromatic nitroso compound precursor may be present in an amount of 1 to 20% w/w of the total composition. Suitably, the encapsulated aromatic nitroso compound precursor may be present in an amount of 1 to 10% w/w, for example 1 to 6% w/w. The encapsulated aromatic nitroso compound precursor may be present in 2% w/w of the total composition.
[0181] A non-encapsulated aromatic nitroso compound precursor may be present in an amount of 1 to 20% w/w of the total composition. Suitably, the non-encapsulated aromatic nitroso compound precursor may be present in an amount of 1 to 10% w/w, for example 1 to 6% w/w. The non-encapsulated aromatic nitroso compound precursor may be present in 2% w/w of the total composition.
[0182] In the compositions of the present invention the oxidant may be a peroxide. For example, the oxidant may be benzoyl peroxide. The oxidant may also be a metal salt, for example a copper salt. Compositions suitable for bonding metal to rubber may be formulated utilising appropriate amounts of an encapsulated oxidant according to the present invention.
[0183] An encapsulated oxidant compound may be present in an amount of 1 to 20% w/w of the total composition. Suitably, the encapsulated oxidant may be present in an amount of 1 to 10% w/w, for example 3 to 8% w/w. The encapsulated oxidant may be present in 4% w/w. The encapsulated oxidant may be present in 8% w/w.
[0184] A non-encapsulated oxidant compound may be present in an amount of 1 to 20% w/w of the total composition. Suitably, the non-encapsulated oxidant may be present in an amount of 1 to 10% w/w, for example 3 to 8% w/w. The non-encapsulated oxidant may be present in 4% w/w. The non-encapsulated oxidant may be present in 8% w/w.
[0185] By encapsulating constituents, the compositions of the present invention eliminate the undesirable need to formulate compounds comprising free nitroso groups in improved curable composition compositions. Encapsulating the oxidant, the encapsulated aromatic nitroso compound precursor, or combinations thereof ensures that the nitroso group is only formed upon oxidation of the precursor during the vulcanisation process, which is the phase where bond formation takes place.
[0186] Desirably, the encapsulant in the compositions of the present invention comprises a stable capsule which will release the active core material upon rupturing via thermal or mechanical means. The encapsulated material may be one of an aromatic nitroso compound or an aromatic nitroso compound precursor. The encapsulated material may be an oxidising agent present in sufficient quantities to oxidise the aromatic nitroso compound precursor to an aromatic nitroso compound in-situ. The encapsulated material may be catalyst for enhancing the rate of reaction between a nitroso aromatic compound and a diene moiety or allylic moiety present in a polymer substrate, such as an elastomer.
[0187] The encapsulant material may be selected from the group consisting of hard, polymerised material, gelatin or resin. For example, suitable resins may comprise urea/formaldehyde resin. The capsules/encapsulant material should be structurally sound, the capsule should not react with the surrounding media, the encapsulated material should not leach through the encapsulant material, and the encapsulant material should be capable of encapsulating core materials that may otherwise spontaneously oxidise or which may be hygroscopic. The capsule walls must also be resistant to chemical attack by the materials contained therein. Suitable capsule/encapsulant materials may be chosen by those skilled in the art and conventional methods of making the capsules may be used.
[0188] The capsules/microcapsules may have an average diameter in the range 20-100 micrometres. Preferably, the microcapsules have walls rupturable under a load greater than about 1.0 kg/cm 2 , preferably greater than 2.0 kg/cm 2 . Suitably, the capsules will rupture under a load between 3 and 5 kg/cm 2 .
[0189] The compositions of the present invention may further comprise a suitable carrier vehicle for one of the encapsulated aromatic nitroso compound, the (encapsulated) aromatic nitroso compound precursor, and/or the (encapsulated) oxidant.
[0190] The compositions of the present invention provide for elastomer to substrate bonding, for example elastomer to metal bonding. The compositions of the present invention comprise at least one encapsulated component, such as an encapsulated oxidant, an encapsulated aromatic nitroso compound precursor, or an encapsulated adhesion promoter to promote crosslinking of the nitrosoaromatic and dinitrosoaromatic materials with the elastomer. The present invention also provides for combinations of the above encapsulated materials.
[0191] In another aspect the composition of the invention may further comprise
i) at least one a film former component comprising at least one non-halogenated hydroxy group-containing resin together with at least one crosslinking agent; ii) at least one epoxysilane having at least one terminal alkoxy silane group; iii) at least one bis-silane; and iv) optionally at least one organic solvent.
[0196] Examples of such compositions (but without the film former of the present invention) are provided in patent application number PCT/EP2011/056826, the contents of which are incorporated herein by reference.
[0197] The improved curing or improved curable composition of this embodiment of the present invention is preferably a one-part improved curable composition, which means, that one or more epoxysilanes and one or more bis-silanes are mixed with one or more halogenated polyolefins, prior to use.
[0198] The aforementioned components are preferably mixed in the presence of at least one organic solvent of the present invention as described above.
[0199] It is advantageous to formulate the improved curable composition of the present invention as a one-part system, because such systems are readily applied to substrates in a single step using conventional techniques, such as spraying, rolling or dipping.
[0200] The improved curable composition of the present invention is preferably storage-stable, which means that the improved curable composition formulation remains homogeneous, as determined by unenhanced visual inspection, when stored for a period of at least about 1 day at 22° C. in a sealed container.
[0201] The term “epoxysilane”, as used herein, refers to a compound having at least one epoxy group and at least one terminal alkoxy silane group per molecule. Desirably, the epoxysilanes contemplated for use in the adhesive of the present invention are selected from compounds having a single epoxy group and a single terminal alkoxy silane group per molecule.
[0202] The term “terminal alkoxy silane group”, as used herein, refers to a functional group at one end of the molecule, wherein said functional group comprises exactly one silicon atom, wherein at least one alkoxy residue is bound to the silicon atom of the terminal alkoxy silane group. It may be appreciated that the epoxysilane may also be bound to a carrier material, such as a silica carrier.
[0203] The improved curable composition of the present invention can comprise any mixture or combination of the aforementioned film former, suitably halogenated polyolefins. One or more halogenated polyolefins may be present in the inventive improved curable composition to provide adequate film properties in an amount in the range of 1 to 30 wt.-%, more preferably in an amount of 3 to 20 wt.-%, and particularly preferably in an amount of 7 to 15 wt.-%, each based on the total weight of the improved curable composition of the present invention.
[0204] If the halogenated polyolefin is selected from chlorinated polyolefins, it is preferred that the chlorinated polyolefin is present in an amount in the range of about 1 to about 30 percent by weight, more preferably in an amount of about 3 to about 20 percent by weight, and particularly preferably in an amount of about 7 to about 15 percent by weight, each based on the total weight of the improved curable composition of the present invention.
[0205] The improved curable composition of the present invention further comprises at least one epoxysilane having at least one terminal alkoxy silane group (hereinafter referred to as epoxysilane).
[0206] The use of epoxysilanes in the improved curable composition of the present invention is preferred, because the utilization of other epoxy resins, such as epoxy resins having no terminal alkoxy silane group, may lead to a significant decrease in the bonding performance of the resulting improved curable composition, especially in regard to heat aging and post-curing of the formed bond.
[0207] In one embodiment of the present invention the terminal alkoxy silane group of the epoxysilane is represented by formula
[0000] *—Si(R I ) u (OR II ) (3-u)
[0000] wherein u is 0, 1 or 2, each R I is independently selected from hydrogen, halogen, alkyl, cycloalkyl, alkenyl, aryl or acyl and each R II is independently selected from alkyl, cycloalkyl, alkenyl, aryl or acyl. In a particular preferred embodiment u is 0 and R II is selected from alkyl, wherein preferred alkyl groups include methyl, ethyl, n-propyl and iso-propyl.
[0208] Suitable terminal alkoxy silane groups include trimethoxysilane, triethoxysilane, tri-n-propoxysilane and/or tri-isopropoxysilane groups.
[0209] To enhance the bonding properties of the improved curable composition of the present invention, it is advantageous that the epoxysilane, which is used in the improved curable composition of the present invention, is a non-polymeric compound, which means that the molecular weight of said epoxysilane is preferably less than 1000 g/mol, more preferably less than 750 g/mol, and particularly preferably less than 500 g/mol.
[0210] The epoxysilane contemplated for use in the practice of the present invention may be a monosilane. The term “monosilane”, as used herein, refers to silane compounds having exactly one silicon atom per molecule, wherein monosilanes are preferred where three alkoxy residues are bound to the silicon atom.
[0211] Suitable epoxysilanes may be represented by formula (I),
[0000]
[0000] wherein R a is a divalent linkage group, comprising 1 to 24, preferably 2 to 20 and more preferably 3 to 10 carbon atoms, R 1 and R 3 independently of one another are selected from C 1-24 alkyl, such as C 1-5 alkyl, C 2-24 alkenyl, C 1-24 alkoxyl or C 3-24 acyl, and R 2 is selected from C 1-24 alkyl, such as C 1-5 alkyl or C 3-24 acyl, and A is either
[0000]
[0000] where R b , R c and R d independently of one another are hydrogen or C 1-6 alkyl;
or
[0000]
[0212] Desirably R b , R c and R d are hydrogen.
[0213] The divalent linkage group R a can be a straight or branched alkylene group of 1 to 24, preferably of 2 to 20 and more preferably of 3 to 10 carbon atoms. Said alkylene group may be interrupted by at least one heteroatom, preferably selected from oxygen, sulfur or nitrogen.
[0214] It is further on preferred that R 1 and R 3 of formula (I) independently of one another are selected from C 1-5 alkoxyl, such as methoxy, ethoxy, n-propoxy or iso-propoxy, and/or R 2 of formula (I) is C 1-5 alkyl, such methyl, ethyl, n-propyl or iso-propyl. More preferably R 1 and R 3 of formula (I) are both selected from methoxy, ethoxy, n-propoxy or iso-propoxy and R 2 of formula (I) is methyl, ethyl, n-propyl or iso-propyl.
[0215] Particularly preferred epoxysilanes are represented by formula (II),
[0000]
[0216] wherein n is an integer from 1 to 10, m is an integer from 0 to 14, R 1a and R 3a independently of one another are selected from C 1-24 alkyl, such as C 1-5 alkyl, C 2-24 alkenyl, C 1-24 alkoxyl or C 3-24 acyl, and R 2a is selected from C 1-24 alkyl, such as C 1-5 alkyl or C 3-24 acyl. Desirably, n is 1, 2 or 3 and/or m is 2, 3 or 4, wherein it is particularly preferred that n is 1 and m is 3.
[0217] It is further on preferred that R 1a and R 3a of formula (II) independently of one another are selected from C 1-5 alkoxyl, such as methoxy, ethoxy, n-propoxy or iso-propoxy, and/or R 2a of formula (II) is C 1-5 alkyl, such methyl, ethyl, n-propyl or iso-propyl. More preferably R 1a and R 3a of formula (II) are both selected from methoxy, ethoxy, n-propoxy or iso-propoxy and R 2′ of formulae (II) is methyl, ethyl, n-propyl or iso-propyl.
[0218] Other particularly preferred epoxysilane contemplated for use in the practice of the present invention are represented by formula (IIa),
[0000]
[0000] wherein v is an integer from 1 to 10, R 1b and R 3b independently of one another are selected from C 1-24 alkyl, such as C 1-5 alkyl, C 2-24 alkenyl, C 1-24 alkoxyl, such as C 1-5 alkoxyl or C 3-24 acyl, and R 2b is selected from C 1-24 alkyl, such as or C 3-24 acyl. Desirably, v is 1, 2 or 3.
[0219] It is further on preferred that R 1b and R 3b of formula (IIa) independently of one another are selected from C 1-5 alkoxyl, such as methoxy, ethoxy, n-propoxy or iso-propoxy, and/or R 2b of formula (IIa) is C 1-5 alkyl, such methyl, ethyl, n-propyl or iso-propyl. More preferably R 1b and R 3b of formula (IIa) are both selected from methoxy, ethoxy, n-propoxy or iso-propoxy and R 2″ of formulae (IIa) is methyl, ethyl, n-propyl or iso-propyl.
[0220] In one embodiment of the present invention the epoxysilane is selected from 3-glycidyloxypropyltrimethoxysilane (GLYMO), 3-glycidyloxypropyltriethoxysilane (GLYEO), 3-glycidyloxypropyltri-n-propoxysilane, 3-glycidyloxypropyltri-iso-propoxysilane, 3-glycidyloxypropyltri-n-butoxysilane, 3-glycidyloxypropyltri-iso-butoxysilane, beta-(3,4-epoxycyclohexyl)-ethyltrimethoxysilane, beta-(3,4-epoxycyclohexyl)-ethyltriethoxysilane, beta-(3,4-epoxycyclohexyl)-ethyltri-n-propoxysilane, beta-(3,4-epoxycyclohexyl)-ethyltri-iso-propoxysilane, gamma-(3,4-epoxycyclohexyl)-propyltrimethoxysilane, gamma-(3,4-epoxycyclohexyl)-propyltriethoxysilane, gamma-(3,4-epoxycyclohexyl)-propyltri-n-propoxysilane, gamma-(3,4-epoxycyclohexyl)-propyltri-iso-propoxysilane and/or combinations thereof.
[0221] The aforementioned epoxysilanes are known in the art and are commercially available from various companies, including Evonik Industries AG, Wacker Chemie AG, Shin-Etsu Chemical and Gelest Inc.
[0222] A single epoxysilane or a mixture of two or more epoxysilanes can be used in the improved curable composition of the present invention.
[0223] To ensure sufficient adhesion to the substrate, especially to metal substrates, it is desirable that one or more epoxysilanes are present in an amount of 0.2 to 5 wt.-%, preferably in an amount of 0.5 to 2 wt.-%, and more preferably in an amount of 0.75 to 1.25 wt.-%, each based on the total amount of the improved curable composition of the present invention.
[0224] The improved curable composition of the present invention further comprises at least one bis-silane. The term “bis-silane”, as used herein, refers to silane compounds having exactly two silicon atoms per molecule, wherein the two silicon atoms are linked with each other by a divalent linkage group and each silicon atom carries three additional substituents, wherein at least one of the three additional substituents is an alkyl or alkoxy residue. Consequently, the bis-silane used in the improved curable composition of the present invention comprises two terminal organo-silyl groups. Under the proviso that the bis-silane contemplated for use in the improved curable composition of the present invention comprises at least one terminal alkoxy silane group, as defined above, said bis-silane does not comprise at least one epoxy group.
[0225] In one embodiment of the present invention the terminal organo-silyl group of the bis-silane is represented by formula
[0000] *—Si(R III ) w (OR IV ) (3-w)
[0000] wherein w is 0, 1, 2 or 3, preferably w is 3, each R III is independently selected from hydrogen, halogen, alkyl, cycloalkyl, alkenyl, aryl or acyl and each R IV is independently selected from alkyl, cycloalkyl, alkenyl, aryl or acyl. In a particular preferred embodiment w is 0 and R IV is selected from alkyl, wherein preferred alkyl groups include methyl, ethyl, n-propyl and iso-propyl.
[0226] To enhance the bonding properties of the improved curable composition of the present invention, it is advantageous that the bis-silane, which is used in the improved curable composition of the present invention, is a non-polymeric compound, which means that the molecular weight of said bis-silane is preferably less than 1000 g/mol, more preferably less than 750 g/mol, and particularly preferably less than 500 g/mol.
[0227] Suitable bis-silanes contemplated for use in the improved curable composition of the present invention may be represented by formula (III),
[0000] (R 5 O) (3-q) (R 4 ) q Si—B—Si(R 6 ) p (OR 7 ) (3-p) formula (III)
[0228] wherein p is 0 to 3, q is 0 to 3, B represents a divalent linkage group comprising 1 to 24 carbon atoms and at least one heteroatom selected from N, S or O, each R 4 and each R 6 is independently selected from hydrogen, halogen, C 1-24 alkyl, C 2-24 alkenyl, C 1-24 alkoxyl or C 3-24 acyl, and each R 5 and each R 7 is independently selected C 1-24 alkyl or C 3 -24 acyl.
[0229] Particular good bonding and drying properties are achieved, when the divalent linkage group B of formula (III) comprises one of the following structural elements:
[0000]
[0000] where R 8 is selected from hydrogen, C 1-24 alkyl, such as C 1-4 alkyl, or C 6-18 aryl;
[0000]
[0000] where each R 9 is independently selected from hydrogen, C 1-24 alkyl, such as C 1-4 alkyl, or C 6-18 aryl and R 10 is selected from C 1-24 alkylene or C 6-18 arylene; or
[0000]
[0230] where Y is selected from O, S, and —NR 11 —, Z is selected from O, S, and —NR 12 —, wherein R 11 and R 12 independently of one another are selected from hydrogen or C 1-24 alkyl, such as C 1-4 alkyl, or C 6-18 aryl; X is the selected from O or S, with the proviso that Y and Z are not both O or S. Preferably Y is NH, Z is NH and X is O.
[0231] In an alternative embodiment the divalent linkage group B of formula (III) comprises the following structural element:
[0000]
[0000] where R 13 is selected from C 1-24 alkyl, such as C 1-4 alkyl.
[0232] Preferred bis-silanes include those having two trisubstituted silyl groups. The substituents may individually be chosen from C 1-24 alkoxy, C 6-18 aryloxy and C 2-24 acyloxy.
[0233] Suitable bis-silanes for use within the present invention include those of formula (IV),
[0000] (R 15 O) 3 Si—(R 14 ) k -D-(R 14 )k-Si(OR 15 ) 3 formula (IV)
[0234] where k is 0 or 1, each R 15 is independently selected from C 1-4 alkyl or C 1-4 acyl and each R 14 is independently selected from C 1-6 alkylene or C 6-12 arylene, and D is selected from one of the following divalent groups:
[0000]
[0235] where R 8a is selected from hydrogen, C 1-24 alkyl, such as C 1-4 alkyl, or C 6-18 aryl;
[0000]
[0236] where each R 9a is independently selected from hydrogen, C 1-24 alkyl, such as C 1-4 alkyl, or C 6-18 aryl and R 10a is selected from C 1-24 alkylene or C 6-18 arylene;
[0000]
[0237] where Y is selected from O, S, and —NR 11a —, Z is selected from O, S, and —NR 12a —, wherein R 11a and R 12a independently of one another are selected from hydrogen or C 1-24 alkyl, or C 6-18 aryl, and X is the selected from O or S, with the proviso that Y and Z are not both O or S. Preferably Y is NH, Z is NH and X is O.
[0238] Examples of suitable bis-silanes for use within the improved curable composition of the present invention include:
[0000]
[0239] where r is from 1 to 10, such as from 1 to 4 and R 16 is selected from C 1-4 alkyl or C 1-4 acyl, and/or
[0000]
[0240] where r is from 1 to 10, such as from 1 to 4 and R 16a is selected from C 1-4 alkyl or C 1-4 acyl.
[0241] In one embodiment of the present invention the bis-silane is selected from bis-(trimethoxysilylethyl)amine, bis-(triethoxysilylethyl)amine, bis-(tri-n-propoxysilylethyl)amine, bis-(tri-iso-propoxysilylethyl)amine, bis-(trimethoxysilylpropyl)amine, bis-(triethoxysilylpropyl)amine, bis-(tri-n-propoxysilylpropyl)amine, bis-(tri-iso-propoxysilylpropyl)amine, bis-(trimethoxysilylethyl)urea, bis-(triethoxysilylethyl) urea, bis-(tri-n-propoxysilylethyl) urea, bis-(tri-iso-propoxysilylethyl)urea, bis-(trimethoxysilylpropyl)urea, bis-(triethoxysilylpropyl)urea, bis-(tri-n-propoxysilylpropyl)urea, bis-(tri-iso-propoxysilylpropyl) urea, and/or combinations thereof. Preferably, bis-(trimethoxysilylpropyl)urea and/or bis-(trimethoxysilylpropyl)amine are used in the present invention, although other bis-silanes may also be used.
[0242] Other desirable bis-silanes include N,O-bis(trimethylsilyl)acetamide N,O-bis(triethylsilyl)acetamide, 1,3-bis(trimethylsilyl)urea, 1,3-bis(triethylsilyl)urea, 1,3-bis(trimethylsilyl)thiourea, 1,3-bis(triethylsilyl)thiourea, and/or mixtures thereof.
[0243] The aforementioned bis-silanes are known in the art and are commercially available form various companies, including Evonik Industries AG, Wacker Chemie AG, Shin-Etsu Chemical and Gelest Inc.
[0244] A single bis-silane or a mixture of two or more bis-silanes can be used in the improved curable composition of the present invention.
[0245] It is desirable that one or more bis-silanes are present in an amount of 0.1 to 2 wt.-%, preferably in an amount of 0.15 to 1 wt.-%, and more preferably in an amount of 0.2 to 0.4 wt.-%, each based on the total amount of the of improved curable composition of the present invention.
[0246] By using a combination of the aforementioned halogenated polyolefins, epoxysilanes and bis-silanes in the improved curable composition of the present invention the elastomer-to-metal bonding properties of the inventive improved curable composition are significantly improved over comparable improved curable composition formulation of the prior art, which do not comprise such a synergistic combination. In addition, the coating properties of the improved curable composition of the present invention are improved over comparable prior art adhesive composition formulations of the prior art. Conventional curable compositions normally require a drying time at elevated temperatures after being applied to substrates, such as metallic substrates. In contrast to that, the improved curable composition of the present invention can be dried at 22° C. in short time periods and the resulting coating is hard and non-tacky. Therefore, it is possible to pre-coat and store different substrates, such as metallic substrates and to directly use these pre-coated substrates later on in bonding operations.
[0247] The improved curable composition of the present invention may advantageously comprise one or more of the aforementioned epoxysilanes in an amount of 0.2 to 5 wt.-%, preferably in an amount of 0.5 to 2 wt.-%, and particularly preferably in an amount of 0.75 to 1.25 wt.-% and one or more of the aforementioned bis-silanes in an amount of 0.1 to 2 wt.-%, preferably in an amount of 0.15 to 1 wt.-%, and particularly preferably in an amount of 0.2 to 0.4 wt.-%, wherein each amount is based on the total amount of the improved curable composition of the present invention.
[0248] A particular durable elastomer to metal bond is formed by the cured product of the improved curable composition of the present invention, when said improved curable composition comprises the epoxysilane and the bis-silane in a weight ratio of 1:0.2 to 1:0.8, preferably in a weight ration of 1:0.3 to 1:0.7.
[0249] The weight ratio of epoxysilane to the bis-silane, as used herein, refers to weight ratio of the total amount of all epoxysilanes to the total amount of all bis-silanes present in the improved curable composition of the present invention.
[0250] The bonding performance of the improved curable composition of the present invention can further be improved by using the following combinations of epoxysilanes and bis-silanes:
3-glycidyloxypropyltrimethoxysilane and bis-(trimethoxysilylpropyl)amine; 3-glycidyloxypropyltrimethoxysilane and bis-(trimethoxysilylpropyl)urea; 3-glycidyloxypropyltriethoxysilane and bis-(trimethoxysilylpropyl)amine; 3-glycidyloxypropyltriethoxysilane and bis-(trimethoxysilylpropyl)urea; 3-glycidyloxypropyltri-n-propoxysilane and bis-(trimethoxysilylpropyl)amine; 3-glycidyloxypropyltri-n-propoxysilane and bis-(trimethoxysilylpropyl)urea; 3-glycidyloxypropyltri-iso-propoxysilane and bis-(trimethoxysilylpropyl)amine; 3-glycidyloxypropyltri-iso-propoxysilane and bis-(trimethoxysilylpropyl)urea.
[0259] Particularly good bonding performances are achieved when the following combinations of epoxysilanes and bis-silanes are used in the amounts given, wherein each amount is based on the total amount of the improved curable composition of the present invention:
from 0.5 to 2 wt.-% of 3-glycidyloxypropyltrimethoxysilane and from 0.15 to 1 wt.-% of bis-(trimethoxysilylpropyl)amine; from 0.5 to 2 wt.-% of 3-glycidyloxypropyltrimethoxysilane and from 0.15 to 1 wt.-% of bis-(trimethoxysilylpropyl)urea; from 0.5 to 2 wt.-% of 3-glycidyloxypropyltriethoxysilane and from 0.15 to 1 wt.-% of bis-(trimethoxysilylpropyl)amine; from 0.5 to 2 wt.-% of 3-glycidyloxypropyltriethoxysilane and from 0.15 to 1 wt.-% of bis-(trimethoxysilylpropyl)urea; from 0.5 to 2 wt.-% of 3-glycidyloxypropyltri-n-propoxysilane and from 0.15 to 1 wt.-% of bis-(trimethoxysilylpropyl)amine; from 0.5 to 2 wt.-% of 3-glycidyloxypropyltri-n-propoxysilane and from 0.15 to 1 wt-% of bis-(trimethoxysilylpropyl)urea; from 0.5 to 2 wt.-% of 3-glycidyloxypropyltri-iso-propoxysilane and from 0.15 to 1 wt.-% of bis-(trimethoxysilylpropyl)amine; from 0.5 to 2 wt.-% of 3-glycidyloxypropyltri-iso-propoxysilane and from 0.15 to 1 wt.-% of bis-(trimethoxysilylpropyl)urea.
[0268] The epoxysilane and the bis-silane used in the present invention are preferably free and mobile components of the improved curable composition of the present invention, which means that said silane compounds are not immobilized on a carrier material, such as a solid surface.
[0269] However, it may be desirable for specific applications that the epoxysilane and/or the bis-silane used in the present invention is/are immobilized on a carrier material, such as a solid surface.
[0270] The improved curable compositions of the present invention can be prepared by conventional means. For ease of application, the components of the inventive of the improved curable composition can be dispersed or dissolved in a liquid carrier, such as an organic solvent or a mixture of different organic solvents. Once the improved curable composition has been applied the liquid carrier evaporates.
[0271] In one embodiment the improved curable composition of the present invention comprises at least one organic solvent as a liquid carrier. The organic solvent may comprise water or water-miscible solvents, wherein it is preferred that the amount of water in the organic solvent is less than 10 wt.-%, preferably less than 5 wt.-%, more preferably less than 1 wt.-%, and particularly preferably less than 0.1 wt.-%, each based on the total amount of the organic solvent.
[0272] Depending on the amount of water present in the organic solvent, it is possible that the epoxysilane and/or the bis-silane used in the present invention are partially or fully hydrolyzed.
[0273] Examples of suitable organic solvents include aromatic and halogenated aromatic hydrocarbons such as benzene, toluene, xylene, chlorobenzene, and dichlorobenzene; halogenated aliphatic hydrocarbons such as trichloroethylene, perchloroethylene, and propylene dichloride; ketones such as methyl ethyl ketone, and methyl isobutyl ketone; ethers, naphthas, etc., including mixtures of such solvents.
[0274] Preferred organic solvents are xylene and toluene, ortho- and para-chlorotoluene, optionally in combination with tetrachloroethylene.
[0275] The improved curable composition of the present invention can comprise any mixture of the aforementioned organic solvents, wherein mixtures of at least one aromatic solvent and at least one non-aromatic solvent are preferred to ensure that a dry and non-tacky film is formed. The amount of organic solvent employed is preferably in the range of about 50 to about 90 percent by weight, more preferably in the range of about 60 to about 80 percent by weight, and particularly preferably in the range of about 65 to about 75 percent by weight, each based on the total amount of the inventive improved curable composition.
[0276] The improved curable compositions of the present invention may additionally comprise any additives conventionally used in improved curable composition formulation that are suitable for use in polymer-to-metal, for example elastomer to metal such as rubber to metal bonding applications.
[0277] Illustrative examples of such additives include reinforcing carbon blacks; fillers such as calcium carbonates, chalks, talcs, silicas or metal oxides; accelerator systems; vulcanization retarders; promoters such as zinc oxide or stearic acid; plasticizers such as aromatic, paraffinic, naphthenic and synthetic mineral oils; light-protecting agents; ozone-protecting agents; processing auxiliaries, sulfur and/or any combination thereof.
[0278] Commonly these additives may be present at a quantity of about 0.1 to about 80 percent by weight, more preferably at a quantity of about 0.1 to about 40 percent by weight, each based on the total amount of the improved curable composition of the present invention.
[0279] One typical formulation of the improved curable composition of the present invention comprises or consists of, based on the total amount of the improved curable composition:
i) from 1 to 30 wt.-% of at least one halogenated polyolefin; ii) from 0.2 to 5 wt.-% of at least one epoxysilane having at least one terminal alkoxy silane group; iii) from 0.1 to 2 wt.-% of at least one bis-silane; and iv) from 40 to 90 wt.-% of at least one organic solvent; v) from 0 to 50 wt.-% of at least one additive.
[0285] Another typical formulation of the improved curable composition of the present invention comprises or consists of, based on the total amount of the improved curable composition:
i) from 1 to 30 wt.-% of at least one chlorinated polyolefin; ii) from 0.2 to 5 wt.-% of at least one epoxysilane having at least one terminal alkoxy silane group selected from the group consisting of 3-glycidyloxypropyltrimethoxysilane, 3-glycidyloxypropyltriethoxysilane, 3-glycidyloxypropyltri-n-propoxysilane, 3-glycidyloxypropyltri-iso-propoxysilane, 3-glycidyloxypropyltri-n-butoxysilane, 3-glycidyloxypropyltri-iso-butoxysilane, beta-(3,4-epoxycyclohexyl)-ethyltrimethoxysilane, beta-(3,4-epoxycyclohexyl)-ethyltriethoxysilane, beta-(3,4-epoxycyclohexyl)-ethyltri-n-propoxysilane, beta-(3,4-epoxycyclohexyl)-ethyltri-iso-propoxysilane, gamma-(3,4-epoxycyclohexyl)-propyltrimethoxysilane, gamma-(3,4-epoxycyclohexyl)-propyltriethoxysilane, gamma-(3,4-epoxycyclohexyl)-propyltri-n-propoxysilane, and gamma-(3,4-epoxycyclohexyl)-propyltri-iso-propoxysilane; iii) from 0.1 to 2 wt.-% of at least one bis-silane; and iv) from 40 to 90 wt.-% of at least one organic solvent; v) from 0 to 50 wt.-% of at least one additive.
[0291] A further typical formulation of the improved curable composition of the of the present invention comprises or consists of, based on the total amount of the improved curable composition:
i) from 1 to 30 wt-% of at least one chlorinated polyolefin; ii) from 0.2 to 5 wt.-% of at least one epoxysilane having at least one terminal alkoxy silane group; iii) from 0.1 to 2 wt.-% of at least one bis-silane selected from the group consisting of bis-(trimethoxysilylethyl)amine, bis-(triethoxysilylethyl)amine, bis-(tri-n-propoxysilylethyl)amine, bis-(tri-iso-propoxysilylethyl)amine, bis-(trimethoxysilylpropyl)amine, bis-(triethoxysilylpropyl)amine, bis-(tri-n-propoxysilylpropyl)amine, bis-(tri-iso-propoxysilylpropyl)amine, bis-(trimethoxysilylethyl)urea, bis-(triethoxysilylethyl)urea, bis-(tri-n-propoxysilylethyl) urea, bis-(tri-iso-propoxysilylethyl)urea, bis-(trimethoxysilylpropyl)urea, bis-(triethoxysilylpropyl)urea, bis-(tri-n-propoxysilylpropyl)urea, and bis-(tri-iso-propoxysilylpropyl) urea; iv) from 40 to 90 wt.-% of at least one organic solvent; v) from 0 to 50 wt.-% of at least one additive.
[0297] Another typical formulation of the improved curable composition of the present invention comprises or consists of, based on the total amount of the improved curable composition:
i) from 1 to 30 wt.-% of at least one chlorinated polyolefin; ii) from 0.2 to 5 wt.-% of at least one epoxysilane having at least one terminal alkoxy silane group selected from the group consisting of 3-glycidyloxypropyltrimethoxysilane, 3-glycidyloxypropyltriethoxysilane, 3-glycidyloxypropyltri-n-propoxysilane, 3-glycidyloxypropyltri-iso-propoxysilane, 3-glycidyloxypropyltri-n-butoxysilane and 3-glycidyloxypropyltri-iso-butoxysilane; iii) from 0.1 to 2 wt.-% of at least one bis-silane selected from bis-(trimethyoxysilylpropyl)urea and/or bis-(trimethoxysilylpropyl)amine; and iv) from 40 to 90 wt.-% of at least one organic solvent; v) from 0 to 50 wt.-% of at least one additive.
[0303] In this context it is preferred that the improved curable composition of the present invention of the invention is substantially free of nitroso-containing compounds. The term “nitroso-containing compound”, as used herein, refers to any compound which comprises at least one nitroso functional group *—N═O. The term “substantially free of nitroso-containing compounds” means that the improved curable composition of the present invention comprises less than 1 wt.-%, preferably less than 0.1 wt.-%, more preferably less than 0.01 wt.-%, and particularly preferably less than 0.001 wt.-% of nitroso-containing compounds, each based on the total amount of the inventive improved curable composition. In another embodiment the improved curable composition of the present invention is totally free of nitroso-containing compounds. In a further embodiment the improved curable composition of the present invention is substantially free of isocyanate-containing compounds. The term “isocyanate-containing compound”, as used herein, refers to any compound which comprises at least one isocyanate functional group *—NCO. The term “substantially free of isocyanate-containing compounds” means that the improved curable composition of the present invention comprises less than 1 wt.-%, preferably less than 0.1 wt.-%, more preferably less than 0.01 wt.-%, and particularly preferably less than 0.001 wt.-% of isocyanate-containing compounds, each based on the total amount of the inventive improved curable composition. It is also desirable that the total amount of all isocyanate-containing compounds and all nitroso-containing compounds is less than 1.5 wt.-%, preferably less than 0.15 wt.-%, more preferably less than 0.015 wt.-%, and particularly preferably less than 0.0015 wt.-% of nitroso-containing compounds, each based on the total amount of the inventive improved curable composition. In another embodiment the improved curable composition of the present invention is totally free of isocyanate-containing compounds or totally free of isocyanate-containing compounds and nitroso-containing compounds.
[0304] Another advantage of the improved curable compositions according to the present invention is that said improved curable compositions are capable of curing to provide excellent bond strength, especially when used to bond polar elastomeric substrates, such as nitrile butadiene rubber (NBR), hydrogenated nitrile butadiene rubber (HNBR) and/or ethylene acrylic elastomers to metallic substrates.
[0305] For example, in rubber to metal bonding tests to determine the bond strength of the improved curable composition of the present invention 85% to 100% rubber failure was observed. Furthermore, the resultant bonds have excellent hot water resistance.
[0306] In another aspect there is provided a process for bonding a material to a substrate, comprising the steps of:
a) providing a curable composition as defined herein; b) providing the material to be bonded in a non-cured form, and c) simultaneously curing the composition and the material to be bonded so that the material is bonded to the substrate.
[0310] Suitably, the material to be bonded cures can form an elastomer, such as rubber.
[0311] In a other aspect there is provided a process for bonding a first substrate to a second substrate, comprising the steps of:
a) providing a curable composition as defined herein; b) applying the curable composition to at least one part of the surface of the first substrate; and c) contacting said surface of the first substrate with a surface of a second substrate, to which the curable composition is optionally applied, under conditions of heat and pressure sufficient to create a cured bond between the two substrates.
[0315] Desirably, the first substrate is an elastomer which is vulcanised or crosslinked prior to bonding to the second substrate
[0316] Suitably, the first substrate is a rubber, and the second substrate is a metal surface.
[0317] Suitably, the rubber is vulcanised or crosslinked concurrently with bonding to the metal surface.
[0318] In a related aspect, a process for crosslinking an elastomeric material, comprising the steps of:
a) providing a composition in a non-cured form comprising
(i) at least one aromatic nitroso or at least one aromatic nitroso precursor compound or combinations thereof; and (ii) a film former component comprising at least one non-halogenated hydroxy group-containing resin together with at least one crosslinking agent;
b) mixing the composition with at least one elastomeric material to form a curable mixture; and c) exposing said mixture to conditions of heat and pressure sufficient to crosslink the elastomer.
[0324] Suitably, the elastomeric material may be a rubber.
[0325] Desirably, the film former component may be used in combination with at least one sulfur impregnated particulate solid as defined above.
[0326] Preferably, the mixture is exposed to heat at a temperature of above about 50° C., more suitably above about 50° C., more suitably still above about 80° C. The most preferred temperature range is between about 150° C. and about 180° C.
[0327] Optionally a pressure of above 1 bar may be applied.
[0328] Prior to bonding, the surface of the metallic substrate may be cleaned according to one or more methods known in the art, such as degreasing, grit-blasting and zinc-phosphatizing.
[0329] As noted above it is a particular advantage that the improved curable compositions of the present invention can be used for bonding polar elastomeric materials to metallic substrates, as described above.
[0330] In one embodiment of the process of the present invention the first substrate may be a metallic substrate and/or the second substrate may comprises or consists of an elastomeric material, like polar elastomeric materials, such as nitrile butadiene rubber (NBR), hydrogenated nitrile butadiene rubber (HNBR) and/or ethylene acrylic elastomers and/or any combination or mixture thereof.
[0331] In step b) of the process described above, the improved curable composition of the invention may be applied to at least one part of the surface of the first substrate, e.g., to at least one part of the metallic surface by spraying dipping, brushing, and/or wiping. After the improved curable composition has been applied, it is preferred that the formed coating is permitted to dry. In some cases, it may be desirable to preheat the first substrate, such as the metallic substrate prior to application of the improved curable composition of the present invention to assist in drying of the improved curable composition. Particularly durable improved curable composition bonds are obtained when the improved curable composition of the present invention is applied in an amount sufficient to form a film having a film thickness in the range of about 3 μm to about 20 μm, more preferably of about 6 μm to about 12 μm.
[0332] Than in step c) of the process of the present invention the surface of the first substrate is contacted with the surface the second substrate, to which the improved curable composition is optionally applied, under conditions of heat and pressure sufficient to create an improved curable composition bond between the two substrates.
[0333] In a preferred embodiment of the present invention the improved bond between the two substrates is formed in step c) of the process of the present invention results from bringing the two substrates together under a pressure from about 20 MPa to about 200 MPa, preferably from about 25 MPa to 50 MPa at a temperature from about 100° C. to about 200° C., preferably from about 160° C. to about 190° C. The formed assembly should preferably remain under the applied pressure and temperature for a period of time of about 1 min to 60 min, more preferably for a period of time of about 3 min to 20 min.
[0334] The conditions of heat and pressure sufficient to create an improved bond between the two substrates could vary depending on the chemical composition of the improved curable composition of the present invention and/or depending on the vulcanization rate of the elastomeric substrate. In one embodiment of the present invention the elastomeric substrate is vulcanized concurrently with bonding to the surface of the metallic substrate in step c) of the inventive process.
[0335] In an alternative embodiment the elastomeric substrate is already vulcanized prior to the bonding process, which means that substantially no vulcanization of the elastomeric substrates occurs in step c) of the process of the present invention.
[0336] Generally, it is desirable that bonding is achieved during the vulcanization of the elastomeric substrate.
[0337] The process of the present invention may be carried out by applying an elastomeric substrate as a semi-molten material to an improved curable composition coated metal surface as in, for example, an injection-molding process. The process of the present invention may also be carried out by utilizing compression molding, transfer molding or autoclave curing techniques. After the process is complete, a bonded assembly is formed, in which the fully vulcanized elastomeric material is bonded to a metallic substrate by the cured product of the inventive improved curable composition of the invention, which comprises the film former described above.
[0338] Therefore, another aspect of the present invention is an article or assembly comprising at least two substrates bound together by the cured product of the improved curable composition of present invention, which comprises the film former described above.
[0339] In a further aspect, the present invention relates to an assembly comprising a first substrate and a second substrate bonded together by an cured improved curable composition of present invention, which comprises the film former described above.
[0340] Desirably, one of the substrates is an elastomer, such as a natural or synthetic rubber. The second substrate may be an elastomer, a metal, glass or other hydroxylated substrate. The invention further extends to a cure product comprising a polymer, for example an elastomer, such as a natural or synthetic rubber and a composition according to the present invention.
[0341] The article of the present invention is preferably a bonded assembly which comprises at least one metallic substrate bonded to at least one elastomeric substrate by the cured product of improved curable composition of the invention, wherein the elastomeric substrate is preferably selected from nitrile butadiene rubber (NBR), hydrogenated nitrile butadiene rubber (HNBR) and/or ethylene acrylic elastomers.
[0342] The article or bonded assembly of the present invention is ready for use in a final application including, but not limiting to, engine mount, damper, or belting. A further aspect of the present invention is the use of an improved curable composition of the present invention for bonding a first substrate to a second substrate, wherein one substrate is an elastomeric substrate. Suitable metallic substrates and suitable polymeric substrate, elastomeric substrates, and polar elastomeric substrates are described above.
[0343] As discussed above, excellent adhesion between polymeric materials, such as elastomeric materials, for example rubber compositions, and metals or hydroxylated surfaces, may be realized through the use of the improved compositions described herein, wherein they include film former as define above.
[0344] In yet a further aspect the present invention provides for a cure product comprising a substrate and an improved composition according to the present invention.
[0345] Another aspect of the present invention relates to an article, comprising at least two substrates bound together by the cured product of an improved composition of the present invention.
[0346] Wherein a metal substrate coated with an improved curable composition of the invention as so described may be adhered to a polymeric material, for example a rubber composition, by applying the polymeric material in an uncured state onto the metal coated with the improved curable composition and curing the polymeric material thereon to bond it to the metal.
[0347] In the case of a rubber polymeric material the uncured rubber may be vulcanized via heat and pressure over a period of time to cure the rubber, resulting in bonding of the rubber to the metal.
[0348] The method may further comprise the step of heating subsequent to mating the first and second substrates. Advantageously, heating may increase the rate of bond formation. Heating may improve bond strength.
[0349] In another aspect there is provided a film forming component for use in a binding curable composition the component comprising at least one aromatic nitroso or at least one aromatic nitroso precursor compound and combinations thereof;
[0350] together with a film former component comprising at least one non-halogenated hydroxy group-containing resin together with at least one crosslinking agent.
[0351] Desirably, the at least one aromatic nitroso or at least one aromatic nitroso precursor compound comprises a compound comprising:
[0352] at least one alkoxy silane moiety; and
[0353] at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof.
[0354] The improved composition of the invention solid may be applied to a target substrate as a thin film or coating. This may allow for uniform (or even) application of the composition to the target substrate. Uniform application of the composition to a target substrate may allow for improved bonding.
[0355] The method of the present invention may additionally comprise the step of:
i. substantially hydrolysing the nitrosilane component of the composition of the present invention.
[0357] At least one alkoxy (or acyloxy) moiety in the compound may be hydrolysed to ensure good bonding. As will be appreciated by a person skilled in the art, the order of steps a) and b) may be reversed. For example, the product may be applied to at least one substrate and then hydrolysed, or the product may be hydrolysed prior to application to the at least one substrate.
[0358] In a further aspect, the present invention provides for a method of bonding two substrates together, the method comprising providing a composition comprising film former defined above and
1. substantially hydrolysing a component comprising:
a) at least one alkoxy silane moiety; and b) at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof;
2. applying the substantially hydrolysed compound of step 1 to at least one substrate; and 3. mating the first and second substrates so as to form a bond therebetween.
[0364] At least one alkoxy moiety in the compound may be hydrolysed to ensure good bonding. As will be appreciated by a person skilled in the art, the order of steps 1 and 2 is inconsequential. For example, the product may be applied to at least one substrate and then hydrolysed, or the product may be hydrolysed prior to application to the at least one substrate. The method may further comprise the step of heating subsequent to mating the first and second substrates. Advantageously, heating may increase the rate of bond formation. Heating may improve bond strength.
[0365] In yet a further aspect, the present invention provides for a method of bonding two substrates together comprising:
1. providing a composition comprising film former (according to the present invention) having and further comprising:
(i) a compound comprising:
a) at least one alkoxy silane moiety; and b) at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof; and
(ii) a carrier for the compound, the carrier comprising at least 0.1% w/w water;
2. heating the composition; and 3. applying a composition to a bonding surface of at least one of the substrates and bringing the bonding surfaces of the substrates together.
As will be appreciated by a person skilled in the art, the order of steps 2 and 3 is inconsequential. For example, the composition may be applied to at least one substrate and then heated, or the composition may be heated prior to application to the at least one substrate.
[0373] The provision of heat may aid in the hydrolysis of the alkoxy silane moiety of the compound. The composition may be heated to a temperature between 30-100° C. Suitably, the composition may be heated to a temperature between 40-60° C. The composition may be heated to 50° C. The composition may be heated for between 1-2 hours. The composition may be heated for up to 2 hours. The composition may be applied directly to the target substrate. The composition may be cooled prior to application to the target substrate.
[0374] The improved composition may be applied to a target substrate as a thin film or coating. This may allow for uniform (or even) application of the composition to the target substrate. Uniform application of the composition to a target substrate may allow for improved bonding.
[0375] The method may further comprise the step of heating subsequent to bringing the surfaces together. Advantageously, heating may increase the rate of bond formation. Heating may improve bond strength, durability and resistance under certain conditions as described above.
[0376] Thus, a metal coated with an adhesive composition as so described may be adhered to a polymeric material, for example a rubber composition, by applying the polymeric material in an uncured state onto the metal coated with the adhesive composition and curing the polymeric material thereon to bond it to the metal. In the case of a rubber polymeric material the uncured rubber may be vulcanized via heat and pressure over a period of time to cure the rubber, resulting in bonding of the rubber to the metal.
[0377] Such bonding to metal and or hydroxylated surfaces is achieved through the nitroso groups which are capable of reacting with polymers. The polymer may comprise alkene/allylic functionality within the polymer chain. For example, diene or allylic functionality within the polymer chain.
[0378] Excellent adhesion between polymeric materials, such as rubber compositions, and metals or hydroxylated surfaces, with minimal waste of silane solution, may be realized through the use of the compounds and compositions as so described. With reference to their use in adhesive applications, the compositions of the present invention are generally thinner than the compositions present in the traditional adhesive systems for rubber bonding, without any loss in performance characteristics.
[0379] In a further aspect the present invention provides for a substrate having a composition according to the present invention pre-applied thereto for subsequent bonding to a second substrate. As used herein, the term pre-applied indicates that the composition of the present invention may be applied to a substrate such that it remains secured thereto, and the resulting pre-treated substrate is suitable for storage. The composition should retain its efficacy over time. The pre-treated substrate may be stored for subsequent bonding to a second substrate. Advantageously, substrates can be coated with the composition in a pre-treatment process, optionally stored, and subsequently utilised in (automated) manufacturing processes. The composition may be pre-applied to a polymeric substrate (such as an elastomer, for example a natural or synthetic rubber), a metal or a hydroxylated surface. The composition may be pre-applied to a metal or a hydroxylated surface. Advantageously, the film former of the invention has tailorable reactivity that can be adjusted by appropriate selection of the at least one non-halogenated hydroxy group containing resin and crosslinker, and selection of amounts used and conditions applied, to deliver the correct level of robustness, and at the same time, allow excellent bonding to the rubber. The film former of the invention gives better control than the chlorinated olefin film formers (a number of the examples of the present invention herein should show excellent pre-bake resistance i.e. up to 10 minutes).
[0380] In a further aspect, the present invention provides for a container having therein a composition comprising film former (according to the present invention) comprising:
(i) a compound comprising:
a) at least one alkoxy silane moiety; and b) at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof; and
(ii) a carrier for the compound, the carrier comprising at least 0.1% w/w water. The compound may be substantially hydrolysed.
[0385] In yet a further aspect, the present invention provides for use of providing a composition comprising film former (according to the present invention) heated from 30 to 100° C. for bonding two substrates together, the composition (according to the present invention) comprising:
1. a compound comprising:
a) at least one alkoxy silane moiety; and b) at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof; and
2. a carrier for the compound, the carrier comprising at least 0.1% w/w water.
[0390] The composition may be heated to a temperature between 40-60° C. The composition may be heated to 50° C. The heated composition may be applied directly to the target substrate. The composition may be cooled prior to application to the target substrate.
[0391] In yet a further aspect the present invention provides a process for bonding two substrates together comprising the steps of:
(i) providing an improved curable composition comprising film former as defined herein; (ii) applying a primer comprising a silicate, an aluminate, a germanate or combinations thereof to at least one substrate; (iii) applying a compound comprising;
a) at least one alkoxy silane moiety; and b) at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof; to at least one substrate, and
(iv) mating the first and second substrates so as to form a bond with the composition.
[0399] It will be appreciates that these process may also utilise at sulfur impregnated particulate solid in combination with the film former of the invention.
[0400] As used herein, the term “applying a primer comprising a silicate, an aluminate, a germanate or combinations thereof” refers to applying an amount of a silicate, an aluminate, a germanate or combinations thereof to a surface for subsequent application of a compound comprising at least one alkoxy silane moiety and at least one aromatic nitroso (precursor) moiety. For example, the primer comprising a silicate, an aluminate, a germanate or combinations thereof may be applied as a deposit, monolayer, thin film, layer, etc. Suitably, a primer comprising a silicate, an aluminate, a germanate or combinations thereof may be applied to the surface of a first substrate for the purpose of priming said first substrate for subsequent bonding to a second substrate. The primer may comprise a silicate, an aluminate or combinations thereof.
[0401] The primer comprising a silicate, an aluminate, a germanate or combinations thereof may be applied to one substrate or both substrates. Advantageously, applying a primer comprising a silicate, an aluminate, a germanate or combinations thereof to substrates may result in improved cure strength, particularly in production and automated processes.
[0402] The primer comprising a silicate, an aluminate, a germanate or combinations thereof may be applied to the at least one substrate in a suitable carrier. For example, the carrier may be a solvent, a wetting agent or a dispersing medium.
[0403] The primer may comprise a component selected from the group comprising glass such as glass fibres, quartz, clays, talcs, zeolites, porcelains, ceramics, silicon substrates and combinations thereof. The primer may comprise a silicate.
[0404] As discussed above, the first substrate and/or the second substrate may be a metallic substrate, a glass substrate or a substrate made of fabrics. Alternatively, it is possible that the first substrate and/or the second substrate comprise(s) or consist(s) of a polymeric material, such as an elastomeric material, like natural or synthetic rubber. Preferred improved curable compositions of the present invention are one-coat improved curable compositions which are adapted to be utilized to bond polymers, such as elastomeric materials to other substrates, such as metallic substrates without the use of a primer. Suitable elastomeric materials are described above.
[0405] The inventive primers and compounds (and compositions) utilised in the method of the present invention may be used in a pre-applied format. As used herein, the term pre-applied indicates that the primer or compound or compositions of the present invention may be applied to a substrate such that it remains secured thereto, and the resulting pre-treated substrate is suitable for storage. The primer or compound of composition should retain its efficacy over time. The pre-treated substrate may be stored for subsequent bonding to a second substrate.
[0406] For example, this may involve pre-applying a primer comprising a silicate, an aluminate, a germanate or combinations thereof to a first substrate, such that it remains secured thereto. Advantageously, substrates can be primed in a pre-treatment process, optionally stored, and subsequently utilised in (automated) manufacturing processes.
[0407] Accordingly, the invention further provides for a substrate having a primer comprising a silicate, an aluminate, a germanate or combinations thereof applied thereto for the purpose of priming said substrate for subsequent bonding to a second substrate using a compound comprising at least one alkoxy silane moiety; and at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof. At least one of the substrates may comprise a polymer comprising diene or allylic functionality within the polymer chain, for example, the polymer may be an elastomer, such as natural or synthetic rubber. The synthetic rubber may be a nitrile butadiene rubber. The synthetic rubber may be HNBR.
[0408] The invention further provides for a substrate having a compound comprising at least one alkoxy silane moiety; and at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof pre-applied thereto for subsequent bonding to a second substrate. A first substrate may comprise a hydroxylated surface as defined herein. A second substrate may comprise a polymer. The polymer may comprise diene or allylic functionality within the polymer chain, for example, the polymer may be an elastomer, such as natural or synthetic rubber. The synthetic rubber may be a nitrile butadiene rubber. The synthetic rubber may be HNBR. Advantageously, substrates can be pre-treated and subsequently utilised in (automated) manufacturing processes.
[0409] The primer or compound or composition of the present invention may be pre-applied to the polymeric substrate (such as an elastomer, for example a natural or synthetic rubber), or the hydroxylated surface. The composition may be pre-applied to the hydroxylated surface. In a further aspect, the invention relates to use of a film former according to the invention in the manufacture of a curing composition. The invention extends to use of a composition comprising a film former as defined herein as a film former in the manufacture of a curing composition. In such use, the curing composition is a composition for bonding an elastomeric material to a substrate for example elastomer, metal, glass or other hydroxylated substrate. Suitably, the curing composition cures during a vulcanisation process. The curable composition comprising the film former of the invention may be used as a crosslinking agent for elastomeric materials.
[0410] The invention extends to a cure product of a curable composition as described herein or the uses as described herein.
[0411] The inventive methods, compounds and compositions of the present invention may find utility in the following non-limiting applications: manufacture of automotive timing belts, bonding to glass/glass fibre reinforced plastic and composite parts, manufacture of reinforced rubbers, tyre manufacture, conveyor belt manufacture and the manufacture of woven materials such as clothing, for example protective clothing.
[0412] The inventive methods, compounds and compositions of the present invention may find utility in the following non-limiting applications: manufacture of automotive timing belts, bonding to glass/glass fibre reinforced plastic and composite parts, manufacture of reinforced rubbers, tyre manufacture, conveyor belt manufacture and the manufacture of woven materials such as clothing, for example protective clothing.
[0413] Where suitable, it will be appreciated that all optional and/or preferred features of one embodiment of the invention may be combined with optional and/or preferred features of another/other embodiment(s) of the invention. In particular the sulfur-impregnated particulate solid material can be utilised will all possible compositions of the invention as set out above.
DETAILED DESCRIPTION
[0414] It should be readily apparent to one of ordinary skill in the art that the examples disclosed herein below represent generalised examples only, and that other arrangements and methods capable of reproducing the invention are possible and are embraced by the present invention.
EXAMPLES
[0415] Prebaking occurs when a metal part coated with a bonding agent (for example in bonding a rubber to metal assembly) is exposed to high temperatures (>160° C.) prior to vulcanization of the rubber. When the rubber to metal bonding agent contains as part of its composition a chlorinated polyolefin and in particular a chlorinated polyethylene with high chlorine content, poor bonding strengths can be observed after this prebaking process. By the inclusion of film former component of the present invention, for example, isocyanates, either free, blocked or a combination of both, epoxy resin or a phenolic resin, prebaked bond strengths are significantly increased.
[0416] When chlorinated polyolefin is removed completely from the formulation, and replaced by the film former component of the invention, a robust, tack free coating may be produced. Polymers resins containing hydroxyl groups such as polyvinyl butyral and cellulose acetate butyrate have been used herein. The addition of the film former component of the present invention, to formulations containing such polymers significantly increases bond strengths.
[0417] Other methods to solve the prebaked bond issues have been to completely remove or replace the chlorinated polyolefin from the system, which may lead to decreased bond performance and so the film former component of the invention provides an excellent alternative.
Rubber to Metal Bond Testing
[0418] Bonded parts were pulled to destruction according to WDK (Association of German Rubber Manufacturing Industry) Guideline 2000 (Assessment of Rubber to Metal Bonding Agents for NVH Applications) outlined below. To test the performance of the bonds produced by the compositions of the invention, P-25 buffer parts are used, which are part of the ASTM-D429-Method F testing procedure.
[0419] Examples of compositions comprising the film former of the present invention.
Example 1
[0420]
[0000]
3699-056
Input:
%
Nitrososilane
8
BSU
1.5
DER 669E
1.5
Silica (Cabosil TS-720)
1.5
PVB (Butvar 72A)
2
Carbon Black (HGD4S)
2.5
Ethyl acetate
83
100
Initial Strength
8.3 MPa
5 minute Pre-bake
8.8 MPa
Strength
Bond Testing according to WDK Standard
PVB = Poly vinyl butyral
BSU = N,N-bis(3-Trimethoxysilylpropyl)urea
DER-669E = High mw solid epoxy resin (Dow)
Example 2
[0421]
[0000]
3699-062
Input:
%
Nitrososilane
8
DER-669E
1.5
BSU
1.5
Silica (Cabosil TS-720)
2
PVB (Mowital B30H)
1.5
Carbon Black (HGD4S)
2.5
CXC-1612
0.1
Ethyl acetate
82.9
100
Initial Bond Strength
9.1 Mpa
5 minute Pre-bake Strength
9.2 MPa
Bond Testing according to WDK Standard
PVB = Poly vinyl butyral
BSU = N,N-bis(3-Trimethoxysilylpropyl)urea
CXC-1612 = Ammonium hexafluoroantimonate (King Industries)
DER-669E = High mw solid epoxy resin (Dow)
Example 3
[0422]
[0000]
3699-072
Input:
%
Nitrososilane
8
BSU
1.5
DER 669-E
1.5
PVB (Mowital B60HH)
2
Silica (Cabosil TS-)720
1.5
Carbon Black (HGD4S)
2.5
CXC-1612
0.01
Ethyl acetate
82.99
100
Initial Strength
8.1 MPa
5 minute Pre-bake Strength
9.8 MPa
Bond Testing according to WDK Standard
PVB = Poly vinyl butyral
BSU = N,N-bis(3-Trimethoxysilylpropyl)urea
CXC-1612 = Ammonium hexafluoroantimonate (King Industries)
DER-669E = High mw solid epoxy resin (Dow)
Example 4
[0423]
[0000]
3699-101
Input:
%
Nitrososilane
8
BSU
1.5
DER 669-E
1.5
PVB (Mowital B30H)
2
Silica (CabosilTS-720)
1.5
Carbon Black (HGD4S)
2.5
NH 4 PF 6
0.1
Ethyl acetate
82.9
100
Initial Strength
10.2 MPa
5 minute Pre-bake Strength
9.3 MPa
Bond Testing according to WDK Standard
PVB = Poly vinyl butyral
BSU = N,N-bis(3-Trimethoxysilylpropyl)urea
DER-669E = High mw solid epoxy resin (Dow)
Example 5
[0424]
[0000]
3640-102
Input:
%
Nitrososilane
8
BSU
1.5
Methylon 75-108
1.5
PVB (Mowital 60T)
1
Silica (Aerosil 200)
1.5
Carbon Black (HGD4S)
2.5
NaSbF 6
0.1
Ethyl acetate
63.9
Isopranol
20
100
Initial Strength
9.9 MPa
5 minute Pre-bake Strength
10.8 MPa
Bond Testing according to WDK Standard
PVB = Poly vinyl butyral
BSU = N,N-bis(3-Trimethoxysilylpropyl)urea
Methylon 75-108 = Phenol Formaldehyde Resin
[0425] All parts are % weight by weight of the composition. *All parts are parts by weight
Example 6
[0426]
[0000]
3729-24
Input:
%
Ethyl acetate
56.7
IPA
20
DNB (30% wt. soln. in xylene)
16.7
Carbon Black (HGD4S)
2.5
Methylon 75108
1.5
Silica (Aerosil 200)
1.5
PVB (Mowital 60T)
1
NaSbF6
0.1
100
Initial Strength
5.7 MPa
5 minute Pre-bake Strength
6.1 MPa
Bond Testing according to WDK Standard
PVB = Poly vinyl butyral
Example 7
[0427]
[0000]
3634-9
Input:
%
Xylene
70
HPE1305
10
Ethyl Acetate
8
Nitrososilane
8
Carbon Black (CK3)
2.5
BSU
1.5
100
Initial Strength
2.2 MPa
5 minute Pre-bake Strength
1.5 MPa
HPE1305 = Chlorinated Polyethylene
Example 8
[0428] With polyvinyl butyral: General improvement in bond strengths by the inclusion of an isocyanate
[0000]
3705-26
%
%
Input:
A
B
Nitrososilane
8
8
BSU
1.5
1.5
Carbon Black (HGD4S)
2.5
2.5
Silica (Cabosil TS-720)
1.5
1.5
PVB (Mowital B60HH)
2
2
Desmodur XP2714
0
2
Ethyl Acetate
84.5
82.5
100
100
Initial Strength
5.1 MPa
7.2 MPa
5 minute Pre-bake Strength
7.6 MPa
9.5 MPa
Bond Testing according to WDK Standard
PVB = Poly vinyl butyral
BSU = N,N-bis(3-Trimethoxysilylpropyl)urea
Example 9
[0429] With cellulose acetate butyrate: General improvement in bond strengths by the inclusion of an isocyanate.
[0000]
3705-43
%
%
Input:
A
B
Nitrososilane
8.0
8.0
BSU
1.5
1.5
Carbon Black (HGD4S)
2.5
2.5
Silica (Aerosil 200)
1.5
1.5
CAB 381-20
2.0
2.0
Desmodur XP2714
0.0
2.0
Ethyl Acetate
19.5
24.2
Xylene
65.0
58.3
100.0
100.0
Initial Strength
4.4 MPa
9.1 MPa
5 minute Pre-bake Strength
6.5 MPa
9.3 MPa
Bond Testing according to WDK Standard
PVB = Poly vinyl butyral
BSU = N,N-bis(3-Trimethoxysilylpropyl)urea
CAB = Cellulose Acetate Butyrate
[0430] Addition of isocyanates (such as Desmodur XP2714 to formulations of a rubber to metal bonding agent that contains
1) a hydroxyl functional polymer such as Mowital B60HH or Eastman CAB 381-20 (PCAB) 2) the nitrososilane molecule defined herein (and see WO2009/118255) significantly increases bond performance, by crosslinking as shown in Examples 8&9
Components Used
Polyisocyanate
[0433] Description: Silane functional polyisocyanate with allophanate structure based on hexamethylene diisocyanate; Form: 100% solids; NCO content: approx 16%. Desmodur XP2714:Supplied from Bayer Material Science
Cellulose Acetate Butyrate Polymer
[0434] Cellulose acetate butyrate polymer used in the present invention contains: Hydroxyl content—0.5-5 wt %, Acetyl content—1-30, Butyryl content—15-65 wt %. A preferred grade, CAB381-20, is supplied by Eastman.
Poly Vinyl Butyral (PVB) Polymer
[0435] Average molar mass of PVB polymers: ˜12,000-100,000. Suitable PVB grades include:
[0000]
Content of polyvinyl
Content of polyvinyl
Grade
alcohol 1)
acetate 2)
Mowital B 16 H
18-21
1-4
Mowital B B20 H
18-21
1-4
Mowital B 30 T
24-27
1-4
Mowital B 30 H
18-21
1-4
Mowital B 30 HH
11-14
1-4
Mowital B 45 M
21-24
1-4
Mowital B 45 H
18-21
1-4
Mowital B 60 T
24-27
1-4
Mowital B 60 H
18-21
1-4
Mowital B 60 HH
12-16
1-4
Mowital B 75 H
18-21
0-4
1) Hydroxyl groups in terms of polyvinyl alcohol
2) Acetyl groups in terms of polyvinyl acetate
[0436] A number of preferred grades of PVB is supplied by Kuraray. One example of a preferred grade of PVB suitable for use in the compositions of the present invention, contains as co-polymers: Polyvinyl Alcohol content: 12-16% and Polyvinyl Acetate content: 1-4%.
Sulfur Impregnated Particulate Solids & Testing
[0437] The sulfur impregnated particulate solid that can be used are sulfur impregnated powered activated carbons or sulfur impregnated powered charcoals.
[0438] A first example of a suitable material is Desorex DY 700 S (Donau Carbon). This is a steam activated powdered carbon, based on selected grades of coal. The activated carbon is impregnated with sulfur in a special, thermal production process and has a good adsorption capacity.
[0000]
Desorex DY 700 S
Impregnation (wt %)
Ca. 1
Moisture content (wt %)
Iodine adsorption (mg/g)
>700
Total surface area (m2/g)
approx. 700
(BET-method)
Granulation (%)
Min. 85
(<300 mesh)
[0439] A second example of a suitable material is Desorex HGC 8×16 S, which is a granular S impregnated activated carbon which is based on coconut shells. The material can be used for the removal of mercury from flue gas, natural gas or other waste gases.
[0000]
Desorex HGC 8 × 16 S
Specifications:
Impregnation (wt %)
approx. 10
Bulk density (kg/m 3 )
500 ± 30
Moisture content (wt %)
<10
(as packed)
Granulation (mesh)
8 × 16
Product data before impregnation:
Total surface area (m 2 /g)
approx. 1000
(BET-method)
CTC-adsorption (wt %)
>60
[0440] A third example of a suitable material is Desorex HGD 4S, which is a sulfur impregnated carbon based on coal. A special thermal impregnation process guarantees a high filtration efficiency and long life time of the activated carbon. Desorex HGD 4S is produced, based on a high activated carbon and has a high adsorption capacity for mercury as well as for organic impurities.
[0000]
Desorex HGD 4 S
Specifications:
Impregnation (wt %)
min. 10
Bulk density (kg/m 3 )
560 ± 30
Moisture content (wt %)
<10
(as packed)
pH - value
approx. 3
Diameter of particles (mm)
approx. 4
Product data before impregnation:
Total surface area (m 2 /g)
1000
(BET-method)
Iodine adsorption (mg/g
950
CTC-adsorption (wt %)
>60
[0441] CK3 (CAS RN 1333-86-4), is a carbon black for application which is used as a reinforcing filler in rubber compounds. The CK 3 used herein is an industrially produced carbon black. CK 3 is a gas black which imparts considerable scorch safety to rubber compounds by delaying the onset of cure.
[0000]
CK 3 (Carbon Black)
Specifications:
CTAB surface
m 2 /g
88
ASTM
area
D 3765
Tint strength
%
116
ASTM
(IRB = 100)
D 3265
OAN
ml/100 g
104
ASTM
D 2414
pH value
3.5
ISO
787/9
Ash content
%
0.05
ASTM
D 1506
Heating loss
%
1.5
ASTM
at packing
D 1509
Sieve residue
ppm
10
ASTM
325 mesh
D 1514
Pour density
g/dm 3
350
ASTM
D 1513
[0442] The BET surface area of the Desorex and CK3 grades are: Desorex HGC 8×16S=total surface area before impregnation with sulfur approx 1000 m 2 /g (from TDS); Desorex HGD-4S=total surface area before impregnation with sulfur 1000 m 2 /g (from TDS); Desorex DY700S=approx 700 m 2 /g (from TDS); Carbopal MB4S(Sulfur free activated carbon for control experiments)=900 m 2 /g (from TDS); and CK3=88 m 2 /g (from TDS via the CTAB test method, which has been superseded by the BET ASTM test).
[0443] Examples of the sulfur impregnated carbon compared to a standard carbon black particle (CK3).
[0000]
Different carbons
A
B
C
D
Nitrososilane
8
8
8
8
Ethyl acetate
8
8
8
8
BSU
0.3
0.3
0.3
0.3
Glymo
0.9
0.9
0.9
0.9
Superchlon HE1200
10
10
10
10
CK3
2.5
0
0
0
Desorex HGC
0
2.5
0
0
Desorex HGD-4S
0
0
2.5
0
Desorex DY700S
0
0
0
2.5
Xylene
70.3
70.3
70.3
70.3
initial
8.1
8.4
9.5
10.8
steam
5
9.5
9.1
8.5
[0444] Examples of different grades of chlorinated polymers with a sulfur impregnated carbon. The grades HPE1515, Superchlon HE1200 and HPE2200H all contain >65% chlorine content. The molecular weights are between 50 and 150,000 g/mol.
[0000]
Different chlorinated
polymers with a Sulfur
impregnated carbon
F
G
H
Nitrososilane
8
8
8
Ethyl acetate
8
8
8
BSU
0.3
0.3
0.3
Glymo
0.9
0.9
0.9
Superchlon HE1200
10
0
0
HPE1515
0
10
0
HPE2200H
0
0
10
Desorex HGC 8 × 16 s
2.5
2.5
2.5
Xylene
70.3
70.3
70.3
initial
8.4
8.7
6.8
steam
9.5
3.9
5.5
CONCLUSION
[0445] The bond strength results indicate that use of curable compositions comprising the film former component of the present invention, that is a non-halogenated hydroxylated resin and a suitable crosslinking agent, in combination with a nitroso-containing material, shows a demonstrable increase in bond performance in both initial and 5-minute pre-bake testing. In particular the pre-bake results demonstrate superior performance of the film former system of the invention. The robustness of this film former in curable compositions means the compositions can be applied to a substrate prior to transport or storage so that they are ready to use as requires and do not display any reduced bond quality on cure.
[0446] As described above, the film former of the invention has tailorable properties depending on the nature of the non-halogenated hydroxylated resin and a suitable crosslinking agent chosen for a given application, cure and operating conditions.
[0447] Inclusion of a sulfur impregnated particulate solid into these compositions is advantageous from the point of view that increase bond durability and resistance is improved post cure.
|
There is provided a curable composition comprising one or more reactive components that cure upon exposure to suitable conditions, the curable composition comprising:
(i) at least one aromatic nitroso or at least one aromatic nitroso precursor compound or combinations thereof; and (ii) a film former component comprising at least one non-halogenated hydroxy group-containing resin together with at least one crosslinking agent.
| 2
|
RELATED APPLICATION
This is a divisional application of application Ser. No. 404,071 as filed Oct. 5, 1973, now U.S. Pat. No. 4,033,947.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide new compounds which are useful as central nervous system depressants, tranquilizers, sedatives and muscle relaxants. Another object is to provide methods for the preparation of these compounds. Another object is to provide compositions for the administration of the compounds of the invention. These and other objects of the present invention will be apparent from the following description.
SUMMARY OF THE INVENTION
It has now been found that 1H-s-triazolo[4,3-a][1,5]benzodiazepin-1,5(6H)-diones of the following formula ##STR3## are useful CNS depressants, tranquilizers, sedatives, and muscle relaxants in mammalian species.
DETAILED DESCRIPTION
The novel 1H-s-triazolo[4,3-a][1,5]benzodiazepin-1,5(6H)-diones of formula 1 are useful CNS depressants, tranquilizers and sedatives. The compounds of formulas 3-12, and the novel compounds of formula 7 are intermediates for the compounds of formula 1. ##STR4## In the foregoing formulas R 1 is H; alkyl of 1-3 carbons optionally substituted by amino, by mono-alkyl wherein the alkyl radical contains 1-3 carbons, by dialkylamino wherein the alkyl radicals contain 1-3 carbons, by phenyl wherein the phenyl ring is optionally substituted by one or more D groups wherein D is as defined below; or phenyl wherein the phenyl ring is optionally substituted by one or more D groups wherein D is as defined below;
R 2 is H, alkyl of 1-3 carbons, hydroxy or acyloxy (1-4 carbons).
X and Y can be the same or different and are hydrogen, F, Cl, Br, trifluromethyl, alkyl of from 1-4 carbons, alkoxy of from 1-4 carbons, nitro, cyano, amino, alkanoylamino of 1-4 carbons, alkylthio of 1-4carbons, alkylsulfinyl of 1-4 carbons or alkyl sulfonyl of 1-4 carbons;
D can be alkyl of 1-3 carbons; halogen, preferably bromine and chlorine; trifluoromethyl; alkoxy of 1-3 carbons; and nitro.
R 4 is alkyl of 1-3 carbons optionally substituted by amino, monalkylamino of 1-3 carbons, dialkylamino of 1-3 carbons, and phenyl wherein the phenyl ring is optionally substituted by one or more groups as defined for D.
R 3 is alkyl of from 1-4 carbons, benzyl or phenethyl;
n is 0, 1 or 2;
R 5 is a group of formula ##STR5## where P and Q may be the same or different and may be hydrogen or phenyl optionally substituted by one or more groups as defined for D, with the proviso that at least one of P and Q is aryl.
R 6 is alkyl of 1-4 carbons optionally substituted by phenyl.
SYNTHESIS
The 1H-s-triazolo[4,3-a][1,4]benzodiazepin-1,5(6H)-diones of formula 1 can be prepared by several methods.
One method (hereinafter called the first method) for the synthesis of compounds wherein R' is hydrogen involves reacting a compound of formulas 3-6 with from about 0.8 to about 6.0, preferably from about 1.0 to about 3.0 molar equivalents of an alkyl carbazate of formula ##STR6## (where R 6 is as defined previously) either along or, preferably, in an inert, organic solvent or mixture of solvents. Typical organic solvents which may be used in the above reaction include aryl hydrocarbons, e.g., benzene, toluene, xylene and the like; chlorinated hydrocarbons such as di-, tri-, tetrachloroethanes and the like; lower molecular weight alkanols of 1-4 carbons such as ethanol, tertiary butyl alcohol, n-butanol and the like; N,N-dialkylformamides, N,N-dialkylalkanoyl amides wherein the alkyl and alkanoyl radicals have 1-4 carbons, such as dimethylformamide, dimethylacetamide and the like; hexamethylphosphorous triamide, ethers, such as dioxane and the like and di-lower alkyl sulfoxides, such as dimethyl sulfoxide and the like. The reaction is carried out at from about 40° C to about 320° C, preferably from about 80° C to about 250° C, until a significant amount of end product is obtained, typically, for from about 1/4 to about 92 hours, preferably from about 1 to about 48 hours.
The final product of formula 1 wherein R' is hydrogen is isolated by conventional techniques. For example, the reaction mixture is evaporated and the residue is partitioned between aqueous sodium bicarbonate and a water-immiscible inert, organic solvent, such as halogenated hydrocarbons, e.g., methylene chloride, chloroform or trichloroethylene; alkyl esters wherein both the acid and alcohol from which the ester is derived may have from 1 to 4 carbon atoms, e.g., ethyl acetate, propyl acetate, ethyl propionate and the like. The organic solvent is washed with water, dried and chromatographed.
Another method for the synthesis of compounds of formula 1 wherein R' is hydrogen involves heating compounds of formula 7 either alone or in an inert, organic solvent at from about 60° C to about 350° C, preferably from about 80° C to about 300° C for from about 1/2 to about 72 hours, preferably from about 1/6 to about 12 hours. Typical inert, organic solvents that are used are those defined in the first method. The products are isolated by conventional techniques. For example, the reaction is diluted with a water-immiscible, inert, organic solvent, washed with water, dried and chromatographed.
Another method (hereinafter called the third method) of synthesis for compounds of formula 1 wherein R' is hydrogen involves reacting compounds of formula 8 with from about 0.8 to about 6, preferably from about 1 to about 3, molar equivalents of acyl derivatives of formula ##STR7## (where W is --OR 6 or halogen, preferably chlorine or bromine), in the presence of a tertiary amine base in an optional inert organic solvent. Typical inert organic solvents which may be used include aryl hydrocarbons such as benzene, toluene, xylene and the like; chlorinated hydrocarbons such as tri- and tetrachloroethanes and the like; ethers such as 1,2-dimethoxyethane, tetrahydrofuran, dioxane and the like; N,N-dialkylformamides and N,N-dialkyl alkanoylamides wherein the alkyl and alkanoyl radicals have 1-4 carbons such as dimethylformamide, dimethylacetamide and the like. Typical tertiary bases include pyridine and the like and triethylamine and the like. The reaction conditions and the isolation of the products are as described in the first method.
Compounds of formula 1 where R' is alkyl of 1-3 carbons substituted by amino, by mono-alkylamino of 1-3 carbons, by di-alkylamino of 1-3 carbons or by phenyl optionally substituted by one or more D groups, are prepared by reacting compounds of formula 1 where R' is hydrogen with from about 0.5 to about 12, preferably from about 0.8 to about 1.2 molar equivalents of an appropriate base, followed by reaction of the thus formed salt with a corresponding molar equivalent of an appropriate substituted alkylating agent of formula R 4 --M where R 4 is as defined previously and M is halogen, preferably chlorine, bromine, iodine; ##STR8## or an alkyl or arylsulfonate of formula ##STR9## where R 7 can be alkyl of 1-6 carbons or aryl of from about 6 to 10 carbons optionally substituted by halogen, nitro or alkyl of 1 to 3 carbons, or R 4 --M may be any other alkylating agent (within the definition of R 4 ) capable of introducing a group as defined for R 4 . The reaction is run in an essentially inert organic solvent.
Typical bases include alkali metal (preferably sodium and potassium) salts as well as thallous salts of lower molecular weight alkanols of 1-6 carbons such as methanol, ethanol, propanol, isopropal, t-butanol, amyl alcohol and the like; alkali metal (preferably sodium) hydrides; alkali metals (preferably sodium and potassium); alkali metal (preferably sodium and potassium) salts of acidic hydrocarbons such as triphenylmethane and the like as well as any other base known to those skilled in the art capable of generating salts of the acidic hydrogen of the triazole ring in compounds of formula 1 wherein R' is hydrogen. Typical organic solvents include those described in the first method.
The reaction is carried out at from about 20° C to about 300° C, preferably from about 0° C to about 100° C for from about 0.2 hour to about 96 hours, preferably from about 0.5 hour to about 72 hours.
The products are isolated by conventional techniques. For example the reaction mixture is evaporated; the residue is diluted with a water-immiscible, inert solvent such as methylene chloride, washed with water, dried and chromatographed.
Compounds of formula 1 wherein R' is phenyl or substituted phenyl can be prepared by reacting compounds of formula 1 wherein R' is hydrogen with at least from about 0.5 to a large excess, preferably at least from about 0.8 to about 100, molar equivalents of a phenyl halide, in the presence of a copper catalyst, in an optional solvent containing from about 0.5 to about 1000, preferably from about 0.8 to about 100, molar equivalents of an appropriate hydrogen halide acceptor. The preferred phenyl halides are those of formula AR--K where AR is phenyl optionally substituted by one or more groups as defined for D and where K is preferably chlorine, bromine or iodine. The preferred copper catalysts are powdered copper metal, copper oxides and cuprous and cupric salts. Optional solvents include N,N-dialkylformamides and N,N-dialkyl alkanoyl amides wherein the alkyl and alkanoyl radicals have 1-4 carbons such as N,N-dimethylformamide, N,N-dimethylacetamide and the like; dialkyl sulfoxides of 2-6 carbons such as dimethyl sulfoxide and the like; and alkylphosphorous triamides of 4-10 carbons such as hexamethylphosphorous triamide. Appropriate hydrogen halide acceptors include alkali metal (preferably sodium or potassium) carbonates, bicarbonates, or lower alkyl carboxylic acid salts thereof (e.g., acetates). The reaction is carried out at from about 50° C to about 200° C, preferably at from about 90° C to about 180° C, for from about 1/4 to about 72 hours, preferably for from about 1/2 to about 14 hours. The product is isolated in a conventional manner. For example, the reaction mixture is diluted with methylene chloride, washed with dilute aqueous ammonium hydroxide and chromatographed.
Compounds of formula 1 where R 2 is hydroxy are prepared by reacting compounds of formula 9 with hydrogen in the presence of an appropriate catalyst, in an inert organic solvent. Typical catalysts include platinum, Raney nickel and, preferably, palladium
Typical solvents include lower alkanols of 1-4 carbons such as methanol, ethanol, and the like; formic acid; lower alkanoic acids of 2-5 carbons such as acetic acid and the like as well as other typical solvents well known to those versed in the art. Typical hydrogenation pressures are from about 0.1 to about 2000 atmospheres, preferably from about 0.8 to about 100 atmospheres. The reactions are carried out for from about 1/2 to about 96 hours, preferably from about 1 to about 72 hours at from about 0° C to about 200° C, preferably from about 20° C to about 120° C. The products are isolated in a conventional manner. For example the catalyst is filtered off, the solvent evaporated and the product chromatographed.
Compounds of formula 1 wherein R 2 is acyl of 1-4 carbons are prepared by reacting compounds of formula 1 wherein R 2 is hydroxy with from about 0.8 to about 6, preferably from about 1 to about 3, molar equivalents of acyl derivatives of formula ##STR10## (where R 8 is alkyl of from 1-3 carbons and W is halogen, preferably chlorine or bromine or ##STR11## either alone or optionally in an inert organic solvent, in the optional presence of a tertiary amine. Typical inert organic solvents which may be used include aryl hydrocarbons such as benzene, toluene, xylene and the like; chlorinated hydrocarbons such as tri- and tetrachlorethanes and the like; ethers such as 1,2-dimethoxyethane, tetrahydrofuran, dioxane and the like; N,N-dialkylformamides and N,N-dialkyl alkanoylamides wherein the alkyl and alkanoyl radicals have 1-4 carbons such as dimethylformamide, dimethylacetamide and the like. Typical tertiary amines include heterocyclic amines such as pyridine and the like and trialkyl amines wherein each alkyl radical has from 1-4 carbon atoms such as triethylamine and the like. The reaction conditions and the isolation of the products are as described in the first method.
Compounds of formula 7 are prepared by reacting compounds of formulas 3-6 with from about 0.8 to about 6.0, preferably with from about 1 to about 3, molar equivalents of an alkyl carbazate of formula ##STR12## in an inert organic solvent. Typical solvents include alkanols of 1-4 carbons such as methanol, ethanol, t-butanol, n-butanol and the like; aromatic hydrocarbons such as benzene, toluene, xylene and the like; chlorinated hydrocarbons such as methylene chloride, chloroform, di-, tri- and tetrachloroethane and the like; ethers such as tetrahydrofuran, dioxane, 1,2-dimethoxyethane and the like; N,N-dialkylformamides, N,N-dialkyl alkanoyl amides wherein the alkyl and alkanoyl radicals have from 1-4 carbons, such as N,N-dimethyl formamide, N,N-dimethylacetamide and the like; hexamethylenephosphorous triamide and dimethyl sulfoxide. The reaction is carried out at from about -30° C to about 160° C preferably at from about 30° C to about 120° C, until a significant amount of end product is obtained, for from about 1/2 to about 96 hours, preferably for from about 2 to about 12 hours. The products of formula 7 are isolated by conventional techniques. For example, the reaction is diluted with a water-immiscible inert organic solvent, washed with water, dried and chromatographed.
Another method for the synthesis of compounds of formula 7 involves reacting compounds of formula 8 with from about 0.5 to about 6, preferably from about 0.8 to about 1.2, molar equivalents of acyl derivatives of formula ##STR13## (where W is as defined previously) in an optional inert organic solvent, in the optional presence of a tertiary amine.
Typical tertiary amines include heterocyclic amines such as pyridine and the like and trialkylamines such as triethylamine and the like.
Typical inert organic solvents include those described for the third method.
The reaction is carried out at from about -30° C to about 150° C, preferably from about 0° C to about 80° C for from about 1/4 hour to about 72 hours, preferably from about 1/2 hour to about 14 hours.
The products of formula 7 are isolated by conventional techniques as, for example, described in the first method.
The starting materials of formulas 3-6 and 8 are described in patent application Ser. No. 365,012 and references cited therein.
The novel compounds of formula 1 are CNS depressants and are useful as, for example, sedatives, tranquilizers and muscle relaxants in mammalian species, e.g., rats, mice and monkeys. Thus, for example, oral administration of a compound of the invention produces ataxia dosage levels of from about 50 to about 200 mg/kg, specifically in rats at about 100 mg/kg.
The compounds of the present invention produce decreased grip strength at a dosage level of from about 5 to about 50 mg/kg, specifically at a dosage level of about 12 mg/kg when administered orally to rats.
The compounds of the present invention have a tranquilizing effect when administered orally at a dosage level of from about 2 to about 25 mg/kg, specifically at a dosage level of about 12 mg/kg when administered via the oral route to rats in a conflict test procedure [cf. J. R. Vogel, B. Beer, D. Clody, Psychopharmacologist 21, 1 (1970)].
The compounds of the present invention in the described dosages may be administered orally; however, other routes such as intraperitoneally, subcutaneously, intramuscularly or intravenously may be employed.
The active compounds of the present invention are orally administered, for example, with an inert diluent or with an assimilable edible carrier, or they may be enclosed in hard or soft gelatin capsules, or they may be compressed into tablets, or they may be incorporated directly with the food of the diet. For oral therapeutic administration, the active compounds of this invention may be incorporated with excipients and used in the form of tablets, troches, capsules, elixirs, suspensions, syrups, wafers, chewing gum, and the like. The amount of active compound in such therapeutically useful compositions or preparations is such that a suitable dosage will be obtained.
The tablets, troches, pills, capsules and the like may also contain the following: a binder such as gum tragacanth, acacia, corn starch or gelatin; an excipient such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid and the like; a lubricant such as magnesium stearate; and a sweetening agent such as sucrose, lactose or saccharin may be added or a flavoring agent such as peppermint, oil of wintergreen, or cherry flavoring. When the dosage unit form is a capsule, it may contain in addition to materials of the above type a liquid carrier such as a fatty oil. Various other materials may be present as coatings or to otherwise modify the physical form of the dosage unit, for instance, tablets, pills or capsules may be coated with shellac, sugar, or both. A syrup or elixir may contain the active compounds, sucrose as a sweetening agent, methyl and propyl parabens as preservatives, a dye and a flavoring such as cherry or orange flavor. Of course, any material used in preparing any dosage unit form should be pharmaceutically pure and substantially non-toxic in the amounts employed.
In the following examples all reactions are run under an inert atmosphere (e.g., argon), at room temperature, using anhydrous solvents unless otherwise indicated; in addition, reactions which are heated are subsequently cooled to room temperature for work-up. In general, solvents are evaporated in a rotary flash vacuum apparatus. In this patent application, the full name of the parent ring system of compounds described as indicated in Column I below is as indicated in Column II.
______________________________________ I II______________________________________"---1H-s-triazolo[4,3-a][1,5]- "---2,4,5,6-tetrahydro-1H-s-benzodiazepine-1,5-dione---" triazolo[4,3-a][1,5]- benzodiazepine-1,5-dione---""---1H-1,5-benzodiazepin---" "---2,3,4,5-tetrahydro-1H- 1,5-benzodiazepin---""---3H-1,5-benzodiazepin---" "---4,5-dihydro-3H-1,5- benzodiazepin---"______________________________________
EXAMPLE 1
8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione
Method A
30.2 g of 7-chloro-5-phenyl-1H-1,5-benzodiazepin-4-one-2-thione and 33.4 g of ethyl carbazate in 600 ml dimethylformamide are refluxed with stirring for 24 hours. During this time, argon is bubbled through the reaction mixture. The reaction is evaporated in vacuo and the title compound is obtained as described in Example 1, Method B.
Method B
7.50 g of 2-(methylthio)-7-chloro-5-phenyl-3H-1,5-benzodiazepin-4-one and 6.27 g of ethyl carbazate are refluxed in dry dimethylformamide (300 ml) while a slow stream of argon is passed through. After 24 hours, the reaction mixture is evaporated to dryness, azeotroped with benzene and triturated with water (25 ml). The precipitates that formed are filtered off and dried. This material is chromatographed on a florisil column (10 g) eluting successively with methylene chloride (60 ml), CH 2 Cl 2 :EtOAc (6:4, 90 ml) and ethyl acetate (75 ml). The fractions containing the product are combined and evaporated to give the title compound. The product is recrystallized from ethyl acetate-hexane.
Method C
3.0 g of 2,7-dichloro-5-phenyl-3H-1,5-benzodiazepin-4-one and 2.5 g of ethyl carbazate in 50 ml of dioxane are refluxed under argon for 24 hours. 2 ml of water is then added, the reaction stirred for 1 hour and the solvent evaporated. The residue is taken up in methylene chloride, washed with dilute aqueous sodium bicarbonate, with water and dried. The solvent is evaporated and the residue is chromatographed on 10-1000μ silica gel thick layer plates (20 × 20 cm) with ethyl acetate-ethanol (9:1) as eluant. The main band, having an approximate Rf range of 0.12-0.28, is removed, stirred with acetone-methanol (9:1) and the silica gel filtered off. The filtrate is evaporated to give the title compound.
Method D
Following the procedure of Example 1, Method B, but substituting 15 g of 2-methoxy-7-chloro-5-phenyl-3H-1,5-benzodiazepin-4-one for 15.8 g of 2-(methylthio)-7-chloro-5-phenyl-3H-1,5-benzodiazepin-4-one in Example 1, Method B, the title compound is obtained.
Method E
3 g of 3-(7-chloro-5-phenyl-3H-1,5-benzodiazepin-4-one-2-yl) carbazic acid ethyl ester is heated at approximately 50° C above its melting point under argon for 25 minutes. The reaction is cooled, dissolved in methylene chloride and purified by column chromatography as described under Method B above to give the title compound.
EXAMPLES 2-27
Following the procedure of Example 1, Method B, but substituting the compounds indicated in Column I below for 2-(methylthio)-7-chloro-5-phenyl-3H-1,5-benzodiazepin-4-one in Example 1, Method B, the compounds indicated in Column II are obtained.
______________________________________ I II______________________________________ 2. 2-(methylthio)-5-phenyl-3H- 6-phenyl-1H-s-triazolo- 1,5-benzodiazepin-4-one [4,3-a][1,5]-benzodiazepine- 1,5-dione 3. 2-(methylthio)-7-trifluoro- 8-(trifluoromethyl)-6-phenyl- methyl-5-phenyl-3H-1,5- 1H-s-triazolo[4,3-a][1,5]- benzodiazepin-4-one benzodiazepine-1,5-dione 4. 2-(methylthio)-7-nitro-5- 8-nitro-6-phenyl-1H-s- phenyl-3H-1,5-benzodia- triazolo[4,3-a][1,5]- zepin-4-one benzodiazepine-1,5-dione 5. 2-(methylthio)-7-methyl-5- 8-methyl-6-phenyl-1H-s- phenyl-3H-1,5-benzodia- triazolo[4,3-a][1,5]- zepin-4-one benzodiazepine-1,5-dione 6. 2-(methylthio)-7-methoxy- 8-methoxy-6-phenyl-1H-s- 5-phenyl-3H-1,5-benzodia- triazolo[4,3-a][1,5]benzo- zepin-4-one diazepine-1,5-dione 7. 2-(methylthio)-7-(methyl- 8-(methylthio)-6-phenyl- thio)-5-phenyl-3H-1,5- 1H-s-triazolo[4,3-a][1,5]- benzodiazepin-4-one benzodiazepine-1,5-dione 8. 2-(methylthio)-7-pentyl-5- 8-pentyl-6-phenyl-1H-s- phenyl-3H-1,5-benzodia- triazolo[4,3-a][1,5]benzo- zepin-4-one diazepine-1,5-dione 9. 2-(methylthio)-7-pentoxy- 8-pentoxy-6-phenyl-1H- 5-phenyl-3H-1,5-benzodia- s-triazolo[4,3-a][1,5]- zepin-4-one benzodiazepine-1,5-dione10. 2-(methylthio)-7-bromo-5- 8-bromo-6-phenyl-1H-s- phenyl-3H-1,5-benzodia- triazolo[4,3-a][1,5]benzo- zepin-4-one diazepine-1,5-dione11. 2-(methylthio)-7-fluoro- 8-fluoro-6-phenyl-1H- 5-phenyl-3H-1,5-benzodia- s-triazolo[4,3-a][1,5]- zepin-4-one benzodiazepine-1,5-dione12. 2-(methylthio)-7-cyano- 8-cyano-6-phenyl-1H- 5-phenyl-3H-1,5-benzodia- s-triazolo[4,3-a][1,5]- zepin-4-one benzodiazepine-1,5-dione13. 2-(ethylthio)-7-chloro- 8-chloro-6-phenyl-1H- 5-phenyl-3H-1,5-benzodia- s-triazolo[4,3-a][1,5]- zepin-4-one benzodiazepine-1,5-dione14. 2-(methylthio)-7-chloro- 8-chloro-6-(2-fluorophenyl)- 5-(2-fluorophenyl)-3H- 1H-s-triazolo[4,3-a][1,5]- 1,5-benzodiazepin-4-one benzodiazepine-1,5-dione15. 2-(methylthio)-7-chloro- 8-chloro-6-(3-chlorophenyl)- 5-(3-chlorophenyl)-3H- 1H-s-triazolo[4,3-a][1,5]- 1,5-benzodiazepin-4-one benzodiazepine-1,5-dione16. 2-(methylthio)-7-chloro- 8-chloro-6-(4-chlorophenyl)- 5-(4-chlorophenyl)-3H- 1H-s-triazolo[4,3-1][1,5]- 1,5-benzodiazepin-4-one benzodiazepine-1,5-dione17. 2-(methylthio)-7-chloro- 8-chloro-6-(2-methoxyphenyl)- 5-(2-methoxyphenyl)-3H- 1H-s-triazolo[4,3-a][1,5]- 1,5-benzodiazepin-4-one benzodiazepine-1,5-dione18. 2-(methylthio)-7-chloro- 8-chloro-6-(3-methoxyphenyl)- 5-(3-methoxyphenyl)-3H- 1H-s-triazolo[4,3-a][1,5]- 1,5-benzodiazepin-4-one benzodiazepine-1,5-dione19. 2-(methylthio)-7-chloro- 8-chloro-6-(2-methylphenyl)- 5-(2-methylphenyl)-3H- 1H-s-triazolo[4,3-a][1,5]- 1,5-benzodiazepin-4-one benzodiazepine-1,5-dione20. 2-(methylthio)-7-chloro- 8-chloro-6-(3-methylphenyl)- 5-(3-methylphenyl)-3H- 1H-s-triazolo[4,3-a][1,5]- 1,5-benzodiazepin-4-one benzodiazepine-1,5-dione21. 2-(methylthio)-7-chloro- 8-chloro-6-(4-methylphenyl)- 5-(4-methylphenyl)-3H- 1H-s-triazolo[4,3-a][1,5]- 1,5-benzodiazepin-4-one benzodiazepine-1,5-dione22. 2-(methylthio)-3-methyl- 4-methyl-8-chloro-6-phenyl- 7-chloro-5-phenyl-3H-1,5- 1H-s-triazolo[4,3-a][1,5]- benzodiazepin-4-one benzodiazepin-1,5-dione23. 2-(methylthio)-3-(benzyl- 4-(benzyloxy)-8-chloro-6- oxy)-7-chloro-5-phenyl- phenyl-1H-s-triazolo- 3H-1,5-benzodiazepin-4- [4,3-a][1,5]benzodia- one zepin-1,5-dione24. 2-(methylthio)-3-methoxy- 4-methoxy-8-chloro-6-phenyl 7-chloro-5-phenyl-3H-1,5- 1H-s-triazolo[4,3-a][1,5]- benzodiazepin-4-one benzodiazepin-1,5-dione25. 2-(methylthio)-8-methyl- 9-methyl-6-phenyl-1H-s- 5-phenyl-3H-1,5-benzodia- triazolo[4,3-a][1,5]benzo- zepin-4-one diazepin-1,5-dione26. 2-(methylthio)-8-chloro- 9-chloro-6-phenyl-1H-s- 5-phenyl-3H-1,5-benzo- triazolo[4,3-a][1,5]- diazepin-4-one benzodiazepin-1,5-dione27. 2-(methylthio)-8-(tri- 9-(trifluoromethyl)-6- fluoromethyl)-5-phenyl- phenyl-1H-s-triazolo[4,3-a]- 3H-1,5-benzodiazepin- [1,5]benzodiazepin-1,5-dione 4-one______________________________________
EXAMPLES 28-34
8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione
Following the procedure of Example 1, Method B, but substituting the alkyl carbazates indicated below for ethyl carbazate in Example 1, Method B, gives the title compound.
28. methyl carbazate
29. propyl carbazate
30. isopropyl carbazate
31. butyl carbazate
32. isobutyl carbazate
33. secondary butyl carbazate
34. n-hexyl carbazate
EXAMPLE 35
2-(Methylthio)-7-chloro-5-phenyl-3H-1,5-benzodiazepin-4-one
To 3.03 g of 7-chloro-5-phenyl-1H-1,5-benzodiazepin-4-one-2-thione in a solution of 0.40 g of sodium hydroxide and 15 ml of methanol is added, with stirring a solution of 1.4 g of methyl iodide in 10 ml of methanol. Stirring is continued for 1 hour, the reaction is then evaporated and suspended in methylene chloride (30 ml). The suspension is filtered through a short Florisil column; the column is washed with ethyl acetate and the combined filtrates are evaporated. The residue is triturated with a minimum amount of absolute ethanol and the title compound is filtered off and dried.
EXAMPLES 36-39
Following the procedure of Example 35 but substituting the compounds indicated in Column I below for methyl iodide and the compounds indicated in Column II for 7-chloro-5-phenyl-1H-1,5-benzodiazepin-4-one-2-thione in Example 35, the benzodiazepinones indicated in Column III are obtained.
__________________________________________________________________________I II III__________________________________________________________________________ benzylbromide 7-(trifluoromethyl)-5-phenyl- 2-(benzylthio)-7-(trifluoromethyl)- 1H-1,5-benzodiazepin-4-one- 5-phenyl-3H-1,5-benzodiazepin- 2-thione 4-one O-propyl p-toluene- 7-nitro-5-(o-chlorophenyl)- 2-(propylthio)-7-nitro-5-(o- sulfonate 1H-1,5-benzodiazepin-4-one- chlorophenyl)-3H-1,5-benzodia- 2-thione zepin-4-one methyl iodide 7-(trifluoromethyl)-5-phenyl- 2-(methylthio)-7-(trifluoromethyl)- 1H-1,5-benzodiazepin-4-one 5-phenyl-3H-1,5-benzodiazepin- 2-thione 4-one diethyl sulfate 7-chloro-5-phenyl-1H-1,5- 2-(ethylthio)-7-chloro- benzodiazepin-4-one-2-thione 5-phenyl-3H-1,5-benzodiazepin- 4-one__________________________________________________________________________
EXAMPLES 40-65
Following the procedure of Example 35 but substituting the compounds indicated in Column I below for 7-chloro-5-phenyl-1H-1,5-benzodiazepin-4-one-2-thione in Example 35, the compounds indicated in Column II are obtained.
______________________________________ I II______________________________________40. 5-phenyl-1H-1,5- 2-(methylthio)-5-phenyl- benzodiazepin-4-one- 3H-1,5-benzodiazepin- 2-thione 4-one41. 7-(trifluoromethyl)-5- 2-(methylthio)-7-(tri- phenyl-1H-1,5-benzo- fluoromethyl)-5-phenyl- diazepin-4-one-2- 3H-1,5-benzodiazepin- thione 4-one42. 7-nitro-5-phenyl- 2-(methylthio)-7-nitro- 1H-1,5-benzodiazepin- 5-phenyl-3H-1,5-benzo- 4-one-2-thione diazepin-4-one43. 7-methyl-5-phenyl-1H- 2-(methylthio)-7-methyl- 1,5-benzodiazepin-4- 5-phenyl-3H-1,5-benzo- one-2-thione diazepin-4-one44. 7-methoxy-5-phenyl- 2-(methylthio)-7-methoxy- 1H-1,5-benzodiazepin- 5-phenyl-3H-1,5-benzo- 4-one-2-thione diazepin-4-one45. 7-(methylthio)-5- 2,7-di(methylthio)-5- phenyl-1H-1,5-benzo- phenyl-3H-1,5-benzodia- diazepin-4-one-2- zepin-4-one thione46. 7-pentyl-5-phenyl-1H- 2-(methylthio)-7-pentyl-5- 1,5-benzodiazepin-4- phenyl-3H-1,5-benzodiazepin- one-2-thione 4-one47. 7-pentoxy-5-phenyl- 2-(methylthio)-7-pentoxy-5- 1H-1,5-benzodiazepin- phenyl-3H-1,5-benzodiazepin- 4-one-2-thione 4-one48. 7-bromo-5-phenyl-1H- 2-(methylthio)-7-bromo-5- 1,5-benzodiazepin-4- phenyl-3H-1,5-benzodiazepin- one-2-thione 4-one49. 7-fluoro-5-phenyl- 2-(methylthio)-7-fluoro-5- 1H-1,5-benzodiazepin- phenyl-3H-1,5-benzodiazepin- 4-one-2-thione 4-one50. 7-cyano-5-phenyl-1H- 2-(methylthio)-7-cyano-5- 1,5-benzodiazepin-4- phenyl-3H-1,5-benzodiazepin- one-2-thione 4-one51. 7-chloro-5-(2-chloro- 2-(methylthio)-7-chloro-5- phenyl)-1H-1,5-benzo- (2-chlorophenyl)-3H-1,5- diazepin-4-one-2-thione benzodiazepin-4-one52. 7-chloro-5-(2-fluoro- 2-(methylthio)-7-chloro-5- phenyl)-1H-1,5-benzo- (2-fluorophenyl)-3H-1,5- diazepin-4-one-2-thione benzodiazepin-4-one53. 7-chloro-5-(3-chloro- 2-(methylthio)-7-chloro-5- phenyl)-1H-1,5-benzo- (3-chlorophenyl)-3H-1,5- diazepin-4-one-2-thione benzodiazepin-4-one54. 7-chloro-5-(4-chloro- 2-(methylthio)-7-chloro-5- phenyl)-1H-1,5-benzo- (4-chlorophenyl)-3H-1,5- diazepin-4-one-2-thione benzodiazepin-4-one55. 7-chloro-5-(2-methoxy- 2-(methylthio)-7-chloro-5- phenyl)-1H-1,5-benzo- (2-methoxyphenyl)-3H-1,5- diazepin-4-one-2-thione benzodiazepin-4-one56. 7-chloro-5-(3-methoxy- 2-(methylthio)-7-chloro-5- phenyl)-1H-1,5-benzo- (3-methoxyphenyl)-3H-1,5- diazepin-4-one-2-thione benzodiazepin-4-one57. 7-chloro-5-(2-methyl- 2-(methylthio)-7-chloro-5- phenyl)-1H-1,5-benzo- (2-methylphenyl)-3H-1,5- diazepin-4-one-2-thione benzodiazepin-4-one58. 7-chloro-5-(3-methyl- 2-(methylthio)-7-chloro-5- phenyl)-1H-1,5-benzo- (3-methylphenyl)-3H-1,5- diazepin-4-one-2-thione benzodiazepin-4-one59. 7-chloro-5-(4-methyl- 2-(methylthio)-7-chloro-5- phenyl)-1H-1,5-benzo- (4-methylphenyl)-3H-1,5- diazepin-4-one-2-thione benzodiazepin-4-one60. 3-methyl-7-chloro-5- 2-(methylthio)-3-methyl-7- phenyl-1H-1,5-benzo- chloro-5-phenyl-3H-1,5- diazepin-4-one-2-thione benzodiazepin-4-one61. 3-(benzyloxy)-7-chloro- 2-(methylthio)-3-(benzyloxy)- 5-phenyl-1H-1,5-benzo- 7-chloro-5-phenyl-3H-1,5- diazepin-4-one-2-thione benzodiazepin-4-one62. 3-methoxy-7-chloro-5- 2-(methylthio)-3-methoxy-7- phenyl-1H-1,5-benzo- chloro-5-phenyl-3H-1,5- diazepin-4-one-2-thione benzodiazepin-4-one63. 8-methyl-5-phenyl-1H- 2-(methylthio)-8-methyl-5- 1,5-benzodiazepin-4- phenyl-3H-1,5-benzodiazepin- one-2-thione 4-one64. 8-chloro-5-phenyl-1H- 2-(methylthio)-8-chloro-5- 1,5-benzodiazepin-4- phenyl-3H-1,5-benzodiazepin- one-2-thione 4-one65 8-(trifluoromethyl)-5- 2-(methylthio)-8-(trifluoro- phenyl-1H-1,5-benzodia- methyl)-5-phenyl-3H-1,5-benzo- zepin-4-one-2-thione diazepin-4-one______________________________________
EXAMPLE 66
7-chloro-5-phenyl-1H-1,5-benzodiazepin-4-one-2-thione
A solution of 28.6 g of 7-chloro-5-phenyl-1H-1,5-benzodiazepine-2,4-dione and 23.3 g of phosphorus pentasulfide in 250 ml of pyridine is refluxed, with stirring, for 40 minutes under argon. The solvent is evaporated in vacuo.
The residue is stirred in ice water and extracted with methylene chloride. The organic phase is washed consecutively with dilute aqueous hydrochloric acid, water and dried. The organic phase is filtered through a short column of neutral III alumina and the filtrate evaporated. The residue is triturated with a small amount of hot benzene and the product filtered off and dried.
EXAMPLE 67
8-chloro-6-(2',4'-dichlorophenyl)-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione
Part A
20 g of 2',4',5-trichloro-2-nitrodiphenylamine in 100 ml of methanol containing 0.2 g of Raney nickel is hydrogenated at an initial hydrogen pressure of 7 atm. until three molar equivalents of hydrogen is consumed. The suspension is filtered and the filtrate evaporated to give the 2',4',5-trichloro-2-aminodiphenylamine.
Part B
To a stirred refluxing solution of 28.7 g of the above produced 2',4',5-trichloro-2-aminodiphenylamine in 400 ml benzene is added, dropwise, a solution of 13.8 g of malonyl dichloride in 45 ml benzene. After addition is complete the reaction was refluxed for 7 hours, concentrated to 1/2 the original volume and cooled. The product, 7-chloro-(2',4'-dichlorophenyl)-1H-1,5-benzodiazepin-2,4-dione, is filtered off and dried.
Part C
Following the procedure of example 66 but substituting the above produced 7-chloro-5-(2',4'-dichlorophenyl)-1H-1,5-benzodiazepin-2,4-dione for 7-chloro-5-phenyl-1H-1,5-benzodiazepine-2,4-dione in example 66, gives 7-chloro-5-(2',4'-dichlorophenyl)-1H-1,5-benzodiazepin-4-one-2-thione.
Part D
Following the procedure of example 35 but substituting the above produced 7-chloro-5-(2',4'-dichlorophenyl)-1H-1,5-benzodiazepin-4-one-2-thione for 7-chloro-5-phenyl-1H-1,5-benzodiazepin-4-one-2-thione in example 35, gives 2-(methylthio)-7-chloro-5-(2',4'-dichlorophenyl)-3H-1,5-benzodiazepin-4-one.
Part E
Following the procedure of example 1, Method B, but substituting the above produced 2-(methylthio)-7-chloro-5-(2',4'-dichlorophenyl)-3H-1,5-benzodiazepin-4-one for 2-(methylthio)-7-chloro-5-phenyl-3H-1,5-benzodiazepin-4-one in example 1, Method B, gives the title compound of formula 1.
EXAMPLES 68-88
Following the procedure of part A to E of the foregoing example but employing as starting materials the substituted compounds of formula 10 wherein the substituents and the position they occupy are indicated below:
__________________________________________________________________________ExampleNo. 3 4 5 6 2' 3' 4' 5' 6'__________________________________________________________________________68. Cl Cl69. Cl70. Cl CH.sub.3 SO.sub.271 CF.sub.3 Cl CF.sub.372. Cl CH.sub.3 CH.sub.373. Cl CH.sub.3 Cl74. Cl CH.sub.3 CH.sub.375. Cl Cl76. Cl Cl77. CH.sub.3 O CH.sub.3 O78. Cl Cl Cl79. Cl OCH.sub.3 OCH.sub.380. Cl81. Cl Cl82. CH.sub.3 O CH.sub.3 O83. Cl CH.sub.384. CH.sub.3 SO.sub.285. Cl CH.sub.3 S86. Cl CH.sub.3 SO.sub.287. Cl F F88. Cl F F__________________________________________________________________________
there is obtained the correspondingly substituted compound of formula I wherein R 1 =hydrogen and wherein the substituents and the position they occupy are indicated below:
__________________________________________________________________________ExampleNo. 7 8 9 10 2' 3' 4' 5' 6'__________________________________________________________________________68. Cl Cl69. Cl70. Cl CH.sub.3 SO.sub.271. CF.sub.3 Cl CF.sub.372. Cl CH.sub.3 CH.sub.373. Cl CH.sub.3 Cl74. Cl CH.sub.3 CH.sub.375. Cl Cl CH.sub.376. Cl Cl77. CH.sub.3 O CH.sub.3 O78. Cl Cl Cl79. Cl OCH.sub.3 OCH.sub.380. Cl81. Cl Cl82. OCH.sub.3 OCH.sub.383. CH.sub.3 Cl84. CH.sub.3 SO.sub.285. Cl SCH.sub.386. Cl CH.sub.3 SO.sub.287. Cl F F88. Cl F F__________________________________________________________________________
EXAMPLE 89
4-Hydroxy-8-chloro-6-phenyl-1H-s-triazolo-[4,3-a][1,5]benzodiazepine-1,5-dione
44.6 g of 4-(benzyloxy)-8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione in 400 ml of ethanol containing 2.0 g of 10% palladium-on-charcoal is hydrogenated at an initial hydrogen pressure of 40 p.s.i. After 0.1 mole of hydrogen has been absorbed, the reaction is stopped, filtered and the solvent evaporated. The residue is triturated with ether and the title compound filtered off and dried.
EXAMPLE 90
8-(methylsulfinyl)-6-phenyl-1H-s-triazolo[4,3-a][1,5]-benzodiazepine-1,5-dione
3.22 g of 8-(methylthio)-6-phenyl-1H-s-triazolo [4,3-a][1,5]benzodiazepine-1,5-dione and 2.14 g of sodium metaperiodate in 500 ml methanol is stirred at +5° C for 24 hours. The reaction is evaporated; the residue dissolved in methylene chloride, washed with water, dried and concentrated. The concentrate is chromatographed on twenty silica gel (1000μ plates, 20 × 20 cm) using acetone-methanol (9:1) as eluting solvent. The band containing the product is removed, stirred with acetone-methanol (4:1) and the silica gel filtered off. The filtrate is evaporated to give the title compound.
EXAMPLE 91
8-amino-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione
33.5 g of 8-nitro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione in 100 ml of ethanol containing 2.0 g of 10% palladium-on-charcoal is hydrogenated at room temperature at an initial hydrogen pressure of 50 p.s.i. The reaction is stopped when 0.3 moles of hydrogen has been absorbed; the suspension is filtered and the filtrate evaporated to give the title compound.
EXAMPLE 92
8-acetamido-6-phenyl-1-H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione
2.91 g of 8-amino-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione and 1.02 g of acetic anhydride in 50 ml pyridine is stirred for 12 hours then refluxed for 30 minutes. The reaction is evaporated; the residue is taken up in chloroform, washed with dilute aqueous sodium bicarbonate, with water and dried. The solvent is evaporated to give the title compound.
EXAMPLE 93
8-(methylsulfonyl)-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione
Following the procedure of example 90, but using 4.14 g instead of 2.14 g of sodium metaperiodate, the title compound is obtained.
EXAMPLE 94
2-Methyl-8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepin-1,5-dione
To an ice-cooled, stirred solution of 3.7 g of 8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione in 100 ml of dried and distilled 1,2-dimethoxyethane is added, in a portionwise manner, 0.57 g of a 57% dispersion of sodium hydride in mineral oil. After the evolution of hydrogen has ceased (15 min), a solution of 1.79 g (0.014 mole) of methyl iodide is added, the ice bath removed and stirring continued at room temperature for 2 hours, followed by heating under reflux for 1 hour. The solvent is then removed by distillation. The residue is dissolved in 100 ml of chloroform, washed twice with 100 ml portions of water, dried and concentrated. Treatment of the residue with a small amount of ether precipitates the title compound which is filtered off, dried and recrystallized from ethyl acetate.
EXAMPLE 95 - 101
Following the procedure of example 94 but substituting the compounds indicated in column I below for methyl iodide in example 94, the compounds indicated in column II are obtained:
______________________________________ I II______________________________________95. 3-dimethylaminopropyl 2-(3-dimethylaminopropyl)-chloride 8-chloro-6-phenyl-1H-s- triazolo[4,3-a][1,5]benzodia- zepine-1,5-dione96. 2-diethylaminoethyl 2-(2-diethylaminoethyl)-8-bromide chloro-6-phenyl-1H-s-triazolo- [4,3-a][1,5]benzodiazepine- 1,5-dione97. 2-dimethylaminoethyl 2-(2-dimethylaminoethyl)-8-chloride chloro-6-phenyl-1H-s-triazolo- [4,3-a][1,5]benzodiazepine- 1,5-dione98. 3-diethylaminopropyl 2-(3-diethylaminopropyl)-8-chloride chloro-6-phenyl-1H-s-triazolo- [4,3-a][1,5]benzodiazepine- 1,5-dione99. Benzyl bromide 2-benzyl-8-chloro-6-phenyl- 1H-s-triazolo[. 4,3-a][1,5]- benzodiazepin-1,5-dione100. p-chlorophenethyl 2-(p-chlorophenethyl)-8-chloro-chloride 6-phenyl-1H-s-triazolo[4,3-a]- [1,5]benzodiazepine-1,5- dione101. 2-(N-benzyl-N-methyl- 2-[2-(N-benzyl-N-methylamino)-amino)ethyl chloride ethyl]-8-chloro-6-phenyl-1H- s-triazolo[4,3-a][1,5]benzodia- zepine-1,5-dione102. 3-[(t-butoxycarbonyl)- 2-[3-[(t-butoxycarbonyl)amino]-amino]propyl chloride propyl]-8-chloro-6-phenyl-1H- s-triazolo[4,3-a][1,5]benzo- diazepine-1,5-dione______________________________________
EXAMPLE 103
2-(2-Methylaminopropyl)-8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione
4 g of 2-[2-(N-benzyl-N-methylamino)ethyl]-8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione in 100 ml of ethanol containing 0.4 g of 5% palladium on charcoal is hydrogenated at 50 p.s.i. hydrogen pressure until 1 molar equivalent of hydrogen is absorbed. The suspension is filtered and the filtrate is evaporated. The residue is triturated with a small amount of cold ether and the title compound is filtered off and dried.
EXAMPLE 104
2-(3-aminopropyl)-8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione
2.5 g of 2-[3-(t-butoxycarbonylamino)propyl]-8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione in 50 ml of trifluoroacetic acid is stirred at room temperature for 2 hours. The reaction is evaporated and the residue is stirred with a solution of 1.9 g of sodium bicarbonate in 400 ml of methanol-water (10:1). After 3 hours the reaction is evaporated and the residue is partitioned between methylene chloride and water. The methylene chloride is washed with water, dried and evaporated to give the title compound.
EXAMPLES 105 - 111
Following the procedure of Example 94 but substituting the compounds indicated in Column I below for 8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazephine-1,5-dione in Example 94, the compounds indicated in Column II are obtained.
______________________________________ I II______________________________________105. 6-phenyl-1H-s-triazolo- 2-methyl-6-phenyl-1H-s-[4,3-a][1,5]benzodia- triazolo[4,3-a][1,5]benzo-zepine-1,5-dione diazepine-1,5-dione106. 8-trifluoromethyl)-6- 2-methyl-8-(trifluoromethyl)-phenyl-1H-s-triazolo- 6-phenyl-1H-s-triazolo[4,3-a]-[4,3-a][1,5]benzodia- [1,5]benzodiazepine-1,5-zepine-1,5-dione dione107. 8-nitro-6-phenyl-1H- 2-methyl-8-nitro-6-phenyl-s-triazolo[4,3-a][1,5]- 1H-s-triazolo[4,3-a][1,5]-benzodiazepine-1,5- benzodiazepine-1,5-dionedione108. 8-methyl-6-phenyl-1H- 2,8-dimethyl-6-phenyl-s-triazolo[4,3-a][1,5]- 1H-s-triazolo[4,3-a][1,5]-benzodiazepine-1,5- benzodiazepine-1,5-dionedione109. 8-methoxy-6-phenyl-1H- 2-methyl-8-methoxy-6-phenyl-s-triazolo[4,3-a][1,5]- 1H-s-triazolo[4,3-a][1,5]-benzodiazepine-1,5- benzodiazepine-1,5-dionedione110. 8-(methylthio)-6-phenyl- 2-methyl-8-(methylthio)-6-1H-s-triazolo[4,3-a]- phenyl-1H-s-triazolo[4,3-a]-[1,5]benzodiazepine- [1,5]benzodiazepine-1,5-1,5-dione dione111. 4-benzyloxy-8-chloro- 2-methyl-(4-benzyloxy-8-6-phenyl-1H-s-triazolo- chloro)-6-phenyl-1H-s-triazolo-[4,3-a][1,5]benzodia- [4,3-a][1,5]benzodiazepine-zepine-1,5-dione 1,5-dione______________________________________
EXAMPLE 112
2-Methyl-4-hydroxy-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione
Following the procedure of example 89 but substituting 2-methyl-4-(benzyloxy)-8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione for 4-(benzyloxy)-8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione in Example 89, the title compound is obtained.
EXAMPLE 113
4-acetoxy-8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione
3.4 g of 4-hydroxy-8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione and 1.0 g of acetic anhydride in 10 ml of pyridine are warmed in a steam bath for 0.2 hour and stirred at room temperature for 10 hours. The reaction mixture is cooled, diluted with 100 ml of methylene chloride and washed with 100 ml water containing 0.84 g sodium bicarbonate. The organic phase is washed four times with water, dried and evaporated. The residue is triturated with a minimum amount of ether and the title compound filtered off, dried and recrystallized from methylene chloride and ether.
EXAMPLE 114
8-chloro-2,6-diphenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione
A mixture of 8.2 g of 8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione, 5 g of copper powder and 2.5 g of potassium acetate in 100 ml of bromobenzene are refluxed for 6 hours with stirring. The reaction is diluted with methylene chloride, filtered through a short Florisil column and the filtrate washed with dilute aqueous ammonium hydroxide. The organic phase is washed with water, dried and the solvent evaporated to give the title compound.
EXAMPLES 115 - 119
Following the procedure of example 114 but substituting the compounds indicated in Column I below for 8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione in Example 114, the compounds indicated in Column II are obtained.
______________________________________ I II______________________________________115. 8-(trifluoromethyl)-6- 8-(trifluoromethyl)-2,6-phenyl-1H-s-triazolo- diphenyl-1H-s-triazolo-[4,3-a][1,5]benzodia- [4,3-a][1,5]benzodiazepine-zepine-1,5-dione 1,5-dione116. 8-nitro-6-phenyl-1H- 8-nitro-2,6-diphenyl-1H-s-triazolo[4,3-a][1,5]- s-triazolo[4,3-a][1,5]-benzodiazepine-1,5- benzodiazepine-1,5-dionedione117. 8-bromo-6-phenyl-1H- 8-bromo-2,6-diphenyl-1H-s-triazolo[4,3-a][1,5]- s-triazolo[4,3-a][1,5]-benzodiazepine-1,5-dione benzodiazepine-1,5-dione118. 9-chloro-6-phenyl-1H- 9-chloro-2,6-diphenyl-1H-s-triazolo[4,3-a][1,5]- s-triazolo[4,3-a][1,5]-benzodiazepine-1,5- benzodiazepine-1,5-dionedione119. 8-chloro-6-(o-chloro- 8-chloro-2-phenyl-6-(o-phenyl)-1H-s-triazolo- chlorophenyl)-1H-s-triazolo-[4,3-a][1,5]benzodia- [4,3-a][1,5]benzodiazepine-zepine-1,5-dione 1,5-dione______________________________________
EXAMPLES 120 - 124
Following the procedure of Example 114 but substituting the compounds indicated in Column I below for 8-chloro-6-phenyl-1H-s-triazolo[4,3-a][1,5]benzodiazepine-1,5-dione in example 114, and substituting o-chlorobromobenzene for bromobenzene in example 114, the compounds indicated in Column II are obtained.
______________________________________ I II______________________________________120. 8-chloro-6-phenyl-1H- 8-chloro-2-(o-chlorophenyl)- s-triazolo[4,3-a][1,5]- 6-phenyl-1H-s-triazolo[4,3-a]- benzodiazepine-1,5- [1,5]benzodiazepine-1,5- dione dione121. 8-(trifluoromethyl)-6- 8-(trifluoromethyl)-2-(o- phenyl-1H-s-triazolo- chlorophenyl)-6-phenyl-1H- [4,3-a][1,5]benzodia- s-triazolo[4,3-a][1,5]- zepine-1,5-dione benzodiazepine-1,5-dione122. 8-nitro-6-phenyl-1H- 8-nitro-2-(o-chlorophenyl)- s-triazolo[4,3-a][1,5]- 6-phenyl-1H-s-triazolo- benzodiazepine-1,5- [4,3-a][1,5]benzodiazepine- dione 1,5-dione123. 8-bromo-6-phenyl-1H- 8-bromo-2-(o-chlorophenyl)- s-triazolo[4,3-a][1,5]- 6-phenyl-1H-s-triazolo- benzodiazepine-1,5- [4,3-a][1,5]benzodiazepine- dione 1,5-dione124. 8-chloro-6-(o-chloro- 8-chloro-2,6-di(o-chloro- phenyl)-1H-s-triazolo- phenyl)-1H-s-triazolo[4,3-a]- [4,3-a][1,5]benzodia- [1,5]benzodiazepine-1,5- zepine-1,5-dione dione______________________________________
EXAMPLE 125
3-(7-chloro-5-phenyl-3H-1,5-benzodiazepin-4-one-2-yl)carbazic acid ethyl ester
Method A
3.2 g of 2-(methylthio)-7-chloro-5-phenyl-1H-1,5-benzodiazepin-4-one and 1.8 g of ethyl carbazate in 100 ml ethanol is refluxed for 14 hours. During this time a slow stream of nitrogen is bubbled through the reaction mixture. The mixture is evaporated, the residue taken up in methylene chloride, washed with water, dried and the solvent evaporated. The residue is chromatographed on 10 1000μ silica gel plates (20 × 20 cm) with acetone-methanol (9:1) eluant. The band containing the product is removed and stirred with acetone-methanol (4:1). The silica gel is filtered off and the filtrate evaporated to give the title compound.
Method B
2.8 g of 2-hydrazino-7-chloro-5-phenyl-3H-1,5-benzodiazepin-4-one and 1.1 g of ethyl chloroformate in 25 ml of triethylamine is stirred at room temperature for 10 hours. The reaction mixture is evaporated and partitioned between 100 ml methylene chloride and a solution of 0.84 g sodium bicarbonate in 50 ml water. The organic phase is dried and evaporated.
EXAMPLE 126
Preparation of Capsule Formulation
______________________________________Ingredient Milligrams per Capsule______________________________________8-chloro-6-phenyl-1H-s-triazolo-[4,3-a][1,5]benzodiazepine-1,5-dione 400Starch 80Magnesium stearate 5______________________________________
The active ingredient, starch and magnesium stearate are blended together. The mixture is used to fill hard shell capsules of a suitable size at a fill weight of 485 milligrams per capsule.
EXAMPLE 127
Preparation of Tablet Formulation
______________________________________Ingredient Milligrams per Tablet______________________________________8-chloro-6-(2'-chlorophenyl)-1H-s-tria-zolo[4,3-a][1,5]benzodiazepine-1,5-dione. 300Lactose 200Corn starch (for mix) 50Corn starch (for paste) 50Magnesium stearate 6______________________________________
The active ingredient, lactose and corn starch (for mix) are blended together. The corn starch (for paste) is suspended in water at a ratio of 10 grams of corn starch per 80 milliliters of water and heated with stirring to form a paste. This paste is then used to granulate the mixed powders. The wet granules are passed through a No. 8 screen and dried at 120° F. The dry granules are passed through a No. 16 screen. The mixture is lubricated with magnesium stearate and compressed into tablets in a suitable tableting machine. Each tablet contains 300 milligrams of active ingredient.
EXAMPLE 128
Preparation of Oral Syrup Formulation
______________________________________Ingredient Amount______________________________________2-Methyl-8-chloro-6-phenyl-1H-s-triazolo-[4,3-a][1,5]benzodiazepin-1,5-dione 500 mg.Sorbitol solution (70% N.F.) 40 ml.Sodium benzoate 150 mg.Sucaryl 90 mg.Saccharin 10 mg.Red Dye (F.D. & Co. No. 2) 10 mg.Cherry flavor 50 mg.Distilled water qs to 100 ml.______________________________________
The sorbitol solution is added to 40 milliliters of distilled water and the active ingredient is suspended therein. The sucaryl, saccharin, sodium benzoate, flavor and dye are added and dissolved in the above solution. The volume is adjusted to 100 milliliters with distilled water.
Other ingredients may replace those listed in the above formulation. For example, a suspending agent such as bentonite magma, tragacanth, carboxymethylcellulose, or methylcellulose may be used. Phosphates, citrates or tartrates may be added as buffers. Preservatives may include the parabens, sorbic acid and the like and other flavors and dyes may be used in place of those listed above.
|
Compounds of the formula ##STR1## which are useful intermediates in the preparation of compounds of the formula ##STR2## which are useful as central nervous system depressants, tranquilizers, sedatives and muscle relaxants.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation of International Application PCT/GB00/03963 filed on Oct. 16, 2000, which designated the U.S. and was published under PCT Article 21(2) in English, and which is hereby incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
This invention relates to an improved database processor and system architecture.
1. Field of the Invention
Relational database management systems (DBMSs) are used throughout organisations for maintaining data that changes on a daily basis recording individual transactions as they occur. These databases are called operational databases and their data processing applications are known as On-Line Transaction Processing (OLTP) applications. DBMSs have been able to perform these functions satisfactorily for some years.
2. Description of Related Art
Increasingly organizations utilize data processing applications which allow them to compare current and past data, enabling them to highlight trends and thus support decision making. In order that the decision support system is effective, many organizations create consolidated data warehouses which collect the data from several heterogeneous operational databases or other information sources and integrate them for retrieval of historical and summary information. This is known as On-Line Analytical Processing (OLAP) and the computations required are complex, involve large volumes of data and typically involve data aggregation.
The functional and performance requirements of OLAP are quite different from those of the OLTP data processing applications traditionally supported by the operational databases.
OLTP applications typically automate clerical data processing tasks such as order entry and banking transactions that are the day-to-day operations of an organisation. These tasks are structured, repetitive and consist of short, atomic isolated transactions which require detailed, up-to-date data, and read or update, a few (tens of) records accessed typically on their primary keys. Operational databases tend to be hundreds of megabytes to gigabytes in size.
OLAP applications in contrast, are targeted for decision support. Historical summarised and consolidated data is more important than detailed, individual records. Since data warehouses typically contain consolidated data from several databases, potentially over long periods of time (for example as indicated in Table I), they tend to be orders of magnitude larger than the operational databases. The workloads are query intensive with mostly ad-hoc, complex queries that can access millions of records.
Most database management systems to-day are based on the relational data model. The central data description construct in this model is a relation which is a set of records, each of which has the same number (and type) of fields. A database is a collection of one or more relations and includes a schema—a description of the data. In the relational model, the schema for a relation specifies its name, the name of each field (or attribute or column) and the domain (type) of each field. For example, a relation called Product may have the following schema: Product(Product — ID:string, Type:string, Day:string, Month:integer, Year:integer), which denotes that each row in the relation has four fields, with field names and types as indicated. An example instance of the Product relation would be:
Product — ID
Type
Production — Year
P1
Shampoo
1997
P2
Soap
1998
P3
Conditioner
1998
Relational systems allow a wide variety of queries to be posed easily. An example of the type of query the relational system enables are user to find is:
Find the products which have been produced in 1998
The most widely used commercial relational database language is the Structured Query Language (SQL). The above query can be posed to the database through ANSI/ISO SQL-92 in the following form:
SELECT P.Product — ID, P.Type, P.Day, P.Month, P.Year FROM Product WHERE P.Year=1998
The abbreviation of P stands for the full relation name (Product).
The result relation of the above query is:
Product — ID
Type
Production — Year
P2
Soap
1998
P3
Conditioner
1998
For OLAP applications a recently proposed multidimensional conceptual model may be used in preference to the tabular model (Table I) of the relational system. Data are represented to the users as a multidimensional Cube. The multidimensional model can be associated with the Sales relation shown in Table I. Each domain is classified either as a Dimension or a Measure of Interest. In this example, the measure of interest is Total — Sales and the dimensions are PRODUCT — ID, STORE, MONTH.
The fundamental operation in OLAP applications is aggregating a measure over one or more dimensions.
In the cube those domains considered as dimensions are placed on the sides of the cube and the measure of interest (Total — Sales) is the content of each cell of the multidimensional array as shown in FIG. 1 .
The cube data model introduced new conceptual operations. The user can ‘rollup’ the cube to obtain a less detailed more abstract view of the data. In the opposite process the user can ‘drill-down’ expanding the representation from the total to a further level of detail. ‘Slice’ amounts to equality selection and ‘dice’ amounts to a range selection. ‘Rotate’ is when the view is rotated 90 degrees clockwise without any rearrangement of the data.
A dimension may be associated with a hierarchy. For example the TIME dimension could have the following hierarchy:
YEAR -------> QUARTER --------> MONTH --------> DAY
The multidimensional operations can utilize such hierarchies, e.g., Rollup of a TIME dimension can be done to each of the above levels as required by the user.
Aggregation which is the fundamental operation in OLAP transactions is classified into Scalar aggregates and aggregate functions. Scalar aggregates calculate a single scalar value from a unary-input relation, e.g., the max value of an attribute in a relation. An aggregate function takes a binary input relation, e.g., Total of Sales in each country. The aggregate functions take relations as input and return relations as an output. They are classified into Distributive, Algebraic and Holistic.
For example, the users of such a system typically wish to obtain information of much larger granularity than a single sale, e. g, The Stores' performance per month, irrespective of the individual product.
This would require as regards the relation in Table I aggregation of Total — Sales over the STORE and TIME dimensions. It can be expressed using the following SQL statement
SELECT Store, Time as (SUM) Sales FROM Sales GROUP-BY Store, Time
to give the result shown in Table II.
There are three disadvantages in the SQL/relational approach. The first is that many different aggregations are possible. In typical practical cases, the Sales relation of the above example may well have many more domains than shown in the example and each different aggregate requires a distinct SQL program. The second disadvantage is that it is by no means easy to visualise the computations conceptually. Finally, most users to-day expect to manipulate their data graphically.
The user interface to the Multidimensional data model (Cube) allows the user to specify the conceptual multidimensional operators graphically, for example as shown in FIG. 2 .
Users in OLAP systems typically require to investigate many of the different possible aggregates. Given a measure of N dimensions there are 2 N possible aggregates (the above example with three dimensions giving rise to 8 aggregates). It is important that users can specify and visualize the different levels of aggregation with ease. Typically this would be done in real time using a graphical user interface operating with the Cube-by operator to explore the multidimensional environment. The Cube-by operator is the n-generalization of simple aggregate functions and it computes Group-bys corresponding to all possible combinations of a list of attributes.
With the introduction of the Cube-by operator it became easier for users to specify and visualize different levels of aggregation. However, the processing required to support this operator is enormous in terms of time and storage. Particularly where hierarchies are involved the effective number of possible combinations becomes unmanageable.
Many workers have attempted to approach the implementation of the Cube-by by directly implementing Materialized Views which are precomputed for later retrieval. This is because it has been judged that the computation of aggregates ‘on the fly’ (i.e., on demand) would be too slow. Though significant research has been carried out to optimize the Materialized View approach, the method is inherently unsatisfactory. First there are a large number of Views. This implies a long precomputation time and precludes even modest update. Storage of the Views requires storage capacity which is possibly more than an order of magnitude greater than that required for the original data.
For the highest aggregations, the pre-computation approach is economical in the additional storage resources consumed, while providing gratifyingly rapid response. The low-level aggregates however are large and numerous, resulting in a many-fold expansion of the original relation. They virtually always require further processing, e.g., restriction, etc., to extract the tuples of interest. The most significant disadvantage, however, of the pre-computational approach is that it is not suited to dealing with update, other than as a batch-type operation separate from its interactive use. While there are undoubtedly situations in which this is acceptable, it nevertheless represents a major restriction on the system performance envelope for this approach.
The major disadvantage of a purely direct computational approach (i.e., on the fly) is the work which must be undertaken for each operation, and hence the much greater delay given equivalent systems performance parameters.
A partial-computation approach is possible but has been a subject of research by many workers mainly because to select the materialized views is not trivial. Systems architecture has also been the subject of research to minimize the total query response and the cost of maintaining the selected views, given a limited amount of resources (time, storage).
The above mentioned approaches have their advantages and disadvantages.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a new and improved database processor and system architecture.
The present invention is directed to a database processor and system architecture capable of operating as as On-line Analytical Processing (OLAP) system for the implementation of multidimensional aggregates of an input relation, and which is arranged to obtain such multidimensional aggregates after a pre-processing stage which identifies aggregates which can be obtained without computation, said pre-processing stage being arranged to:
i) identify and store the primary keys derived from the schema of the input relation; ii) establish a Group-by schema generator to generate schemas from minimum arity to maximum arity of aggregate for the possible aggregates of the input relation; iii) sequentially in an arity order beginning with single columns and proceeding in an order in which each lower level of every sub-tree is visited before any root (i.e., breadth-wise from the lowest level to the highest node of the lattice) comparing the generated schemas with the primary keys stored in step (i) augmented by any previous schema identified as being a key and in the event of a generated schema containing a stored key treating the input relation as the virtual representation of the corresponding Group-by aggregate without computation.
Preferably the arity order is the sequence minimum arity to maximum arity. Alternatively the arity order (known as ‘post order’) may be used in which all the sub-trees of each sub-tree are visited before the root of that sub-tree. This commences with a least some schemas of minimum arity followed by those higher arities which utilise schemas of the minimum arity which have already been dealt with, and so on. In any event the order ensures that those schemas of higher arity are dealt with subsequently to the sub-schemas of lower arity. Accordingly for a schema ABC the sub-schemas are A, B, C, AB, AC, BC and the order referred to may be A,B, C, AB, AC, BC or A, B, AB, C, AC, BC or B, C, BC, A, AB, AC, etc.
Preferably in accordance with the present invention, in sequence, each schema which is not found to contain a stored key according to step (iii) is subjected to a secondary check step, wherein an upper bound size of the Group-by relation defined by the current such schema is evaluated and the size of the input relation is compared against that upper bound size and in the event of the upper bound size not being less than the size of the input relation, sequentially comparing the tuples of the current schema and in the absence of tuple-duplication recognising that the current schema is a key and treating the input relation as the virtual representation of the corresponding Group-by aggregate without computation.
The upper bound size of the Group-by relation defined by the current schema may be evaluated according to a pre-determined algorithm for example based upon the product of the cardinalities (i.e., number of distinct values in a column) of the relation. There are various other algorithms which may take into account previously-evaluated upper bound sizes.
Preferably those generated Group-by schemas which are recognised as being or as containing a key are effectively stored to permit subsequent retrieval of the corresponding Group-by aggregate without computation. The store may contain pointers to such schemas since such pointers in effect represent the schema.
It will be understood that, in accordance with Relational Theory, a Relation R, which is defined over Domains {d 1 . . . d n }, is composed of a set of tuples each of which has the same number and type of fields. (The complete tuple must be distinct for it to conform to the definition of any Relation as being a set of tuples). One domain (or combination of domains which is minimal in number) of a given relation has values which uniquely identify each element (n-tuple) of that relation. Such a domain (or combination) is called a primary key. In general there may be several primary keys. Primary Keys belong to two different categories: Definitional and Observational.
Observational Primary Keys are dimension domains, or a set of dimension domains that together possess the unique identification property for a relation within a particular dataset or instance of the database.
The unique identification property is invariant for an observational primary key in a read-only database, but may be destroyed by updates to the dataset. Thus an observational primary key is equivalent to a definitional primary key in a read-only database, or until an update to the relation occurs in the case of a transactional database.
Definitional Primary Keys are those observational keys which have been defined as part of the schema (e.g., by the database designer) and remain keys irrespective of allowed changes in the data set.
The present invention is founded upon the fact that where the result of an aggregate is equivalent to the input relation the aggregate does not require to be explicitly computed. For example, consider an Aggregation as any operation (applied to a parent relation R) that produces a result relation Rc which consists of a projection of the relation R over a subset of domains, while at the same time applying an operator (e.g., SUM) to the attribute defined as the Measure of Interest. Each tuple of the result relation Rc is either derived from a single tuple of R, or from the combination of two or more tuples of R which have the same dimensional values in the dimensions projected in Rc as shown in FIG. 3 .
By virtue of the present invention the amount of aggregate computation and aggregate storage required in an OLAP system is significantly reduced.
Preferably and also independently, those Group-by schemas which require computational aggregation are computationally aggregated and each aggregate is assessed to identify whether or not it is similar to the parent relation by having almost the same cardinality (i.e., number of tuples) as the input relation, in which case to reduce storage space only those tuples that differ from the input relation need to be represented, whereby the aggregate can be obtained from this representation of the difference and from the input relation.
It will be understood in the context of database processors that items may be represented by explicit storage of the item or by various other known techniques which enable the item to be realised.
As a result of the present invention and the preferred embodiments thereof the database processor and system architecture can effectively represent a significant percentage (typically greater than 50%) of the aggregates, as though everything had been computed, the storage of these representations being within the original database and even if the remainder of the aggregates are actually computed and stored these are within a small percentage of the space required by the conventional materialised views process, and the amount of processing is greatly reduced. Typically over different datasets savings of the order of 50% in space and time can be achieved.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Embodiments of the present invention will now be described by way of example with reference to the accompanying drawings in which:
FIG. 1 illustrates a multi-dimensional cube;
FIG. 2 shows the FIG. 1 cube from a different perspective and illustrates the effect of roll-up and drill-down operations;
FIG. 3 illustrates a dataset R and the aggregation dataset R c produced by the SUM operator applied to R;
FIGS. 4 and 5 together illustrate three alternative known pre-processing stages for use with three known querying stages together forming three known OLAP systems;
FIGS. 6 and 7 illustrate the pre-processing and the querying stages of an OLAP system in accordance with the present invention;
FIGS. 8A , 8 B, 9 and 10 identify detailed methods used in the system of FIGS. 6 and 7 .
DETAILED DESCRIPTION OF THE INVENTION
By way of comparison with the present invention conventional OLAP systems are shown in FIGS. 4 and 5 . The earliest conventional system (Approach II) has no materialisation but uses the data retrieval mechanism which directly calls the aggregator to compute on the fly the necessary aggregation which is then returned as a result. The only storage is that required by the database (DB).
Approach I has full materialization and the system pre-computes all possible aggregates in advance. These are stored as materialized views in an additional materialized view (MV) store for later querying and requires use of an indexing mechanism. Unfortunately the MV storage required is excessive, the process requires a great deal of data manipulation which takes a considerable time and consequently is limited to systems requiring only moderate updates.
Approach III is a compromise between the first two in that the system selects in advance a sub-set of the possible aggregates and these are computed and stored as materialized views in an Mv store which is additional to the DB store. When a query has to be handled the system first checks whether the required result is already stored as a materialized view. Failing which, the aggregator is activated to compute the required result directly. This system results in a considerable saving in MV storage required for the materialized views but is achieved at the cost of a much higher variance in the time required to obtain a result.
The system in accordance with the present invention is shown in block diagram form in FIGS. 6 and 7 . Like the conventional system (Approach III) employing stored materialised views, the system of FIGS. 6 and 7 also has a pre-processing stage. However, the operation of the system in the pre-processing stage is entirely different in that those aggregates which do not require to be computed are identified so that they can be retrieved from the input relation stored in the data base, whilst those aggregates which do require to be computed are computed and stored as materialised views, or if the aggregate is sufficiently similar to the parent relation the aggregate is stored in a difference format with a pointer to the parent relation. This is schematically shown in FIGS. 8A , 8 B, 9 and 10 .
As shown in FIG. 8A a Group-by schema generator 30 issues schemas in sequence in an arity order which is essentially from minimum arity to maximum arity of aggregate for the possible aggregates of the input relation to an advance Materialised views selector 31 which operates to categorise the schemas into lists K and/or E failing which the schemas are directed to an aggregator 32 to compute aggregations. The K list initially stores any primary keys derived from the schema of the input relation and is subsequentially loaded with observational keys from the Group-by schemas identified by the categorisation process. The E list stores all Group-by schemas which contain a key previously stored in the K-list or which are found to be a key and from which the corresponding aggregate can be obtained without computation.
In the first pass the generator 30 for the required Group-by schemas issues these sequentially to a check unit 33 which examines the schema of the Group-by and checks its domains against the key list K to determine whether or not the schema contains a stored K-list key. At this point the K list contains all of the primary keys derived from the input relation augmented by any previous Group-by schema identified as being a key. Any Group-by schema which contains a key of the parent relation has a corresponding aggregate which can be represented by the parent relation itself and hence that aggregate does not require to be computed and stored, instead the schema is inserted directly into the E list.
Alternatively, if there is no match according to unit 33 the Group-by schema is subjected to a secondary check to identify if the schema is itself a key and which is based on size estimation in check unit 34 . On receipt of a schema unit 34 evaluates an upper bound size (ES) of the Group-by relation defined by that schema and then compares that evaluation with the size of the input relation. If the current upper bound size is not less than the input relation size then the individual tuples as defined by the current schema are sequentially compared by unit 35 , each succeeding tuple being compared with all its predecessors which are stored in unit 35 and provided a duplicate tuple is not detected (i.e., duplication is absent) the process continues until all the tuples have been compared. If at this stage no duplication has been detected the schema is recognised as being a key and is added to both the K and E lists provided that on a further check of these tuples the total size is found to be the same as that of ES.
The E list, as a result, contains (pointers to) all aggregations which are equal in size to their parent and which hence neither require to be computed explicitly nor stored. The K list contains the primary keys derived from the schema of the input relation augmented by any Group-by schema identified as itself being a key.
Group-by schemas which are not entered into the E list are directed to the aggregator 32 for aggregation on a computational basis. Aggregator 32 may operate on the conventional basis. Alternatively aggregator 32 may operate on a modified basis to reduce the storage space required for computed aggregates, as shown in FIG. 8B .
The aggregator 32 of FIG. 8B computes the aggregates and then categorises each aggregate according to size in comparison with the size of the parent relation.
If the size is less than that of the parent but within a specified threshold distance (t) of it the aggregator 32 stores this aggregate in a D-list difference format. This is made up of two parts, a small aggregate relation the tuples of which are each aggregates of more than one tuple of the parent, and a pointer to the parent relation. The appropriate entry specifying the relation and the small aggregate relation as well as the schema of the aggregate are inserted into the D list.
We define a relation R′ to be similar to the relation R if a number n′ R of equivalent tuples in R′ is within a threshold t s of the number of the corresponding tuples n R in R.
n R ′ n R < t s < 1
The value of t s may be pre-determined or may be varied since its size influences the required storage volume and the retrieval time of an aggregate.
If the difference is larger than t then the aggregate, or at least a pointer to it, is entered into a C-list which contains pointers to all aggregates which have been conventionally computed and stored in a materialised views (MV) store.
With regard to the difference production procedure utilized in FIG 8 B consider by way of example the relation R (p,s,t) shown in FIG 9 aggregated to the relation Rc (p,s). As can be seen two (R′ t ) tuples (P 2 , S 2 , 70 ) and (P 1 , S 2 , 20 ) are equivalent to the corresponding tuples (R t ) in R (P 2 , S 2 , T 1 , 70 ) and (P 1 , S 2 , T 2 , 20 ) respectively. The remaining tuple (R d ) is different being an aggregate of three tuples (R a ) in R. The two relations R and Rc are represented indirectly by storing only the parent relation R and Rd where Rd consists of the tuples of Rc which are not equivalent to any in the parent relation R.
The algorithm required for this process requires the following operations:
R′ t =R c α R
R d =R c −R′ t
where:
(α) is the semi-join relational operation, and (−) is the difference operator.
When a query is received the system of FIG. 7 may require to obtain those aggregates which are stored in the D-list format of FIG. 8B and this is achieved as shown in FIG. 10 using the stored relation R d in the following operations;
R′ t =π pls {overscore (( R α R d ))}
R c =R d ∪R′ t
where {overscore ((R α R d ))} is the anti-semijoin operation and (∪) is the union operator.
As will be readily understood by an expert in the field, the implementation of this algorithm can be rendered faster if an explicit representation (such as a bit list) of the set of tuples being selected from the parent relation (readily computed during the aggregation pre-processing phase) is stored in association with the two component part relations.
Otherwise the FIG. 7 system obtains the required aggregate by using the content of the C-list as a pointer to the previously computed and stored aggregate or alternatively via the E-list which stores the schemas of those aggregates which do not require computation but which are to be found from the input relation which is already stored in the original database.
TABLE I
SALES
Product
Store
Time
Total Sales
P1
S1
Jan
50
P1
S1
Feb
34
P1
S2
March
22
P2
S3
Jan
8
P2
S3
Jan
96
P2
S1
Jan
56
P2
S1
Apr
45
P3
S2
Feb
98
P3
S2
Jan
33
TABLE II
Store
Time
Total Sales
S1
Jan
106
S1
Feb
34
S2
March
22
S3
Jan
104
S1
Apr
45
S2
Feb
98
S2
Jan
33
|
A database processor is provided for on-line analytical processing. The processor is arranged to obtain multi-dimensional aggregates of an input relation. Prior to aggregation, the processor performs a pre-processing stage in which the processor identifies Group-bys that are equivalent to the root relation and thus can be derived directly from the root relation without computation. In this manner, the computational time and storage of the multidimensional aggregates is reduced since only unique Group-bys in the lattice are computed and stored.
| 8
|
BACKGROUND TO THE INVENTION
This invention relates to a mine prop headboard that can be used to support a preload bag.
Elongate mine props, typically timber-based, are widely used to provide yielding support to the hanging wall in mine stopes. Conventional practice is to trim the prop to length in the stope and then to tilt it to an upright orientation between the footwall and the hanging wall. Timber wedges are then hammered into position between the hanging wall and the top of the prop. The wedges have a dual purpose. Firstly, they serve to wedge the prop in position to prevent it from falling over during blasting. Secondly, they are employed to apply a degree of axial preload to the prop.
It is highly desirable to apply a fairly large axial preload force to the prop at installation, since this will immediately render the prop suitable to take the working load of the hanging wall as the hanging wall closes towards the footwall. However preload force applied by wedges as described above is very much less than that which is desirable.
It has therefore been proposed to provide the prop with a headboard on which an inflatable bag can be supported. During installation, the bag is positioned in a deflated condition on the headboard, between the head of the prop and the hanging wall. The bag is then inflated to a substantial pressure with a settable grout with the result that a substantial preload force, possibly in the range 10t to 20t, is applied axially to the prop.
SUMMARY OF THE INVENTION
A first aspect of the invention provides a mine prop headboard which is dimensioned to support an inflatable grout bag and which is adapted for location transversely on an end of an elongate mine prop which is in use installed upright between a hanging wall and a footwall in a mine working, the headboard comprising:
a chock assembly which includes parallel, elongate timber chocks and which defines an upper support surface, and
reinforcement means secured to and extending over the support surface of the chock assembly to provide tensile reinforcement for the chock assembly when a grout bag is in use positioned on the headboard and is inflated with grout under pressure thereby to apply a compressive axial force to the prop between the hanging wall and the footwall.
In the preferred embodiment, the reinforcement means comprises a sheet steel member fastened intimately to and extending over the support surface of the chock assembly. Conveniently, opposite ends of the sheet steel member are bent over to form bag-locating flaps which in use are locatable over opposite extremities of the grout bag thereby to locate the bag relative to the chock assembly.
Conveniently also, the sheet steel member is nailed to the chocks. Typically, the chocks are spaced apart by at least one endgrain timber block in which the timber grain is operatively vertical.
There may be a pair of chocks spaced apart by at least one block, the chocks and the at least one block, in combination, forming an H-shape in plan view.
Advantageously, a centralising formation which operates in use to centralise the combination of the chocks and the at least one block on the end of the elongate prop. The centralising formation may comprise a hole in the underside of the headboard, the hole being adapted to receive a peg protruding from the end of the prop.
The headboard may also include a sheet steel anchoring member which extends across the at least one block and is secured to the chocks on opposite sides of the at least one block. The sheet steel anchoring member may have generally a top-hat or channel cross-section.
In addition, the headboard may include an opening which is located in a position to grant access to a filler nozzle for the grout bag.
Another aspect of the invention provides the combination of a mine prop headboard as summarised above and an elongate mine prop, the headboard spanning transversely across the upper end of the mine prop, preferably with the upper end of the mine prop bearing partially against the at least one block and partially against the chocks. The combination may furthermore include an inflatable grout bag located on and supported by the headboard.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings in which:
FIG. 1 shows a perspective view of a mine prop headboard of the invention;
FIG. 2 shows a plan view of the headboard;
FIG. 3 shows an underplan view of the headboard;
FIG. 4 shows a cross-section at the line 4--4 in FIG. 2;
FIG. 5 illustrates the cross-section of the sheet steel anchoring member;
FIG. 6 illustrates the cross-section of an alternative sheet steel anchoring member;
FIG. 7 illustrates the cross-section of another sheet steel anchoring member; and
FIG. 8 illustrates the headboard of the invention in use.
DESCRIPTION OF EMBODIMENTS
FIG. 1 shows a mine prop grout bag supporting headboard 10 which in use is located transversely across the top of a conventional elongate, timber-based mine prop 12. The prop 12 could, for instance, be a conventional PIPESTICK or other prop.
The headboard 10 has four timber components, namely two elongate, rectangular section timber chocks 14 and two side-by-side rectangular timber blocks 18 which space the chocks apart from one another. The assembly of chocks and blocks form an H-shape in plan or underplan view. In the chocks 14, the timber grain runs in the longitudinal direction, while in the blocks 18, the timber grain is operatively vertical, i.e. into the plane of the paper in FIGS. 2 and 3.
The headboard 10 includes a sheet steel anchoring member 20 which is of a generally top-hat cross-sectional shape. The sheet steel typically has a gauge of 0,8 mm. As illustrated in FIG. 5, the blocks 18, only one of which is visible, nest within the anchoring member and are secured to the anchoring member by means of nails 22 driven laterally through the sheet steel and into the timber of the blocks.
The anchoring member 20 is then located between the two chocks 14 with the side portions 24 of the member passing about the chocks as illustrated in FIG. 4. Referring to FIG. 3, a sheet steel strap 26 passes over the blocks and overlies the chocks 14. Nails 28 are driven through the overlying portions of the strap, through the relevant portions of the anchoring member 20 and into the chocks.
A central locating hole 30 is formed in the underside of the headboard as seen in FIG. 3.
Referring to FIGS. 1 and 2, a sheet steel reinforcing member 32, typically of 0,8 mm gauge, is laid out over the upper surface of the assembly of chocks and blocks and is intimately secured to that assembly by an array of nails 34. Those nails 34A at the edges of the sheet steel member 32 also pass through the extremities of the anchoring member 20.
While the width of the sheet steel member 32 corresponds closely with that of the assembly of chocks and blocks, its length is somewhat greater than that of the assembly. End regions of the sheet steel member 32 are folded over as illustrated to form two flexible flaps 36.
The combination of anchoring member 20, strap 26 and reinforcing member 32, and the array of securing nails, ensures that the headboard 10 has a robust, integral structure which can be manhandled under normal conditions without breaking up. In practice, the chocks 14 will typically have a dimensions of 100 mm×100 mm×750 mm, and the blocks 18 dimensions of 120 mm×120 mm×100 mm. With these dimensions the headboard 10 has a mass of around 15 kg and so can be manhandled with comparative ease by a single mine worker. Although not illustrated in the drawings, a handle can be provided on the headboard to facilitate carrying.
In use, the prop 12 is first trimmed to approximate length, taking the thickness of the headboard into account, to suit the spacing between the hanging wall and the footwall in a mine working. Next, a nail 40 or other peg (FIG. 1) is hammered centrally into the upper end of the prop 12 so that a portion of the nail protrudes. With the prop lifted just above horizontal on the mine footwall, the nail is located in the hole 30. A rectangular inflatable grout bag 44 of known type, seen in FIG. 8, in this case one manufactured by Tufbag (Pty) Limited, is then placed on the upper surface of the headboard, i.e. on the sheet steel member 32, with its ends underneath the flaps 36 and with its filler nozzle aligned with an opening 42 formed in the member 32.
The prop 12 and headboard 10 are then canted upright to bring the prop to a substantially vertical position with the upper surface of the headboard 10 lying in a substantially horizontal plane and with the upper surface of the deflated bag 44 just beneath the hanging wall. Settable grout, typically a grout of the kind supplied for the purpose by Fosroc (Pty) Limited is then pumped into the bag 44. The pump that is used is typically of the kind made for the purpose by Nicro (Pty) Limited. The bag expands as it is inflated and comes into contact with the hanging wall. The bag is typically inflated to a pressure of about 4 bar, generating an axial compressive load of around 10t on the prop 12. The pump is then disconnected and a non-return valve in the nozzle of the bag ensures that the applied pressure in the bag is maintained.
The installed position of the prop, headboard and bag is illustrated in FIG. 8.
It will be appreciated that the function of the nail 40 and hole 30 is to centralise the headboard, on installation, on the upper end of the prop 12. Referring to FIG. 3, the line 46 indicates the perimeter of the prop 12 and it will be noted that the diameter of the prop is slightly greater than the relevant lateral dimension of the blocks 18. In general, the diameter of the prop 12 should not be too great in relation to the lateral dimension of the blocks 18 so that there is not too great an overlap between the chocks 14 and the prop. Too great an overlap could in practice in lead to crushing and early failure of the chocks 14.
The preload applied to the prop 12 on installation renders the prop immediately capable of performing a propping function. In other words, there is no need to wait for the hanging wall to close on the footwall before the prop starts taking any meaningful load. As closure of the stope takes place with passage of time, the prop yields axially, by shortening in length, but still continues to support the applied load.
It will be appreciated that the upper part of the headboard is subjected to substantial tensile bending forces under the axially applied load. The lower part is subjected to correspondingly high compressive bending forces. Excessive bending forces could lead to destruction of the headboard. The tensile forces are however resisted efficiently by the sheet steel member 32 which, being intimately connected to the chocks 14, creates what is in effect a composite steel and timber headboard structure.
The compressive forces in the lower part of the headboard are likewise resisted to some extent by the anchoring member 20, and the strap 26 binds the chocks to one another and resists any tendency for the chocks to move apart under the applied compressive loading.
The endgrain, nature of the blocks 18, i.e. the orientation in the direction of load application, also serves an important function under loading. It will be appreciated that the blocks are stronger in compression than the chocks because of their grain orientation. Under applied loading during initial testwork, it has been observed that the blocks are in fact displaced upwardly relative to the chocks and actually begin to deform the sheet steel member 32 in the central region. This deformation is indicated by the numeral 50 in FIG. 7.
The end result is that the blocks perform a "punching" action on the inflated grout bag and tend to displace grout material in the bag to the sides. It is anticipated that after the load has been applied for some time, the hanging wall will eventually come into virtually direct contact with the blocks 18, via the bag and member 32, so that the prop 12 takes direct loading from the hanging wall.
The flaps 36 also serve an important function. With the ends of the grout bag located beneath these flaps, the bag is unable to move sideways, in the relevant direction, relative to the headboard, and therefore maintains its central position relative to the headboard and prop.
As an alternative to the use of a nail or peg in the end of the prop and a corresponding hole in the headboard, various other centralising techniques may be used. The underside of the headboard could, for instance, have a ring or other formation mounted thereon into which the end of the prop would fit during installation. This would avoid the necessity for a worker to hammer a nail into the end of the prop after the prop has been trimmed to length.
FIG. 6 shows an alternative cross-sectional shape for the anchoring member. In this case, the anchoring member 60 is of true top-hat configuration, without the side portions 62 of the member 20 that locate against the sides of the chocks. It is believed that the anchoring member 20 is however preferable because the side portions 62 will assist the headboard in resisting bending loads.
FIG. 7 illustrates another cross-sectional shape for the anchoring member. In this case, the anchoring member 70 is merely in the form of a channel with re-entrant lips 72 as illustrated. The base 74 of the channel spans beneath the blocks 18 and secural is achieved by means of vertically applied nails which are driven through the lips 72 into the chocks 14. There is no direct attachment to the blocks 18. With this type of anchoring member, the plate 26 used with the anchoring members described previously can be omitted.
An important advantage of the illustrated headboard is the fact that it can be manufactured at modest cost, since the major components are timber, typically of the Saligna variety, and thin gauge sheet steel.
Despite the modest cost, it is anticipated that the headboard will be able to withstand the imposed loading comfortably. In initial testwork in an hydraulic press, a headboard of the illustrated type was able to withstand a compressive load of 70t without failing.
|
The mine prop headboard (10) is used to support an inflatable grout bag (44) and is located transversely on an end of an elongate mine prop (12) which is in use installed upright between a hanging wall and a footwall in a mine working. The headboard includes a chock assembly which is composed of parallel, elongate timber chocks (14). A steel reinforcement sheet is secured to and extends over the support surface of the chock assembly to provide tensile reinforcement a grout bag is placed on the headboard and is inflated with grout under pressure sufficient to apply a compressive axial force to the prop between the hanging wall and the footwall.
| 4
|
TECHNICAL FIELD
[0001] This disclosure relates to temperature sensors and more particularly to fuel, or fuel vapor, temperature sensing using an inductive fuel level sensor.
BACKGROUND
[0002] Current automotive fuel or fuel vapor temperature sensing is performed with a thermistor positioned within a fuel tank. This requires an additional component (the thermistor) in the fuel system. It also requires two electrical connections, e.g., one for signal output and one for electrical ground.
[0003] The ground connection can be shared. However, this still requires a minimum of one extra system electrical connection. The disadvantage to this approach is the cost of the thermistor and the extra electrical connections. Another concern is the ability of the thermistor to withstand being in contact with the fuels and fuel vapors. It is therefore advantageous to provide a fuel or fuel vapor temperature sensing apparatus and method that does not require either extra components nor extra electrical connections and that can provide long term reliability.
SUMMARY OF THE INVENTION
[0004] This disclosure provides a method and apparatus for utilizing an inductive coil fluid level sensor to measure the temperature of the fuel, or fuel vapors, in a fuel tank depending upon the location of the sensor within the tank. The inductive coil sensor is connected to a Fuel Control Unit containing the sensor electronics to drive the inductive coil sensor and read the corresponding fuel or fuel vapor temperature.
[0005] The method comprises charging the sensor to generate a voltage across the sensor, measuring the voltage across the sensor at the temperature of the sensor, measuring the voltage across the sensor at a reference temperature; and from the voltage measured across the sensor at the temperature of the sensor and the voltage measured across the sensor at the reference temperature, calculating the temperature of the sensor with respect to the reference temperature.
[0006] The sensor comprises an inductive coil receptive of a magnetic core moveable within the coil, a device linked to the core and responsive to the level of the fluid in a container and a circuit charging the inductive coil generating thereby a voltage across the inductive coil indicative of the temperature of the fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a generalized schematic diagram of an electro-mechanical system having an electric circuit including an inductive coil sensor for determining the temperature of a fuel or fuel vapor in a container;
[0008] [0008]FIG. 2 is a schematic diagram of a first embodiment of the inductive coil sensor of FIG. 1 immersed within the fuel;
[0009] [0009]FIG. 3 is a schematic diagram of a second embodiment of the inductive coil sensor of FIG. 1 immersed within the fuel vapor;
[0010] [0010]FIG. 4 is a schematic diagram of a first exemplary embodiment of the electric circuit of FIG. 1 including a model of an inductive coil sensor for determining the temperature of a fuel or fuel vapor in a container;
[0011] [0011]FIG. 5 is a schematic diagram of a second exemplary embodiment of the electric circuit of FIG. 1 including a model of an inductive coil sensor for determining the temperature of a fuel or fuel vapor in a container;
[0012] [0012]FIG. 6 is a schematic diagram of a third exemplary embodiment of the electric circuit of FIG. 1 including a model of an inductive coil sensor for determining the temperature of a fuel or fuel vapor in a container;
[0013] [0013]FIG. 7 is a schematic diagram of an electric circuit, including a model of an inductive coil sensor, for determining the level of a fuel in a container;
[0014] [0014]FIG. 8 is a graphical representation of the square wave driving pulse voltage, V pulse , of FIG. 1 and the resultant voltage, V coil , across the inductive coil sensor;
[0015] [0015]FIG. 9 is a graphical representation of the exponential decay of V coil wherein the core of the inductive coil sensor is not inserted into the coil; and
[0016] [0016]FIG. 10 is a graphical representation of the exponential decay of V coil wherein the core of the inductive coil sensor is fully inserted into the coil.
DETAILED DESCRIPTION OF THE INVENTION
[0017] An inductive coil is constructed by winding a given number of turns of conductive wire onto a bobbin. Copper is typically used due to its low cost and low electrical resistance. Although the resistance of the inductive coil, R coil , is small, it is easily measurable. Copper has a very well defined change in resistance due to temperature. The temperature coefficient of resistance, α, for Copper as given by The Engineers' Manual by Hudson is 0.00393 per degree C. at 20 degrees C. By analyzing the change in resistance in the copper coil, R coil , the temperature change of the coil, T coil , can be determined.
[0018] Referring now to FIG. 1, a generalized schematic diagram is shown of an electro-mechanical system 100 having an electric circuit 100 a including an inductive coil sensor 108 for determining the temperature of a fluid such as a fuel or fuel vapor in a container. The sensor 108 for measuring the temperature of the fluid 104 , comprises an inductive coil 108 b receptive of a magnetic core 108 a moveable within the coil 108 b. A flotation device 106 a is mechanically linked at 106 to the core 108 a and responsive to the level of the fluid 104 in the container 102 , such as a fuel tank. A circuit 100 a charges the inductive coil 108 b generating thereby at 110 b a voltage, V coil , across the inductive coil 108 b indicative of the temperature of the fluid 104 .
[0019] As the flotation device 106 a rises and falls with the level of the fuel 104 , the core 108 a falls and rises as the lever arm 106 pivots about point P. The movement of the core 108 a within the coil 108 b causes the effective inductance of the coil 108 b to change in a measurable way. As seen in FIG. 1, the inductive coil sensor 108 may be located remote from the fuel tank 102 or as seen in FIG. 2 and 3 , may be located within the fuel tank 102 . To measure the temperature, T v , of the fuel vapor 104 a, the inductive coil sensor 108 is located within the tank 102 above the fuel 104 . To measure the temperature, T f , of the fuel 104 , the inductive coil sensor 108 is located within the tank 102 immersed within the fuel 104 .
[0020] In FIG. 1, an input terminus 110 a of input resistor 110 is energized by a square wave signal, V pulse , having values of 0 volts and V cc volts as seen for example at 202 in FIG. 8. Such a voltage input at 110 a results in a corresponding coil voltage, V coil , at an output terminus 110 b of the input resistor 110 . In FIG. 1, V coil is amplified by an amplifier 130 which provides as output a signal, V out , which is filtered at 140 . The output of the filter is provided as input to an analog-to-digital converter (ADC) 146 .
[0021] Referring to FIG. 4, a first exemplary embodiment of the circuit 100 a of FIG. 1 is shown. In FIG. 4, V pulse is provided by an oscillator 120 connected to the base of a pnp bipolar junction transistor 112 (Q 1 ) having a supply voltage, V cc , of 5 volts provided by a power source 118 . Q 1 112 is used to switch V cc to the coil sensor through R in 110 . The coil sensor 108 of FIG. 1 can be modeled as a parallel RLC circuit 124 , 126 , 128 . In the circuit shown in FIG. 4, R in is chosen to be much larger than R coil 128 . This allows the resistance of the coil, R coil , to be neglected in determining the effective inductance of the coil to determine fuel level. The value of V coil is relatively low if R in is much greater than R coil as required to measure the effective inductance of the coil 108 a.
[0022] A method of measuring R coil is to measure the voltage, V coil , across the coil 108 . In order to measure V coil , the square wave 202 used to measure the effective inductance is halted temporarily at zero volts and transistor Q 1 in FIG. 4 would remain turned “on” (for about 100 msec) until the coil 108 is fully charged. Once the coil 108 is fully charged, the voltage across the coil is given by
V c o i l = R c o i l R c o i l + R i n × V i n . ( 1 )
[0023] If R in and V in do not vary with temperature, then R coil would be the only temperature dependent variable. To accomplish this, R in is chosen to be a discrete resistor with a low temperature coefficient as is common with carbon resistors. The voltage difference between V cc and V in is negligible for low currents flowing through Q 1 . V cc can vary somewhat with temperature but this can be neglected if the analog-to-digital converter (ADC) 146 is also powered by V cc . Therefore, the coil voltage, V coil , can be approximated to vary in the same fashion as the temperature coefficient of resistance of copper (0.393% per degree C).
[0024] As seen in FIGS. 1 and 8, V in is alternately energized and de-energized at 110 a by a square wave pulse, V pulse , 202 having values of zero volts and V cc volts. When V pulse is positive (Q 1 off), V coil grows exponentially as seen at 208 in FIG. 8. When V pulse is zero (Q 1 on), the inductor 126 is charging and V coil decays exponentially as seen at 204 a. Depending upon the time constant, τ L , of the coil sensor 108 , as seen at 206 a, V coil will decay to a substantially constant value V L after a prescribed time interval, t o . It will be appreciated from FIGS. 9 and 10 that as the core 108 a moves into and out of the coil 108 b, the time constant, τ L , of the coil sensor 108 changes and the rate of the exponential decay will change. Thus, FIG. 9 is representative of the sensor 108 charging when the core 108 a is substantially out of the coil 108 b and FIG. 10 is representative of the sensor 108 charging when the core 108 a is more fully encompassed by the coil 108 b. Q 1 is left turned on for a sufficiently long time interval, t 1 >t o (e.g., 100 msec) until V coil settles to the substantially DC voltage level of V L . At such time, in the circuit model 108 of FIG. 4, inductor 126 acts as a short circuit and capacitor 124 acts an open circuit. Thus, at t 1 a voltage divider is created between V in at 110 a, V coil at 110 b and electrical ground at 148 . Thus, since V in approximates V cc ,
V L ( T c o i l ) = R c o i l ( T c o i l ) R c o i l ( T c o i l ) + R i n × V c c . ( 2 )
[0025] In the circuit of FIG. 1, V L is about 120 mV if R coil is about 25 Ohms and R in is 1000 Ohms. If V L has been measured at a reference temperature T 0 , then
V L ( T 0 ) = R c o i l ( T 0 ) R c o i l ( T 0 ) + R i n × V c c . ( 3 )
[0026] R coil varies with temperature T coil according to the equation:
R coil ( T coil )= R coil ( T 0 )[1+α( T coil −T 0 )], (4)
[0027] where α is the temperature coefficient of resistance. Equations (2) and (3) can be substituted into Eq. (4) to give the difference between T coil and T 0 :
T c o i l - T 0 = 1 α [ ( V L ( T c o i l ) V L ( T 0 ) ) ( V c c - V L ( T 0 ) V c c - V L ( T c o i l ) ) - 1 ] . ( 5 )
[0028] As best understood from Eq. 5, V in may be used therein for V cc .
[0029] Depending upon the location of the inductive coil sensor 108 within the tank 102 (FIGS. 2 and 3), due to the intimate contact between the fuel 104 or fuel vapor 104 a and the coil 108 b, the temperature of the coil is equal to the temperature of the fuel 104 or fuel vapor 104 a respectively, i.e., T coil =T f or T coil =T v .
[0030] To read a low voltage accurately, a higher resolution ADC 146 is required. A method to reduce the accuracy requirements of the ADC 146 is to amplify the V coil signal as shown at 130 in FIG. 5. In FIG. 5, in a second exemplary embodiment of the circuit 100 a, the amplifier 130 of FIG. 1 comprises an operational amplifier 134 having resistors 132 and 138 and capacitor 136 in a negative feedback circuit. The operational amplifier 134 accepts as input thereto V coil , at a positive terminal, and provides as output V out . V out is an amplified V L (Gain=R 138 /R 132 =33.2, V out is about four volts, given that R coil is about 25 Ohms) which is filtered by an RC lowpass filter 142 , 144 and provided as input to a microcontroller ADC 146 to determine coil temperature T coil .
[0031] A second method to increase V coil is to use a smaller R in , such as R in(temp) <R in , as seen in FIG. 6. In FIG. 6, in a third exemplary embodiment of the circuit 100 a, the square wave 202 used to drive Q 1 is halted temporarily while Q 2 is turned “on” until the coil 108 is fully charged. The voltage across the coil is then given by
V c o i l = R c o i l R c o i l + R i n ( t e m p ) × V i n ( t e m p ) . ( 6 )
[0032] Referring to FIG. 7, a schematic diagram of an electric circuit, including a model of an inductive coil sensor 108 , for determining the level of a fuel in a container, is shown generally at 100 b. Diode D 1 , connected between nodes 110 b and 110 c, causes the circuit 100 a to analyze the negative portion 208 of the V coil waveform. The negative voltage 208 is used rather than the positive voltage 204 , 206 because a wiring harness short to either electrical ground or battery voltage will produce a zero output at the Opamp 134 . Resistor 144 provides the discharge resistance with current flowing through the diode 140 and determines the time constant for exponential decay in combination with the inductive coil (L coil /R 144 ). Resistors 146 , 132 and capacitor 148 filter the input signal V out , to the operational amplifier 134 . The Opamp 134 acts as an integrator to provide an analog voltage output, V op , that corresponds to fuel level, which is read by a microcontroller (not shown).
[0033] While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration only, and such illustrations and embodiments as have been disclosed herein are not to be construed as limiting the claims.
|
This invention provides a method and apparatus for utilizing an inductive coil fluid level sensor to measure the temperature of the fuel, or fuel vapors, in a fuel tank depending upon the location of the sensor within the tank. The inductive coil sensor is connected to a Fuel Control Unit containing the sensor electronics to drive the inductive coil sensor and read the corresponding fuel or fuel vapor temperature.
| 6
|
BACKGROUND
[0001] 1. Field
[0002] This patent specification describes an image forming apparatus, and more particularly an image forming apparatus having an improved operability and maintainability associated with an image forming mechanism.
[0003] 2. Related Art
[0004] A background image forming apparatus such as an ink jet printer includes a mechanism for adjusting a gap between a recording sheet and an ink jet head including a port for discharging ink. The gap adjustment mechanism is provided to a guide rod for supporting a carriage having a head. The gap adjustment mechanism includes a lever having an operation unit partially exposing itself to outside of the image forming apparatus, and when a user operates the lever according to a type of paper, the gap adjustment mechanism causes the guide rod to move up and down. When the guide rod moves up and down, the carriage supported by the guide rod moves up and down so that a gap between a sheet and the head is adjusted.
[0005] However, the gap adjustment mechanism is not configured for an image forming apparatus wherein the image forming unit is removable.
SUMMARY
[0006] This patent specification describes an image forming apparatus which includes a removable image forming unit and a gap adjustment mechanism. The removable image forming unit includes at least a carriage having an ink jet head, and a recording medium conveyance member. The gap adjustment mechanism is configured to allow the removable image forming unit to be disengaged from the image forming apparatus, while also providing the functionality that allows a gap between a recording sheet and an ink jet head including a port for discharging ink to be adjusted.
[0007] The gap adjustment mechanism preferably includes a first portion and a second portion which are joined with and separated from each other for attachment and detachment of the removable image forming unit to and from the image forming apparatus.
[0008] In one example, the gap adjustment mechanism includes a carriage travel lever unit having first and second levers separably engaged with each other. The second lever includes an operation part for, in gearing with the first lever, causing the carriage to vertically travel so that a gap between the ink jet head and a sheet on the recording medium conveyance member is adjusted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] A more complete appreciation of the disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0010] FIG. 1 is a schematic illustration of a configuration of an image forming apparatus according to an embodiment;
[0011] FIG. 2A is a front view of a carriage included in the image forming apparatus of FIG. 1 ;
[0012] FIG. 2B is a bottom view of the carriage shown in FIG. 2A ;
[0013] FIG. 3 is a frontal perspective view of the image forming apparatus of FIG. 1 ;
[0014] FIG. 4 is another perspective appearance view of the image forming apparatus of FIG. 1 ;
[0015] FIG. 5 is a perspective view of the image forming apparatus of FIG. 1 with a first door opened and second and third doors (not shown) opened;
[0016] FIG. 6 is a perspective view of the image forming apparatus of FIG. 1 with an image forming unit pulled out;
[0017] FIG. 7 is an illustration of a carriage support mechanism of a sliding rail according to an embodiment;
[0018] FIG. 8 is a schematic illustration for explaining the carriage support mechanism of FIG. 7 ;
[0019] FIG. 9 is an illustration of a gap adjustment mechanism and peripherals thereof in an image forming apparatus according to an example;
[0020] FIG. 10 is a perspective view of the gap adjustment mechanism of FIG. 9 ;
[0021] FIG. 11 is a perspective view of a portion of the image forming apparatus of FIG. 1 with first and second lever units joined;
[0022] FIG. 12 is a perspective view of a portion of the image forming apparatus of FIG. 1 with the first and second lever units separated;
[0023] FIG. 13 is a schematic illustration of an exemplary front edge of the second lever unit which includes a rollable ball member; and
[0024] FIG. 14 is a schematic illustration of another exemplary front edge of the second lever unit which includes a rotatable cylindrical member.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] In describing preferred embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner. Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, particularly to FIG. 1 , an image forming apparatus according to a preferred embodiment is described.
[0026] A general configuration of the image forming apparatus according to the embodiment is described below referring to FIG. 1 . As shown in FIG. 1 , an image forming apparatus 1 includes an image forming unit 2 , an image reading unit 11 , a cartridge loading unit 35 , and a sheet feeding cassette 41 . The image forming apparatus 1 further includes a sheet discharge tray 7 , a separation roller 42 , a friction pad 43 , a pair of sheet feeding rollers 49 , and pairs of sheet discharge rollers 74 , 75 , 76 , and 77 including discharge rollers and spurs.
[0027] The image forming unit 2 is attachably and detachably mounted to the image forming apparatus 1 , and includes a carriage 23 and a guide rod 21 for guiding the carriage 23 . The carriage 23 includes heads (not shown) having respective discharge ports for discharging ink in yellow, magenta, cyan, black 1, and black 2 (hereinafter referred to as Y, M, C, B- 1 , and B- 2 , respectively) onto a sheet. The image forming unit 2 further includes a conveyance belt 31 , a drive roller 32 , a driven roller 33 , a pressure roller 36 , a charge roller 37 , and a guide member (platen) 38 . The conveyance belt 31 is stretched around the drive roller 32 and the driven roller 33 with adequate tension.
[0028] The image reading unit 11 includes an exposure glass 12 , a first traveling body 15 , a second traveling body 18 , a lens 19 , and an image reading element 20 such as a CCD. The first traveling body 15 includes a light source 13 for illuminating a document and a mirror 14 . The second traveling body 18 includes two mirrors 16 and 17 . The image reading unit 11 is arranged at an upper position of the image forming apparatus 1 . The first and second traveling bodies 15 and 18 are arranged so as to be able to make a reciprocating motion in a main scanning direction.
[0029] The cartridge loading unit 35 accommodates ink cartridges 34 C, 34 B- 1 , 34 B- 2 , 34 M, and 34 Y.
[0030] The sheet feeding cassette 41 stores a plurality of sheets P, and can be inserted to and extracted from a front side of the image forming apparatus 1 (a front side in FIG. 1 ).
[0031] In the image reading unit 11 , the image reading element 20 is located behind the lens 19 . The first and second traveling bodies 15 and 18 scan an image to obtain image data, and send an image signal representing the image data to the image reading element 20 . The image reading element 20 receives and digitizes the image signal, and processes the digitized image signal.
[0032] The image forming unit 2 forms an image on a sheet P according to the processed image signal. In detail, the drive roller 32 , driven by a drive motor (not shown), rotates at a predetermined rotation speed so that the conveyance belt 31 rotates at a predetermined speed. The charge roller 37 having a voltage applied from a high-voltage power supply (not shown) charges the conveyance belt 31 . The conveyance belt 31 is guided by the guide member 38 in an area facing the image forming unit 2 . The pressure roller 36 presses the sheet P onto the conveyance belt 31 at a position facing the drive roller 32 .
[0033] Each of the ink cartridges 34 C, 34 B- 1 , 34 B- 2 , 34 M, and 34 Y including ink liquid is connected to a supply pump (not shown). The supply pump is operated as necessary to supply the ink liquid to the carriage 23 . The ink cartridges 34 C, 34 B- 1 , 34 B- 2 , 34 M, and 34 Y are attachably and detachably mounted in the cartridge loading unit 35 .
[0034] The image forming apparatus 1 can receive data of an image from an external equipment via one of a communication cable and a network, and process the data. The image forming unit 2 forms an image from the data. The external equipment for inputting the data to be used by the image forming unit 2 to form the image includes an image processing apparatus such as a computer, an image reading apparatus such as an image scanner, an imaging apparatus such as a digital camera, and so forth.
[0035] As shown in FIG. 2A and as described above, the carriage 23 includes heads 24 C, 24 B- 1 , 24 B- 2 , 24 M, and 24 Y (hereinafter the suffixes representing the colors are omitted as necessary). As shown in FIG. 2B , each of the heads 24 (hereinafter each of the heads 24 is represented as head 24 as necessary) includes 384 discharge ports 24 a arranged in two rows×192 columns. The head 24 determines a distance in a sub-scanning direction in which recording can be performed while the sheet P is stopped. The distance represents a height of one line. After recording of one line is finished, the sheet P is conveyed in the main scanning direction so that next one line can be recorded.
[0036] Next, an image forming operation of the image forming apparatus 1 is described below referring to FIG. 1 .
[0037] After an original is set on the exposure glass 12 of the image reading unit 11 , when a start button (not shown) is pressed, the first and second traveling bodies 15 and 18 start traveling. The first traveling body 15 emits light from the light source 13 . The light is reflected from a surface of the original. While emitting the light, the first traveling body 15 further reflects the reflected light toward the second traveling body 18 . The mirrors 16 and 17 of the second traveling body 18 reflect the directed light into the image reading element 20 through the lens 19 . An image on the original is read through the above operations so that image data is generated. Alternatively, image data is sent from the external equipment (not shown) via a communication cable and so forth.
[0038] The sheet feeding cassette 41 feeds the sheet P to the separation roller 42 and the friction pad 43 so that the sheet P is separated from the rest and is conveyed one after another. The separated sheet P is conveyed by the pair of sheet feeding rollers 49 into the image forming unit 2 . In the image forming unit 2 , the sheet P is pressed by the pressure roller 36 onto the conveyance belt 31 . The sheet P electrostatically adheres to a surface of the conveyance belt 31 having been charged by the charge roller 37 , and is conveyed to a position facing the carriage 23 . When the sheet P comes to the position, the conveyance belt 31 stops moving. Then, while reciprocating according to the image data the carriage 23 discharges predetermined ink liquid at a predetermined position on the sheet P in a stationary state so that one line of an image is recorded on the sheet P. After the one line is recorded in the main scanning direction, the conveyance belt 31 is driven for a predetermined time to move the sheet P for the one line, and is stopped. Then, as described above, while reciprocating in the main scanning direction, the carriage 23 discharges the ink liquid according to the image data to record a next line of the image. The operation is repeated a predetermined number of times to form the image on the sheet P. Then, the sheet P is conveyed to the discharge tray 7 by the pairs of sheet discharge rollers 74 , 75 , 76 , and 77 .
[0039] Next, attachment and detachment of the image forming unit 2 to and from the image forming apparatus 1 are described below referring to FIGS. 3 to 6 .
[0040] As shown in FIGS. 3 and 4 , a housing of the image forming apparatus 1 includes a first door 50 , a second door 51 , and a third door 54 . The first door 50 is arranged on a side face of the image forming apparatus 1 . The second and third doors 51 and 54 are arranged on a front face of the image forming apparatus 1 .
[0041] When the first, second, and third doors 50 , 51 , and 54 are opened, the image forming unit 2 can be detached from and attached to the image forming apparatus 1 .
[0042] As shown in FIG. 5 , the image forming apparatus 1 includes a connector unit 200 , a connector unit 201 , a lower rail 202 , and a rail guide 203 . The connector unit 200 includes connectors 200 a , 200 b , 200 c , 200 d , and 200 e . The connector unit 200 is arranged on the image forming unit 2 , and can be connected with the connector unit 201 . The connector unit 201 includes connectors (not shown), and is arranged on the first door 50 of image forming apparatus 1 . The lower rail 202 is arranged on the image forming unit 2 , and is supported by the rail guide 203 .
[0043] When the first door 50 is opened, connections of the connectors 200 a to 200 e with the corresponding connectors of the connector unit 201 are cut. In other words, opening the first door 50 electrically disconnects the image forming unit 2 from the image forming apparatus 1 .
[0044] After the connection between the image forming unit 2 and the image forming apparatus 1 is broken by the opening of the first door 50 , the second and third doors 51 and 54 (not shown) are opened. Then, the image forming unit 2 is drawn from the image forming apparatus 1 in a frontward direction.
[0045] As a result, the image forming unit 2 is pulled out of the image forming apparatus 1 as shown in FIG. 6 . As shown in FIG. 6 , the image forming unit 2 and the cartridge loading unit 35 are integrally formed according to the embodiment, and the cartridge loading unit 35 can be attached to and detached from the image forming apparatus 1 together with the image forming unit 2 .
[0046] When the image forming unit 2 and the cartridge loading unit 35 are separately formed, the connection between an ink supply path (not shown) extending from the cartridge loading unit 35 to the image forming unit 2 and the image forming unit 2 needs to be broken to pull the image forming unit 2 out of the image forming apparatus 1 .
[0047] In the case, ink may leak out from the ink supply path. In the embodiment, on the other hand, since the image forming unit 2 and the cartridge loading unit 35 are integrally formed, the disconnection between the ink supply path and the image forming unit 2 is not required. As a result, ink does not leak from the ink supply path.
[0048] FIG. 7 illustrates a supporting mechanism for the carriage 23 . As shown in FIG. 7 , the carriage 23 is translatably supported by the guide rod 21 and a sliding rail 22 in the main scanning direction. The guide rod 21 is provided with a gap adjustment mechanism 100 which is described later in detail referring to FIGS. 9 and 10 . The guide rod 21 penetrates the carriage 23 to support the carriage 23 , and is mounted on a side panel (not shown) of the image forming unit 2 . The sliding rail 22 includes a hood 22 a for supporting the sliding rail 22 .
[0049] As shown in FIG. 8 , the carriage 23 is provided with an arm 23 a extending toward the sliding rail 22 , and with a sliding member 23 b arranged on a leading edge of the arm 23 a . The sliding member 23 b contacts a side face of a rail of the hood 22 a to support the carriage 23 .
[0050] Next, the gap adjustment mechanism 100 is described below in detail referring to drawings. The gap adjustment mechanism 100 is used when printing is performed on a sheet having large thickness such as cardboard to maintain an appropriate gap between the sheet and the head 24 . When the gap adjustment mechanism 100 is operated, the guide rod 21 moves up and down. When the guide rod 21 moves up and down, the carriage 23 supported by the guide rod 21 moves up and down together with the guide rod 21 . As a result, the gap between the sheet and the head 24 mounted to the carriage 23 is adjusted.
[0051] As shown in FIG. 9 , the gap adjustment mechanism 100 includes a first lever unit 110 and a second lever unit 120 . The first lever unit 110 includes an eccentric plate 111 and an arm unit 113 . The eccentric plate 111 is provided with a hole 111 a and a stopper 111 b . The stopper 111 b is provided with a convex portion 111 c.
[0052] The arm unit 113 includes a concave portion 113 a for mounting the arm unit 113 , a side plate mount hole 113 b loosely pierced with a notched screw 211 , a spring hold hole 113 c , a guide member 113 d , and a joint concave portion 113 e . The convex portion 111 c is to be set into the concave portion 113 a of the arm unit 113 .
[0053] The second lever unit 120 includes a joint convex portion 121 having a front edge 121 a , a mount hole 122 , and a cover unit 123 serving as an operation unit. The cover unit 123 includes a tab 123 a.
[0054] The image forming unit 2 includes a side plate 2 a . The first lever unit 110 is rotatably mounted to the side plate 2 a . The side plate 2 a includes regulation members 210 a and 210 b , and a hold hole 213 . The image forming apparatus 1 includes a wall 1 a . The wall 1 a includes a pin 150 and a regulation protrusion 151 .
[0055] The first and second lever units 110 and 120 are configured to be separated from and joined with each other in gearing to attachment and detachment of the image forming unit 2 .
[0056] The guide rod 21 is provided with a leading edge. The hole 111 a of the eccentric plate 111 has a substantially D shape at a position off a center of the eccentric plate 111 . The leading edge of the guide rod 21 is trimmed into the same substantially D shape as the hole 111 a , and is engaged with the hole 11 a . The regulation members 210 a and 210 b on the side face 2 a of the image forming unit 2 are arranged above and below, respectively, the stopper 111 b of the eccentric plate 111 . The stopper 111 b abuts on one of the regulation members 210 a and 210 b to regulate an amount of rotation of the eccentric plate 111 .
[0057] With the notched screw 211 screwed into the side plate 2 a of the image forming unit 2 , the first lever unit 110 can be rotatably mounted to the side plate 2 a of the image forming unit 2 . The spring hold hole 113 c holds an end of a twist spring 212 . Another end of the twist spring 212 is held by the hold hole 213 indicated by a dashed line in FIG. 9 . The hold hole 213 is arranged at such a position on the side plate 2 a that a distance between the hold hole 213 and the spring hold hole 113 c becomes the shortest within a rotatable range of the arm unit 113 when the stopper 111 b is positioned at a midpoint between the regulation members 210 a and 210 b . Therefore, when the stopper 111 b is positioned at the midpoint, a force applied by the twist spring 212 to the arm unit 113 reaches maximum. The force applied by the twist spring 212 causes the arm unit 113 to rotate in one of clockwise and anti-clockwise directions in FIG. 9 so that the stopper 111 b abuts on one of the regulation members 210 a and 210 b . In other words, the stopper 111 b is always forced to abut on one of the regulation members 210 a and 210 b . As a result, vibration of the image forming apparatus 1 is prevented from causing the gap adjustment mechanism 100 to move so that the gap between the head 24 and the sheet does not shift.
[0058] The guide member 113 d is arranged at a right end of the arm unit 113 in FIG. 9 . The guide member 113 d includes an inclined plane inclining to a front side toward the joint concave portion 113 e as shown in FIG. 10 . The inclined plane receives the front edge 121 a of the joint convex portion 121 of the second lever unit 120 so that the front edge 121 a abuts on the inclined plane to guide the joint convex portion 121 into the joint concave portion 113 e.
[0059] The second lever unit 120 is rotatably mounted on the wall 1 a of the image forming apparatus 1 with the mount hole 122 put on the pin 150 extending from the wall 1 a by using a ring (not shown). The joint convex portion 121 extends frontward at a left end of the second lever unit 120 . When the image forming unit 2 is installed in the image forming unit 1 , the joint convex portion 121 is joined with the joint concave portion 113 e of the arm unit 113 . A right end of the second lever unit 120 is provided with the cover unit 123 having an arc shape. A part of the cover unit 123 and the tab 123 a are exposed from a window 51 a arranged on a side face of the second door 51 as shown in FIG. 4 . The wall 1 a of the image forming apparatus 1 is provided with the regulation protrusion 151 for regulating rotation of the second lever unit 120 due to self weight.
[0060] Next, a shift operation of the gap between the head 24 and the sheet is described below referring to FIG. 9 . At first, a user pinches the tab 123 a , and moves the tab 123 a to a lower side. When the tab 123 a is moved to the lower side, the second lever unit 120 rotates in the clockwise direction centering on the mount hole 122 . When the second lever unit 120 rotates in the clockwise direction, the joint convex portion 121 pushes up the joint concave portion 113 e of the first lever unit 110 against the force applied by the twist spring 212 . Then, the arm unit 113 of the first lever unit 110 rotates in the anti-clockwise direction centering on the side plate mount hole 113 b , and as a result, the concave portion 113 a pushes down the convex portion 111 c . The convex portion 111 c is pushed down to move the stopper 111 b downward to part from the regulation member 210 a arranged above the stopper 111 b . When the stopper 111 b moves downward, the eccentric plate 111 rotates in the clockwise direction. The clockwise rotation of the eccentric plate 111 causes the guide rod 21 engaged with the eccentric plate 111 to move upward. As a result, the carriage 23 moves upward.
[0061] When the user moves the tab 123 a further down, and the stopper 111 b is caused to move to a position lower than the midpoint between the regulation members 210 a and 210 b , the force applied by the twist spring 212 changes from a force causing the stopper 111 b to move upward to a force causing the stopper 111 b to move downward. The force applied by the twist spring 212 and the force applied by the user to push down the tab 123 a cause the stopper 111 b to abut on the regulation member 210 b arranged below the stopper 111 b . As a result, the gap between the head 24 and the sheet is shifted from a position for plain paper to a position for cardboard.
[0062] The first and second lever units 110 and 120 can be joined as shown in FIG. 11 , and can be separated as shown in FIG. 12 .
[0063] As shown in FIG. 11 , when the image forming unit 2 is placed inside the image forming apparatus 1 , the joint convex portion 121 of the second lever unit 120 is joined with the joint concave portion 113 e of the first lever unit 110 . As shown in FIG. 12 , when the image forming unit 2 is slid in a frontward direction and removed from the image forming apparatus 1 , the first lever unit 110 and the second lever unit 120 are separated from each other. A right side part of the second lever unit 120 arranged at the right of the mount hole 122 , which includes the cover unit 123 , is heavier than a left side part of the second lever unit 120 arranged at the left of the mount hole 122 , which includes the joint convex portion 121 . Therefore, when the second lever unit 120 is released from the joint concave portion 113 e of the first lever unit 110 , the second lever unit 120 rotates in the clockwise direction centering on the mount hole 122 . Then, a lower end of the cover unit 123 abuts on the regulation protrusion 151 , and the regulation protrusion 151 stops the second lever unit 120 to rotate. Therefore, the regulation protrusion 151 prevents the joint convex portion 121 from not abutting on the inclined plane of the guide member 113 d.
[0064] On the other hand, even when the first lever unit 110 is released from the joining with the second lever unit 120 , the force applied by the twist spring 212 keeps the stopper 111 b to abut on one of the regulation members 210 a and 210 b . Therefore, the guide member 113 d of the first lever unit 110 is regulated so as to abut on the joint convex portion 121 .
[0065] When the image forming unit 2 is slid into the image forming apparatus 1 (in a backward direction in FIG. 12 ), the once removed image forming unit 2 is again placed inside the image forming apparatus 1 . When the image forming unit 2 is slid, the front edge 121 a of the joint convex portion 121 of the second lever unit 120 abuts on the inclined plane of the guide member 113 d of the first lever unit 110 . When the image forming unit 2 is further slid into the image forming apparatus 1 with the front edge 121 a of the joint convex portion 121 abutting on the inclined plane of the guide member 113 d , the joint convex portion 121 is guided by the inclined plane to move to a lower side. As the front edge 121 a of the joint convex portion 121 has a spherical shape so that the front edge 121 a has small frictional drag on the inclined plane, the front edge 121 a smoothly moves on the inclined plane. When the image forming unit 2 is further slid into the image forming apparatus 1 to mount the image forming unit 2 on the image forming apparatus 1 , the joint convex portion 121 is guided by the inclined plane to join with the joint concave portion 113 e of the first lever unit 110 . As a result, the first lever unit 110 and the second lever unit 120 are joined with each other.
[0066] While the front edge 121 a of the joint convex portion 121 has a spherical shape in the embodiment, the front edge, in another example, may include a ball member so that the joint convex portion includes a rollable ball. In the case, a concave member is provided at a front end of the joint convex portion so as to receive the ball member. When the front edge abuts on the inclined plane to move toward the joint concave portion, the ball member rolls. As a result, the frictional drag between the inclined plane and the front edge is reduced, and the joint convex portion can smoothly move on the inclined plane. The shape of the member included in the front edge is not limited to the ball shape as shown in FIG. 13 . The front edge may include a cylindrical member so that the joint convex portion includes a rotatable cylinder as shown in FIG. 14 instead. Similar to the front edge shown in FIG. 13 , when the front edge shown in FIG. 14 abuts on the inclined plane to move, the cylindrical member rotates, and the frictional drag between the inclined plane and the front edge can be reduced.
[0067] While the user pinches the tab 123 a to move the tab up and down so that the gap between the head 24 and the sheet can be manually adjusted, the gap may be adjusted in another way. For example, the gap may be automatically adjusted by driving the second lever unit by a motor. In such a case, the user sets a type of paper in an operation section, and the motor can be driven based on, for example, set information to rotate the second lever unit so that the gap between the head and the sheet is adjusted. In another example, a thickness detection sensor for detecting a thickness of the sheet may be provided in a sheet conveyance route, and the gap may be adjusted by driving the motor based on output information of the thickness detection sensor to rotate the second lever unit. The thickness detection sensor may be a transmit photodetector. The transmit photodetector detects a thickness of the sheet from an amount of light transmitted the sheet. As the sheet becomes thicker, the amount of light transmitted the sheet becomes smaller. Therefore, when the amount of light is smaller than a predetermined value, it is judged that the sheet is cardboard, and the motor is driven to rotate the second lever unit so that the gap between the head and the sheet is shifted to the position for cardboard.
[0068] While in the examples and embodiments described supra the first and second lever units 110 and 120 include the joint concave portion 113 e and convex portion 121 , respectively, and the first and second lever units 110 and 120 are separated from and joined with each other in gearing to attachment and detachment of the image forming unit 2 , in another example, the first lever unit can include a joint convex portion and the second lever unit can includes a joint concave portion instead. In the case, a guide member for guiding the joint convex portion of the first lever unit to the joint concave portion of the second lever unit can be provided at a left end of the second lever unit. In such an example, when the image forming unit is attached to the image forming apparatus, the joint convex portion of the first lever unit abuts on an inclined plane provided to the guide member of the second lever unit. Further, when the image forming unit is slid in an attaching direction, the joint convex portion of the first lever unit pushes the inclined plane. As a result, the second lever unit rotates, and the joint convex portion of the first lever unit relatively moves on the inclined plane to join with the joint concave portion of the second lever unit.
[0069] Further, while in the examples and embodiments described supra the regulation members 210 a and 210 b for regulating the rotation of the first lever unit 110 are arranged on the side face 2 a of the image forming unit 2 , the regulation members may be arranged on an outer casing covering the side face of the image forming unit.
[0070] The above-described specific examples and embodiments are illustrative, and many variations can be introduced on these examples and embodiments without departing from the spirit of the disclosure or from the scope of the appended claims. For example, elements and/or features of different examples and illustrative embodiments may be combined with each other and/or substituted for each other within the scope of this disclosure and appended claims.
[0071] This patent specification is based on a Japanese patent application, No. JP2005-079038 filed on Mar. 18, 2005 in the Japan Patent Office, the entire contents of which are incorporated by reference herein.
|
An image forming apparatus includes a removable image forming unit including at least a carriage having an ink jet head, and a recording medium conveyance member, and includes a gap adjustment mechanism including a carriage travel lever unit having first and second levers separably engaged with each other. The second lever includes an operation part for, in gearing with the first lever, causing the carriage to vertically travel so that a gap between the ink jet head and a sheet on the recording medium conveyance member is adjusted.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for reducing the thickness of a piece of material, and, more particularly, is directed to a portable apparatus for planing wood.
2. Description of the Invention Background
Generally, a planer is used to finish a piece of lumber, i.e., to uniformly reduce the thickness of the lumber while achieving a smooth, flat surface. The basic components of a typical planer are a table, a cutterhead, infeed and outfeed rollers, and a motor. The table levels and supports the workpiece as the workpiece is fed into the planer and is passed under the rapidly rotating cutterhead. The cutterhead includes two or more knives secured within its cylindrical head which cut away thin slivers of wood as the workpiece is passed beneath it. The powered infeed and outfeed rollers grip and support the workpiece as they advance and pull the workpiece through the cutterhead. These rollers are typically spring mounted so that the pressure exerted by the rollers on the workpiece can be adjusted to ensure the rollers properly engage and guide the workpiece through the planer. The motor drives the cutterhead and the powered rollers.
Typical portable planers have only one cutterhead located above the planer table. Thus, both sides of the board must be passed through the planer to attain the desired finished surface. Additionally, several passes through the planer may be required to remove the desired amount of wood from the workpiece. For instance, portable planers, due to their size and weight, cannot remove more than 1/32 of an inch of stock in one pass for a finished cut and can remove about a maximum of 3/32 of an inch on a preliminary cut. Thus, several passes through the planer may be required to achieve a desired thickness of the workpiece. The depth of cut adjustments are made by lowering the cutterhead towards the workpiece or by raising the table, and thus the workpiece, towards the cutterhead.
Prior planers, particularly portable planers, cause damage to each end of the workpiece. In particular, when the workpiece is fed into the planer, it is initially only supported by the powered, spring mounted infeed roller. When the workpiece contacts the cutterhead, it is thrust against the cutterhead which causes the cutterhead to jump. This jumping action results in indentations or "snipes" being formed in at least the first few inches of the workpiece. The sniping discontinues when the workpiece is advanced further into the planer and is supported by both the infeed and outfeed roller. The support by both rollers prevents the workpiece from being thrust against the cutterhead. Similarly, as the workpiece exits the planer, and is supported only by the outfeed roller, the workpiece is again thrust against the cutterhead, causing it to jump. This jumping action again results in snipes being formed in the last few inches of the workpiece. Therefore, current planers cause damage to both the first and the last few inches of each end of a workpiece, which are therefore not useable as finished stock.
Thus, there is a need for a planar that can uniformly reduce the thickness of a workpiece without causing damage to each end of the workpiece.
There is a further need for a planer that is relatively lightweight and a portable.
There is yet another need for a planer with the above-mentioned attributes that is relatively inexpensive to manufacture.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a planer apparatus having a frame member that supports and mounts at least one column member. The frame member includes a top portion and a bottom portion. A head, which includes a cutterhead for removing slivers of wood from a workpiece, is slidably engaged on the column member between the top and bottom portions of the frame member. The head member has two side portions. A locking plate, mounted within the bottom portion of the frame member, extends to the top portion of the frame member such that the locking plate is adjacent to the side portions of the head member. A locking assembly mounted on the head member tightens the side portions of the head member and the locking plates together such that when the locking assembly is tightened, the head member is maintained at a particular vertical position along the column member.
In a preferred embodiment, four column members are mounted between the top and bottom portions of the frame member and two locking plates are mounted on either side of the bottom portion of the frame member. The locking plates are made from steel and are substantially U-shaped such that each side of the locking plates forms a fork. The locking assembly extends between the forks of the locking plates. The locking assembly includes a rod assembly and a locking bar assembly. The rod assembly includes a rod having threads on one end and a hub on the other end and the rod assembly is received within the locking bar assembly. The hub of the rod assembly includes a lever which is used to rotate the rod assembly within the locking bar assembly. The locking bar assembly includes a shoe on each end and a tube extending between the shoes. The locking bar assembly extends between the locking plates such that the shoes of the locking bar assembly abut the forks of the locking plates. The shoes include indentations that are sized and shaped to correspond to the size and shape of the forks of the locking plates.
The locking bar assembly may further include spacers mounted between the ends of the tube and each shoe. One side of the tube is threaded on its inside and the spacer mounted between the shoe and the tube on the threaded side includes a screw and a lock nut. The screw has threads corresponding to the threads on the inside of the tube such that when the screw is threadably engaged with the tube, the distance between the shoes can be extended such that the shoes abut the forks of the locking plate.
The rod assembly extends beyond the side portions of the head member such that the hub of the rod abuts the outer side of one side portion of said head member and the threaded end of the rod extends beyond the outer side of the other side portion of the head member. The rod assembly includes a lock nut which engages the threaded end of the rod for tightening the locking assembly against the locking plate and the side portions of the head member to maintain the head member in a particular vertical location along the column members.
Accordingly, the present invention provides solutions to the aforementioned problems present in planer apparatuses that cause indentations or snipes on each end of the workpiece by providing a planer apparatus that secures the head member in a particular vertical location. These and other details, objects, and advantages of the invention will become apparent as the following description of the present preferred embodiment thereof proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, there are shown present preferred embodiments of the invention wherein like reference numerals are employed to designate like parts and wherein:
FIG. 1 is a perspective view of a preferred planer apparatus of the present invention;
FIG. 2 is a front elevational view of a preferred planer apparatus of the present invention;
FIG. 3 is an enlarged partial cross-sectional view of a preferred planer apparatus taken along section III--III of FIG. 2;
FIG. 4 is a partial side view of a preferred planer apparatus taken along section IV--IV of FIG. 3;
FIG. 5 is a top view of a disassembled locking assembly of the present invention;
FIG. 5a is a side view of the locking assembly of the present invention taken along section a--a of FIG. 5;
FIG. 6 is a top view of the locking assembly inserted within the planer apparatus; and
FIG. 7 is a partial side view of a preferred planer apparatus taken along section VII--VII of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings for the purpose of illustrating the present preferred embodiments of the invention only and not for purposes of limiting the same, the Figures show a planer apparatus, generally designated as 10. While the planer apparatus is well-adapted to be a portable apparatus, those skilled in the art will appreciate that the subject planer apparatus 10 can be constructed as a "permanent" fixture for planing purposes. Accordingly, the subject invention should not be limited to use solely as a portable planer apparatus.
Referring more particularly to FIGS. 1 and 2, there is shown a planer apparatus 10 that includes a frame, including top frame members 20 and 22 and a base 24, a table 30 mounted on the base 24 for supporting a workpiece, and a handle 12 mounted between the top frame members 20 and 22, for carrying and transporting the planer apparatus 10. Side guards 14 and 16, mounted between the top frame members 20, 22 and the base 20 24, enclose the movable drive systems of the planer apparatus 10. In a preferred embodiment, the frame members 20, 22 and the base 24 are made from aluminum. The base 24 is substantially rectangular in shape and supports four column members 40, 42, 44, and 46. See FIG. 3. In particular, the columns 40, 42, 44, and 46 are preferably mounted between the top frame members 20 and 22 and the base 24 at or near each corner of the base and the corresponding corner of the top frame members 20 and 22. The columns 40, 42, 44, and 46 are preferably made from corrosion resistant steel and slidably engage a head 50, in which a cutterhead 80 is rotatably mounted. As will be described in further detail below, when rotated, the cutterhead uniformly removes small amounts of wood from a workpiece as the workpiece is passed through the planer apparatus 10. A motor 60, mounted on the head 50, rotates the cutterhead, as well as the infeed and outfeed rollers 90 and 92, which are used to help support and move the workpiece through the planer apparatus 10.
The height of the head 50 relative to the table 30, and thus the height of the cutterhead 80, is adjusted by the height adjusting spindles 66 and 68. See FIG. 3. The height adjusting spindles 66 and 68 are mounted between the top frame members 20, 22 and the base 24 and are in threaded engagement with the head 50. The height adjusting spindles 66 and 68 are rotated by rotating a crank 67 and the rotation of the spindles is translated to axial movement of the head 50. Thus, depending upon which direction the crank is rotated, the head is moved axially either upwards, towards the top frame portions 20, 22, or downwards, towards the table 30. The position of the head 50 relative to the table 30 determines how much wood from the workpiece is removed by the planer apparatus 10 in a particular pass of the workpiece through the apparatus 10. A locking assembly 100 mounted within head 50 maintains the head 50 in the desired vertical position relative to the table 30. In particular, head locking plates 70 and 74 are attached to the base 24 and extend to the top frame members 20 and 22. See FIGS. 4 and 7. The locking plates 70, 74 are preferably made from steel, are U-shaped, and include forks 71, 72 and 75, 76, respectively. The locking assembly 100 presses the head 50 against the forks 71, 72 and 75, 76 of the locking plates 70 and 74, respectively, to retain the head 50 in a desired position, as will be discussed further below.
Referring as well to FIG. 3, a bottom view of the head 50 is shown slidably engaged on column members 40, 42, 44, and 46. The head 50 is preferably made from aluminum casting and includes side portions 52 and 54. The cutterhead 80 is rotatably mounted within the side portions 52 and 54 of head 50. An infeed roller 90 and an outfeed roller 92 are rotatably mounted within the side portions 52 and 54 of the head 50 on either side of the cutterhead 80. Referring as well to FIGS. 4 and 7, the axle 81 of the cutterhead 80 extends between the forks 71, 72 and 75, 76 of the locking plates 70 and 74, respectively. The locking assembly 100 is preferably positioned above the cutterhead 80 and also extends between the forks 71, 72 and 75, 76 of the locking plates 70 and 74 and straddles the side portions 52 and 54 of the head 50 to retain the head 50 in a vertical position.
Referring more particularly to FIG. 5, the locking assembly 100 includes a rod assembly 110 and a locking bar assembly 120, the rod assembly 110 being received within the locking bar assembly 120. The rod assembly includes a rod 112 threaded on one end 114 and having a hub 116, preferably having a hexagonal shape, on the other end. An actuator lever 118, including a knob 119, is preferably threadably attached to the hub 116.
As shown in FIG. 5, the locking bar assembly 120 includes head lock shoes 122 and 124, a hollow cylindrical tube 126, and spacers 130 and 132. The head lock shoes 122 and 124 include cylindrical portions 121 and 123, respectively. The tube 126 preferably includes one end 125 that is machined to have a smaller outer diameter than the outer diameter Dl of the tube 126. The end 125 fits within the spacer 130 and the cylindrical portion 121 of the head lock shoe 122 such that an edge 128 of the tube 126 abuts the spacer 130. The other end 127 of the tube 126 is internally threaded to receive spacer 132. In particular, the spacer 132 includes a hollow jack screw 134 and a lock nut 138. One end 133 of the jack screw 134 is threaded and corresponds with the threads on the inside end 127 of the tube 126 and the other end 135 of the jack screw 134 comprises a cylindrical surface which is sized to fit within the cylindrical portion 123 of the head lock shoe 124. The jack screw 134 also includes a hexagonal surface 136 to facilitate the turning thereof by, for example, a wrench. Thus, the lock nut 138 is threaded onto the jack screw 134 and end 133 of the jack screw 134 is then threaded into the end 127 of the tube 126. The position of the jack screw 134 within the threaded end 127 of the tube 126 is secured when the lock nut 138 is tightened against the edge 129 of the tube 126. The other end 135 of the jack screw 134 is inserted within the cylindrical portion 123 of shoe 124. Each component, the shoes 122, 124, including cylindrical portions 121, 123, the tube 126, and the spacers 130, 132, including the jack screw 134 and the lock nut 138, each include a bore to define a coaxial passage extending through the locking bar assembly 120 for receiving the rod assembly 110. The jack screw 134 enables the overall length of the locking bar assembly 120 to be adjusted to compensate for variances in manufacturing dimensions, as will be explained in further detail below. Alternatively, the end 127 of the tube 126 and the spacer 132 may have the same design as the tube end 125 and the spacer 130. In this embodiment, the length of the locking bar assembly 120 cannot be adjusted. However, in either embodiment, the tube 126 is in secured engagement with the head lock shoes 122 and 124. This arrangement of the locking bar assembly 120 ensures that when the locking assembly 100 is tightened, the vertical position of the head 50 relative to the table 30 is maintained without causing alignment problems through over-tightening the locking assembly 100, as will be discussed in further detail below.
Referring as well to FIG. 5a, the head lock shoes 122 and 124 are preferably made from aluminum casting and are substantially rectangular in shape. Each shoe 122, 124 includes indentations 122a, 122b and 124a, 124b, respectively, on each side of the shoe. These indentations correspond in both size and shape to the forks 71, 72 and 75, 76 of the locking plates 70 and 74. Referring more particularly to FIG. 6, the locking assembly 100 is received between the side portions 52 and 54 of the head 50 such that the locking bar assembly 120 is located between the locking plates 70 and 74. Specifically, the indentations 122a, 122b and 124a, 124b of the head lock shoes 122 and 124 fit securely against the forks 71, 72 and 75, 76 of the locking plates 70 and 74 and the forks 71, 72 and 75, 76 abut the side portions 52 and 54 of the head 50. In the preferred embodiment, to establish a "snug" fit with the forks 71, 72 and 75, 76 of the locking plates 70, 74, the jack screw 134 is rotated within tube 126 to either expand or contract the locking bar assembly 120. As used herein, "snug" means that the indentations 122a, 122b and 124a, 124b are in contact with, and exert a slight force against, the forks 71, 72 and 75, 76 of the locking plates 70 and 74. When the desired fit is obtained between the shoes 122, 124 and the forks 71, 72 and 75, 76, the lock nut 138 is secured against the edge 129 of the tube 126 to lock the jack screw 134 in position. After the locking bar assembly 120 has been installed in the above-described manner, the threaded end 114 of the rod assembly 110 is inserted through the side portion 54 of head 50, into the locking bar assembly 120, and through the side portion 52 of the head 50. Referring as well to FIG. 7, a lock nut 140, having a threaded bore 142, is positioned adjacent to the side portion 52 of the head 50. The threaded bore 142 receives the threaded end 114 of the rod 112. In a preferred embodiment, the lock nut 140 is rectangular in shape; however, any shape is suitable so long as the lock nut is sufficiently large to engage the side portion 52 of the head 50 and to distribute the forces to 5 tighten the locking assembly 100. To tighten the locking assembly 100, a user rotates the lever 118 which turns the rod 112. The rod 112 rotates within the locking bar assembly 120 and the end 114, in threaded engagement within bore 142, rotates within the lock nut 140. Thus, the locking assembly 100 is either tightened or loosened depending upon whether the lever 118 is rotated clockwise or counter-clockwise. When the locking assembly 100 is tightened, the end 117 of the hub 116 presses against the side portion 54 of the head 50 and the lock nut 140 is pulled into the side portion 52 of the head 50. This results in the shoes 122 and 124 being firmly clamped against the forks 71, 72 and 75, 76 of the locking plates 70 and 74 and the forks 71, 72 and 75, 76 being firmly clamped against the side portions 52 and 54 of the head 50. This arrangement of the locking bar assembly 120, i.e., the 20 length of the tube 126 and the engagement of the tube 126 within spacers 130, 132 enables the locking assembly 100 to maintain the head 50 in a particular vertical position relative to the table 30 while preventing the locking assembly 100 from being over-tightened which could result in deformation of the planer apparatus 10. The maintenance of the vertical position of the head 50 relative to the table 30 while the planer is in use prevents the workpiece from being marred with indentations or snipes on each end of the workpiece.
In a preferred embodiment, the cutterhead 80 is rotatably mounted within the side portions 52 and 54 of the head 50, i.e., the axle 81 of the cutterhead 80 is rotatably mounted within conventional bearings 82 mounted in the head 50. The cutterhead 80 includes at least two knives 84 mounted in a flute 86 formed in the cutterhead 80. The knives 84 are preferably secured using lock screws 85. When the cutterhead is rotated, the knives 84 remove small amounts of wood from the workpiece to plane the workpiece to a desired thickness.
The infeed roller 90 and the outfeed roller 92 are also rotated to help grip and guide the workpiece into and out of the planer apparatus 10. In the preferred embodiment, the infeed and outfeed rollers 90, 92 are coated with neoprene, or a similar like material, which is capable of gripping and guiding the workpiece, yet is malleable to prevent damage to the finished workpiece surface. The axles 91 and 93 of the infeed roller 90 and the outfeed roller 92 are rotatably mounted in bearings 94 and 96, respectively. The bearings 94 and 96, which are preferably conventional bearing blocks, are mounted in the head 50 and are held in place using bearing block mounting plates 95 and 97, which are screwed into the head 50. The bearings 94 and 96 are preferably spring mounted to head 50 by springs 98 and 99 which are placed between the bearings 94 and 96 and the head 50. See FIGS. 4 and 7. The infeed and outfeed rollers are spring mounted to enable the rollers to adjust to the uneven surface of a workpiece. However, as noted previously, as the workpiece is fed into the planer apparatus 10 and is supported only by the spring mounted infeed roller, there is a tendency for the end of the workpiece to be thrust up against the cutterhead 80. Similarly, as the workpiece exits the planer apparatus 10, and is secured only by the spring mounted outfeed roller, there is a tendency for the exit end of the workpiece to be thrust up against the cutterhead 80. If the cutterhead 80 is not secured, it can move when the workpiece is thrust against it, resulting in the indentations or snipes being formed into each end of the workpiece. Notably, the threaded spindles 66 and 68, onto which the head 50 is threadably mounted, typically have some play between the threads. Thus, the spindles are generally not sufficient to retain the head 50 in a particular vertical position relative to the table 30. However, when the locking assembly 100 is tightened, it secures the head 50, and thus the cutterhead 80, against the locking plates 70, 74 such that substantially no vertical movement of the cutterhead 80 occurs when the workpiece is thrust against the cutterhead 80 as the workpiece enters and exits the planer apparatus 10. Thus, the locking assembly 100 reduces the amount of damage caused to each end of the workpiece due to sniping, resulting in a significant cost savings as each end of the workpiece no longer needs to be discarded because it's damaged.
The height of the cutterhead 80 in relation to the table 30, via vertical movement of the head 50, determines the amount of wood that is removed from the workpiece. A scale 18 is preferably located on the side guard 16 to show the exact position of head 50, and thus the cutterhead 80, in relation to table 30. In particular, the head preferably includes a pointer 19 which indicates the position of the cutterhead 80 on the scale 18 in relation to table 30. The position of the cutterhead 80 relative to the scale 18 determines the amount of wood that is to be removed from the workpiece with each pass of the workpiece through the planer apparatus 10. As previously discussed, rotation of the height adjusting spindles 66 and 68 cause the head 50 to move axially along the columns 40, 42, 44, and 46. In particular, the crank 67 rotates the spindle 68. The spindle 68 is rotatably connected to spindle 66 by a sprocket and chain arrangement known in the art. Thus, rotation of spindle 68, using the crank 67, simultaneously causes the rotation of spindle 66 such that each side of the head 50 is axially translated equally and thus remains level to ensure even planning of the workpiece. In a preferred embodiment, spindles 66 and 68 are provided with acme threads. The skilled artisan will appreciate that acme threads are more suited for raising and lowering an apparatus, i.e., such as the head 50, and can withstand high loads. The spindle threads are preferably designed such that one rotation of the crank 67 translates to a specified axial distance traveled by the head 50. Thus, preliminary adjustments of the cutterhead 80 height can be made by rotating the crank 67 through a specified rotation.
Referring to FIG. 3, the cutterhead 80 is operably coupled to the motor 60. In particular, a belt 64 is operably supported on a drive pulley 83 (which is mounted onto the axle 81 of cutterhead 80) and a drive pulley 63 (which is mounted on a shaft 62 of motor 60) to operably couple the cutterhead 80 to the motor 60. Additionally, the infeed roller 90 and the outfeed roller 92 are operably coupled to the cutterhead 80 in a known manner. In particular, a gear reduction box 150, including a plurality of gears mounted to the axles 81, 91, and 93 of the cutterhead, the infeed roller, and the outfeed roller, respectively, are engaged with gear chains to translate the rotation of the cutterhead 80, which is rotated by the motor 60, into rotation of the infeed and outfeed rollers 90, 92. As is known in the art, the speed (revolutions per minute) of the infeed and the outfeed rollers 90, 92 is reduced by the gear box 150. Thus, the motor serves to rotate the shaft 62 and drive the belt 64 to rotate the cutterhead 80. Rotation of the cutterhead 80 causes the gears and gear chains within gear box 150 to rotate, resulting in rotation of the infeed and outfeed rollers 90 and 92 at the desired speed. Those of ordinary skill in the art will appreciate that other drive/gear arrangements could be successfully employed.
Referring to FIGS. 1 and 2, the table 30 is formed by attaching a wear plate, preferably made from stainless steel, to the base 24. This wear plate facilitates the workpiece being easily guided across the table. Additionally, the table 30 includes a front table 32 and a back table 34 that each abut opposite sides of the main table 30. The front table 32 and the back table 34 include height adjusting screws (not shown) which are mounted to the bottom frame portion 24 of the planer apparatus 10 to ensure that the workpiece is supported by a substantially even, level surface as it is fed into the planer. The base 24 also preferably has a criss-cross pattern of ribs formed within it. This rib structure adds rigidity to the base and thus reduces the amount of deformation of the table 30. This reduction in table deformation also helps to reducing sniping because deflection of the table tends to cause the workpiece to be unevenly cut by the cutterhead 80.
As can be gleaned from the above description, the subject invention represents a vast improvement over prior planing apparatuses. In particular, the subject invention significantly reduces material damage resulting from sniping and chatter of the cutterhead during planing. Such novel attributes serve to greatly reduce the amount of damaged material that typically must be discarding after planing. The subject invention is also capable of being constructed in a manner that facilitates its portability, thus making it an ideal choice for the home wood-working shop. The skilled artisan will appreciate that various changes in the details, materials, and arrangements of the components which have herein been described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principal and scope of the invention as expressed in the appended claims.
|
A locking apparatus for selectively locking a driven cutterhead at a desired elevation relative to a support surface of a planing apparatus having a frame assembly for supporting the cutterhead relative to the support surface. The locking apparatus includes at least one locking plate having a first and second sides attached to the frame assembly. The locking apparatus also includes a first clamping block attached to the cutterhead and disposed adjacent to the first side of the locking plate and a second clamping block disposed adjacent to the second side of the locking plate. Additionally, the locking apparatus includes means attached to the first and second clamping blocks for selectively drawing the first and second clamping blocks into clamping engagement with the locking plate to lock the cutterhead at a desired elevation.
| 1
|
CROSS-REFERENCE TO OTHER APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 08/846,318, filed Apr. 30, 1997, now U.S. Pat. No. 5,951,951, issued on Sep. 14, 1999.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to measuring and detecting coagulation and coagulation-related activities in fluids, particularly human blood. More particularly, the present invention relates to an improved activated clotting time test for citrated blood samples which provides accurate and reliable detection of coagulation-related activities regardless of the amount of time which has elapsed since the sample was drawn.
2. Description of the State of the Art
Blood coagulation is a complex chemical and physical reaction which occurs when blood comes into contact with an activating agent, such as an activating surface or an activating reagent. In accordance with one simplified conceptual view, the whole blood coagulation process can be generally viewed as three activities: platelet adhesion, platelet aggregation, and formation of a fibrin clot. In vivo, platelets flow through the blood vessels in an inactivated state because the blood vessel lining, the endothelium, prevents activation of platelets. When a blood vessel is damaged, however, the endothelium loses its integrity and platelets are activated by contact with tissue underlying the damaged site. Activation of the platelets causes them to become “sticky” and adhere together. Additional platelets then adhere to the activated platelets and also become activated. This process continues until a platelet “plug” is formed. This platelet plug then serves as a matrix upon which blood clotting proceeds.
If the chemical balance of the blood is suitable, thrombin is then produced which causes conversion of fibrinogen to fibrin, which forms the major portion of the clot mass. During clotting, additional platelets are activated and trapped in the forming clot, contributing to clot formation. As clotting proceeds, polymerization and cross-linking of fibrin serves as the permanent clot. Thus, platelet activation plays a very important function in blood coagulation.
A number of different medical apparatuses and testing methods exist for measuring and determining coagulation and coagulation-related activities of blood. These apparatuses and methods provide valuable medical information to an attending physician. For example, the information assists a physician in prescribing medication, predicting post-operative bleeding and prescribing various therapies. Some of the more successful techniques of evaluating blood clotting and coagulation are the plunger techniques illustrated by U.S. Pat. No. 4,599,219 to Cooper et al., U.S. Pat. No. 4,752,449 to Jackson et al., and U.S. Pat. No. 5,174,961 to Smith, all of which are assigned to the assignee of the present invention, and all of which are incorporated herein by reference.
Automated apparatuses employing the plunger technique for measuring and detecting coagulation and coagulation-related activities generally comprise a plunger sensor cartridge or cartridges and a microprocessor controlled apparatus into which the cartridge is inserted. The apparatus acts upon the cartridge and the blood sample placed therein to induce and detect the coagulation-related event. The cartridge includes a plurality of test cells, each of which is defined by a tube-like member having an upper reaction chamber where a plunger assembly is located and where the analytical test is carried out, and a reagent chamber which contains a reagent or reagents. For an activated clotting time (ACT) test, for example, the reagents include an activation reagent to activate coagulation of the blood. A plug member seals the bottom of a reagent chamber. When the test commences, the contents of the reagent chamber are forced into the reaction chamber to be mixed with the sample of fluid, usually human blood or its components. An actuator, which is a part of the apparatus, lifts the plunger assembly and lowers it, thereby reciprocating the plunger assembly through the pool of fluid in the reaction chamber. The plunger assembly descends by the force of gravity, resisted by a property of the fluid in the reaction chamber, such as its viscosity. When the property of the sample changes in a predetermined manner as a result of the onset or occurrence of a coagulation-related activity, the descent rate of the plunger assembly therethrough is changed. Upon a sufficient change in the descent rate, the coagulation-related activity is detected and indicated by the apparatus.
Certain discoveries have been made which contribute to a better understanding of the role of platelets in an ACT test. Such discoveries suggest that the activation of the platelets has a significant and previously unappreciated effect on ACT test results. While it has long been suspected that platelet activation contributes to total blood coagulation times, until fairly recently, there has been no technique available for confirming and quantifying the impact of platelet activation on ACT. U.S. Pat. No. 5,314,826 to Baugh describes an improved ACT test which includes a platelet activation phase to accommodate the effects of platelet activation. In the platelet activation phase an activating reagent is mixed with a sample of blood to be tested, then the mixture is gently agitated in such a manner and for a period of time sufficient to establish a predetermined and predictable contribution to the ACT from platelet activation. To evaluate platelet function, two simultaneous ACT tests (with different platelet activation phases) are performed, and the difference between the ACTs is indicative of the platelet functionality of the sample of blood. In a further improvement, described in U.S. Ser. No. 08/640,275, filed Apr. 30, 1996, the sample of blood is mixed with a chemical platelet activating agent to facilitate the participation of active platelets in the blood clotting reaction, thereby shortening the clotting time of the blood. If the platelets are inactive or not functioning normally, the activator will have minimal or no effect on the clotting time. Both U.S. Pat. Nos. 5,314,826 and 5,925,319 are assigned to the assignee of the present invention, and are incorporated by reference in their entireties herein.
Although previous apparatuses using the plunger sensing technique have proven generally satisfactory, the need for certain enhancements has been identified. Specifically, while these techniques can measure and detect coagulation and coagulation-related activities in a sample of blood, none are designed to reliably reflect the true in vivo coagulation conditions regardless of the amount of time which has lapsed since the blood sample was drawn. Most of the apparatuses currently available for monitoring platelet function are designed specifically for freshly drawn blood, or the test must be performed on a sample of citrated whole blood at a predetermined time after the blood is drawn, for reasons which will be discussed below. Citrated whole blood is whole blood collected in a medium containing a calcium chelating agent, such as sodium citrate (citrate). The whole blood is mixed with the citrate or calcium chelating agent when the sample is collected.
Calcium plays a significant role in the analysis of blood clotting. The act of drawing blood initiates clotting reactions, and unless something is done to stop the process, the clotting times have no diagnostic significance. The formation of a clot is a multi-step process and several of these steps require the presence of calcium ions. By removing the calcium ions, as is the effect when the blood is collected in citrate, the blood can be prevented from clotting. To reinitiate the clot-forming process, calcium is added back into the whole blood (recalcification). Many ACT tests, including many platelet function assays, can be performed on blood which has been collected into a medium containing a calcium chelating agent. A calcium chelating agent is a chemical which reacts with the calcium in such a fashion that the calcium can no longer function in blood coagulation. The most common chelating agent is a salt of citric acid (citrate), since it has the fewest side effects on the components of the clotting system. By collecting blood into a medium containing a calcium chelating agent such as citric acid, sample collection and the assay on the citrated sample can be separated by a time period of up to several hours.
Most hospitals and laboratories would like to be able to use citrated whole blood. The use of citrated whole blood means that the assay does not have to be run at bedside, and allows transport of the sample from the patient to a clinical laboratory for testing. Existing coagulation detection apparatuses can perform ACT tests on recalcified samples of whole blood collected initially in citrate or in some other calcium chelating agent, to thereby provide the convenience for delaying the assay from the time when the blood sample was collected. Unfortunately, for many individuals, there is a marked difference in results of an ACT test run at bedside and a recalcified ACT test on a citrated whole blood sample. In an ACT test performed on fresh drawn whole blood, the contribution of platelets is rate limiting. However, in a recalcified ACT test performed on citrated whole blood at a significant time after collection of the sample, some component of platelet participation has been activated. Consequently, the time component of coagulation required to form this activity is not reflected in the recalcified ACT test results because the activity has partially or fully developed. Thus, after approximately the first 30-60 minutes after drawing the blood sample in citrate, the coagulation component from platelet activity has concluded and, consequently, when the recalcified ACT test is performed, the amount of time for the activation is not included within the results of the ACT test. The recalcified activated clotting times of the citrated blood get shorter and shorter until activation is complete. The magnitude of this initial drop in the activated clotting time depends upon the elapsed time after drawing the sample, as well as the individual subject or patient from whom the blood was drawn. Platelets in a stored citrated sample become activated at a rate and to a degree which varies from individual to individual.
Thus, to obtain ACT test results which reliably reflect the true condition of platelets in vivo, the ACT test must be performed either at bedside approximately contemporaneously with drawing the blood sample or at a predetermined time after collection to extrapolate the patient's baseline (non-activated) clotting time. When the test cannot be performed at bedside, the time of draw must be specified on the sample tube, as well as instructions regarding the timing of the test(s). Not only does this time factor complicate the performance of ACT tests, but such tests are generally subject to variable results and inaccuracies because individual variations in collection and test procedures are introduced by the technicians processing the samples and conducting the tests.
A need therefore exists for an improved activated clotting time test which can accurately and reliably detect coagulation and coagulation-related activities in blood samples regardless of the amount of time which has elapsed since the sample was obtained. The ability to measure and evaluate platelet activation and function independent of the time interval between collection and testing is important, particularly when the blood sample must be transported to a different location for evaluation. At the present time, there is no known apparatus or method which is universally applicable to both fresh-drawn blood and citrated whole blood which has been stored for an unspecified amount of time.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide an improved activated clotting time test.
It is a more specific object of the present invention to provide an improved activated clotting time test which can detect coagulation and coagulation-related activities, and particularly platelet function-related activities, in a citrated blood sample regardless of the amount of time which has elapsed since the sample was obtained.
It is further an object of the present invention to provide an improved activated clotting time test which reliably reflects the true in vivo platelet function, and which can accommodate citrated whole blood which has been stored for an unspecified length of time.
Additional objects, advantages and novel features of this invention shall be set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the following specification or may be learned by the practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities, combinations, and methods particularly pointed out in the appended claims.
To achieve the foregoing and other objects and in accordance with the purposes of the present invention, as embodied and broadly described therein, the present invention is directed to an apparatus for performing a platelet functionality test on a blood sample. The apparatus comprises a plurality of test cells. Each of the cells comprises a platelet function restoration agent, an anticoagulant agent and a clotting reagent. At least one of the cells further comprises a platelet activating agent. A clotting time is determined for each of the aliquot portions, and the relative clotting times of the aliquot portions in the cells are determinative of the platelet functionality of the sample.
The present invention is also directed to an apparatus for performing a platelet functionality test on a blood sample containing platelets. The apparatus comprises a plurality of test cells. Each of the cells comprises heparin, kaolin, and a sufficient quantity of calcium chloride to achieve optimal platelet function in the blood sample. At least one of the cells further comprises platelet activating factor. A clotting time is determined for each of the aliquot portions, and the relative clotting times of the aliquot portions in the cells are determinative of the platelet functionality of the sample.
The present invention is further directed to an apparatus for performing a platelet functionality test on blood containing platelets using a plunger sensor technique. The apparatus comprises a cartridge having first and second test cells, each test cell containing a platelet function restoration agent, an anticoagulant agent and a clotting reagent. The first test cell further comprises a platelet activating agent. A clotting time is determined for each of the test cells, and the relative clotting times of the cells are determinative of the platelet functionality of the blood.
The present invention is also directed to a method for performing an activated clotting time test on a sample of blood containing platelets. The method comprises the steps of combining a platelet function restoration agent, an anticoagulant agent, a platelet activating agent, and the sample of blood to be tested to form a test mixture. The platelets of the sample are activated by adding a clotting reagent to the test mixture at the start of the activated clotting time test, and the test is terminated upon detecting a predetermined change in a property of the test mixture. The activated clotting time of the sample of blood is calculated based on the elapsed time.
The present invention is also directed to a method for performing an activated clotting time test on a sample of blood containing platelets using a plunger sensor apparatus. The apparatus comprises at least one test cell and a plunger assembly within the test cell. The test cell includes a reaction chamber and a reagent chamber, the reaction chamber comprising a platelet function restoration agent, an anticoagulant agent, and a platelet activating agent. The reagent chamber comprises a clotting reagent. The method comprises the steps of dispensing a sample of blood into the reaction chamber to form a first test mixture, then combining the first test mixture with the clotting reagent from the reagent chamber to form a second test mixture. The plunger assembly is reciprocated in the second test mixture by alternately lifting the plunger assembly and allowing the plunger assembly to descent through the test mixture. The point in time at which a predetermined property of the second test mixture changes by a predetermined expected amount is detected by sensing the descent of the plunger assembly, the predetermined property affecting the activated clotting time test. The elapsed time is measured from the beginning of the step of combining the first test mixture with the clotting reagent to the point in time at which the property of the second test mixture changes by the predetermined expected amount, and the activated clotting time of the sample of blood is calculated based on the elapsed time.
The present invention is further directed to a method for performing an activated clotting time test on a sample of blood containing platelets using a plunger sensor apparatus. The apparatus comprises at least one test cell and a plunger assembly within the test cell. The test cell includes a reaction chamber and a reagent chamber, the reaction chamber comprising heparin, platelet activating factor, and a sufficient quantity of calcium chloride to achieve optimal platelet function in the blood sample. The reagent chamber comprises kaolin. The method comprises the steps of dispensing a sample of blood into the reaction chamber to form a first test mixture, then combining the first test mixture with the kaolin from the reagent chamber to form a second test mixture. The plunger assembly is reciprocated in the second test mixture by alternately lifting the plunger assembly and allowing the plunger assembly to descent through the test mixture. A point in time at which a predetermined property of the second test mixture changes by a predetermined expected amount is detected by sensing the descent of the plunger assembly, the predetermined property affecting the activated clotting time test. An elapsed time is measured from the beginning of the step of combining the first test mixture with the kaolin to the point in time at which the property of the second test mixture changes by the predetermined expected amount. The activated clotting time of the sample of blood is calculated based on the elapsed time.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the preferred embodiments of the present invention, and together with the descriptions serve to explain the principles of the invention.
In the Drawings
FIG. 1 is a graph of activated clotting times of whole blood vs. the concentration of platelet activating factor (PAF), showing the effects of storage in sodium citrate (anticoagulant) on clotting time. The upper curve 12 of the graph represents the behavior of a sample of fresh whole blood, tested within one minute of drawing the sample. The bottom curve 14 represents the behavior of a sample of blood from the same individual collected in a 3.8% solution of sodium citrate (referred to herein as “citrate collection medium”), specifically in a 9:1 ratio of blood to citrate collection medium, and stored for 45 minutes;
FIG. 2 is a graph of calculated platelet function of heparinized and citrated whole blood vs. the elapsed time period after which the blood sample was drawn. The upper curve 22 of the graph represents the behavior of a sample of whole blood which contains 3 units per milliliter of heparin (anticoagulant). The bottom curve 24 represents the behavior of the same blood collected in a 3.8% citrate collection medium (9:1 ratio of blood to collection medium);
FIG. 3 is a graph similar to the graph of FIG. 1 . The upper curve 32 of the graph represents the behavior of a sample of fresh whole blood, tested within one minute of drawing the sample. The middle curve 34 represents the behavior of the same blood collected in a 3.8% citrate collection medium (9:1 ratio) and stored for 45 minutes, then tested in a cartridge with 15 millimolar (mM) of additional calcium chloride. The bottom curve 36 represents the behavior of the same citrated blood (curve 34 ), but without adding calcium chloride prior to testing;
FIG. 4 is a graph similar to FIG. 2 . The horizontal (broken) line 42 represents the baseline (non-activated) clotting time of a sample of fresh whole blood, tested immediately after drawing the sample. The upper curve 44 represents the behavior of the same blood collected in a 3.8% citrate collection medium (9:1 ratio) and stored for 45 minutes, then tested in a cartridge with 15 mM calcium chloride added prior to testing. The bottom curve 46 represents the behavior of the same citrated blood (curve 44 ), but without adding calcium chloride prior to testing;
FIG. 5 is a perspective view of a 6-channel plunger sensor cartridge, a 4-channel plunger sensor cartridge, and a high sensitivity coagulation detection apparatus with which the cartridges are used on selectively alternate basis, all of which comprises an apparatus for measuring and detecting coagulation and coagulation-related factors in fluids, in accordance with the present invention;
FIG. 6 is a front elevational view of the 6-channel plunger sensor cartridge shown in FIG. 5; and
FIG. 7 is an enlarged vertical sectional view through one of the test cells of the plunger sensor cartridge, taken in the plane of line 7 — 7 shown in FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a solution to the problem relating to the initial drop in recalcified activated clotting times of citrated whole blood samples. This initial drop in recalcified activated clotting times is believed to result from a platelet procoagulant activity which commences after drawing the blood sample, even though the blood sample is collected in citrate or some other calcium chelating agent. To eliminate the initial drop in activated clotting times, and thus more accurately reflect the true in vivo coagulation conditions, it was discovered that the effects of the platelet procoagulant activity can be reversed by mixing the citrated whole blood with a calcium source prior to performing the activated clotting time test. The method of the present invention thus involves a pre-test recalcification step to reestablish the in vivo platelet function in the citrated blood sample prior to commencing the test. Contemporaneously with the pre-test recalcification, an anticoagulant is introduced into the blood sample to inhibit pre-test coagulation and coagulation-related reactions. In a preferred embodiment, the calcium source and anticoagulant are included as test reagents in the test cell, and dissolved in the blood sample within the cell prior to commencing the activated clotting time test, i.e., prior to introducing the clotting reagent into the test mixture.
FIG. 1 presents curves 12 and 14 which compare the effects of storage time on the baseline and activated clotting times of whole blood. Curve 12 illustrates the baseline (non-activated) clotting time of fresh-drawn whole blood and the response of fresh whole blood to increasing PAF concentrations. Curve 14 illustrates the baseline clotting time of citrated whole blood and the response of citrated blood to increasing PAF concentrations. Citrated whole blood is whole blood collected in a 3.8% sodium citrate collection medium, defined as 3.8 grams of sodium citrate per 100 ml of water. A 3.8% sodium citrate collection medium is that which is frequently used to collect and preserve blood for clotting assays. Note that the baseline clotting time is less for the delayed (citrated) blood sample, due to platelet activation (i.e., platelet procoagulant activity) during the 45-minute storage period. The clotting times in the cells with PAF activation (i.e., PAF concentrations of 6.25 to 150 nM) are essentially identical for both samples. Since the platelet function evaluation is based on the difference between the activated (150 nM PAF) and non-activated (0 nM PAF) clotting times, the calculated platelet function is less for the citrated whole blood sample than for freshly drawn blood from the same individual.
FIG. 2 presents curves 22 and 24 which compare the effect of delay in testing samples of heparinized and citrated whole blood. Curve 22 illustrates the loss in calculated platelet function over time for heparinized whole blood. Curve 24 illustrates the loss in calculated platelet function over time for a sample of citrated whole blood obtained from the same individual. It can be seen that the loss in platelet function is significantly greater for the citrated blood sample than for the heparinized blood sample. However, some hospitals and laboratories would prefer to use citrated whole blood rather than heparinized blood for platelet function tests. Blood collection tubes containing a citrate collection medium (commonly referred to as “blue-top tubes”) are commercially available, whereas collection tubes containing an appropriate quantity of heparin as the anticoagulant are not. Thus, the present invention offers a significant advantage over existing methods and apparatuses, by providing a solution to the instability problem associated with the use of citrated whole blood. More specifically, the present invention provides an improved test which reliably reflects the true in vivo platelet function, regardless of the amount of time the blood sample has been stored in citrate.
FIG. 3 presents curves 32 , 34 and 36 which compare the baseline and activated clotting times of freshly drawn whole blood and samples of citrated whole blood, with and without a pre-test recalcification step. Curve 32 illustrates the baseline clotting time of fresh-drawn whole blood and the response of fresh blood to increasing PAF concentrations, similar to curve 12 in FIG. 1 . Curve 34 illustrates the baseline and activated clotting times of a sample of citrated whole blood which has been incubated or mixed with a calcium source in a pre-test recalcification step prior to performing the platelet function test. Curve 36 illustrates the baseline and activated clotting times of a sample of citrated whole blood similar to curve 34 , but without the pre-test recalcification step. Although the activated clotting times of curves 32 , 34 and 36 are relatively similar, the baseline (non-activated) clotting times are significantly greater for both the fresh-drawn blood sample and the citrated blood sample which had been recalcified prior to testing. Consequently, because the baseline clotting time for the recalcified citrated blood sample is similar to that of fresh blood, the former sample provides an accurate representation of the in vivo coagulation conditions.
FIG. 4 presents curves 44 and 46 which compare the changes in platelet function over time for two whole blood samples obtained from the same individual, one of which had been recalcified prior to testing (curve 44 ). Line 42 represents the baseline (non-activated) clotting time of the fresh-drawn whole blood, tested immediately after drawing the sample. Curve 44 illustrates the calculated platelet function over time for the citrated blood sample which had been incubated or mixed with a calcium source prior to commencing the test. Curve 46 illustrates the loss in platelet function over time for citrated whole blood which had not been recalcified prior to testing, similar to curve 24 in FIG. 2 . It can be seen that the platelet function of the blood sample which had been recalcified prior to testing parallels the platelet function of the fresh-drawn sample (i.e., simulates the in vivo platelet function of the blood), even after 60 minutes of storage in citrate.
To practice the improved platelet function test of the present invention, which provides a reliable indication of the in vivo platelet function regardless of the amount of time which has elapsed since the sample was obtained, each of the test cells in the platelet function test cartridge includes a novel reagent composition. This novel reagent composition (shown in FIG. 7 as reagent composition 80 in reaction chamber 94 ) may be either a liquid or a solid powder, and includes three components: a platelet function restoration agent (hereinafter referred to as the “restoration agent”), an anticoagulant agent, and a predetermined amount of a platelet activating agent, as will be discussed below. The restoration agent may be any substance which reverses the loss in platelet function due to the presence of a calcium chelating agent, such as sodium citrate, i.e., any substance which restores the platelet function in the citrated blood sample to reflect the true in vivo (non-activated) platelet function. In the presently preferred embodiment of the invention, the restoration agent is calcium chloride. However, any substance which is known or found to be functionally equivalent to calcium chloride in restoring the platelet function of citrated blood may be used in the practice of the present invention. Thus, although calcium chloride is the presently preferred calcium salt for use in the invention, any calcium salt which functions in a similar manner to calcium chloride may be used in the invention. Similarly, although many blood coagulation reactions are currently believed to require calcium ions as cofactors, any substance which is known or subsequently found to be functionally equivalent to calcium in facilitating these coagulation reactions may be used, either individually or in combination with calcium, in the practice of the present invention.
The concentration of the restoration agent required to restore the platelet function of the blood sample to reflect the true in vivo (non-activated) platelet function will depend, in part, upon the concentration of the calcium chelating agent in the blood sample and the stoichiometry of the chelating and coagulation reactions. However, the concentration of the restoration agent must be sufficient to achieve optimal platelet function in the blood sample prior to performing the platelet function test, i.e., the concentration must be sufficient to realize maximum restoration effect such that any further increase in concentration has a negligible effect on baseline clotting time. With the presently preferred restoration agent, calcium chloride, the restoration agent concentration in the blood sample is between about 1 and about 50 millimolar, preferably between about 10 and about 20 millimolar, more preferably between about 12 and 18 millimolar, and most preferably between about 14 and 16 millimolar.
The anticoagulant agent of the reagent composition 80 prevents coagulation-related activities within the blood sample prior to commencement of the ACT test, i.e., the anticoagulant agent is added to the blood sample to prevent the initiation of coagulation-related reactions which might otherwise result from the presence of the restoration agent in the sample. For example, when calcium chloride (restoration agent) is introduced into a citrated blood sample, additional calcium ions become available which may participate in various coagulation-related activities, thereby negating the anticoagulant effects of citrate. Although additional citrate could be added to chelate the additional calcium and thus nullify the effects of the calcium chloride (thereby inhibiting pre-test coagulation), such an additive would be likely to adversely affect the ACT test results, by inhibiting the coagulation-related activities the ACT test is designed to detect. Thus, the anticoagulant agent of the reagent composition 80 must function in a manner other than by chelating calcium ions. In general, the anticoagulant agent may be any substance having anticoagulant activity and which is neither reactive with nor affected by the restoration agent or the other test components. A wide variety of suitable anticoagulant compounds are known and readily available to the art including, for example, heparin (an acid mucopolysaccharide) and argatroban ((2R,4R)-4-methyl-1-[N 2 -(RS)-3-methyl-1,2,3,4-tetra-hydro-8-quinolinesulfonyl)-L-arginyl]-2-piperidinecarboxylic acid hydrate). In a particularly preferred embodiment, the anticoagulant agent is heparin, which, together with antithrombin III, accelerates the inhibition of activated factor X and thrombin.
The concentration of the anticoagulant agent in reagent composition 80 required to prevent the initiation of pre-test coagulation-related reactions will depend upon the anticoagulant activity of the particular agent. With the presently preferred anticoagulant agent, heparin, the anticoagulant agent concentration in the blood sample is between about 0.1 unit and about 10 units, preferably between about 1 unit and about 5 units, and more preferably between about 2 units and about 4 units per milliliter of blood sample.
The final component of the novel reagent composition 80 of the present invention is a platelet activating agent which serves as the chemical platelet activator to facilitate evaluation of the function of platelets in the blood sample to be tested. More specifically, the platelet activating agent enhances the ability of active platelets to effectively participate in the blood clotting reaction and thereby shortens the clotting time of the blood. If the platelets are inactive or not functioning normally, the platelet activating agent will have a lessened or no effect on the clotting time. Platelet activating agents are well known and readily available in the art. Suitable platelet activating agents for use in the methods and apparatus of the present invention include, without limitation, platelet activating factor (1-O-alkyl-2-acetyl-sn-glyceryl-3-phosphorylcholine, a biologically active phospholipid, commonly referred to as “PAF”), adenosine diphosphate (ADP), arachidonic acid, collagen, epinephrine, and ristocetin. In a particularly preferred embodiment, the platelet activating agent is PAF (described in Demopoulos, et al., J. Biol. Chem., 254:9355-9358 (1979)).
The specific concentrations of the platelet activating agent in reagent composition 80 of the present invention (i.e., reagent composition 80 in reaction chamber 94 of the test cell 66 , shown in FIG. 7) will depend, in part, upon the activating efficiency of the particular agent. However, to determine the “baseline” or “non-activated” clotting time of the blood sample, the concentration of the platelet activating agent in at least one (“baseline”) cell (e.g., cells 66 A and 66 B in cartridge 64 ) will be zero, regardless of the particular agent. With the exemplified platelet activating agent, PAF, the final concentration of platelet activating agent in the blood sample within the “activated” cell(s) of the test cartridge is between about 0.1 nM and about 10 μM, preferably between about 0.1 nM and about 3 μM, more preferably between about 0.1 nM and about 1 μM, and most preferably between about 1 nM and about 200 nM.
As discussed previously, reagent composition 80 of the present invention may be either a liquid or a solid powder, although a solid powder form (commonly referred to as a “dry fill”) is preferred. To prepare reagent composition 80 as a solid or dry fill, predetermined amounts of the three components (restoration agent, anticoagulant agent, and platelet activating agent) are combined and mixed with a saline (NaCl) solution preferably containing a protein, such as bovine serum albumin, to stabilize the platelet activating agent. The mixture may be diluted, if necessary, with additional saline solution to achieve the desired platelet activating agent concentrations. A predetermined amount of each solution of reagent composition 80 is placed in the reaction chambers 94 of the test cells 66 (shown in FIGS. 5, 6 and 7 ) and allowed to evaporate, leaving a solid or dry fill residue of reagent composition 80 .
In one embodiment of the invention, at least two of the test cells comprise different amounts of the platelet activating agent, thus providing a series of differing clotting times. In the exemplified embodiment shown in FIG. 6, for example, the first two cells 66 A and 66 B contain no platelet activating agent (the “baseline ” cells). However, each successive cell 66 C, 66 D, 66 E, and 66 F includes increasing amounts of platelet activating agent. Although the concentrations and proportions may vary depending upon the particular reagent components (as discussed above), the following table provides an illustration of suitable concentrations of the presently preferred components in reagent composition 80 , following dilution with the blood sample:
TABLE 1
Concentrations of Components in Reagent Composition 80
(Test Cartridge 64)
Reagent
Cell 66A
Cell 66B
Cell 66C
Cell 66D
Cell 66E
Cell 66F
PAF
0.0
ng
0.0
ng
1.25
nM
6.25
nM
12.5
nM
150
nM
Heparin
3
units/ml
3
U/ml
3
U/ml
3
U/ml
3
U/ml
3
U/ml
Calcium
15
mM
15
mM
15
mM
15
mM
15
mM
15
mM
chloride
The improved ACT test of the present invention also includes a clotting reagent in the reagent chamber (shown in FIG. 7 as reagent chamber 92 ) of each test cell 66 . The clotting reagent (discussed below and shown in FIG. 7 as clotting reagent 90 ) includes a platelet activator (commonly referred to as a surface activator), such as kaolin, to activate blood Factors XII and/or XI. However, as will be appreciated by those of skill in the art, other platelet activating reagents which function in a similar manner to kaolin may be used for the practice of the invention, such as diatomaceous earth. The clotting reagent 90 may be present in either a solid or liquid form, although the presently preferred reagent is in a liquid form. To prepare a liquid clotting reagent 90 , the activator component may be dissolved in an appropriate buffered solution, a variety of which are known to those skilled in the art, including HEPES (hydroxyethyl-piperazine ethanesulfonic acid) buffer. A bacteriostatic agent such as sodium azide may also be included in clotting reagent 90 . In a particularly preferred embodiment, clotting reagent 90 comprises kaolin, HEPES buffer, calcium chloride (to achieve a linear clotting time response), and sodium azide as the bacteriostatic agent. As discussed more fully below, and as illustrated in the examples hereof, an appropriate amount of clotting reagent 90 is introduced into the reagent chamber 92 of each cell of the test cartridge 64 , 65 .
To determine the platelet function in accordance with one embodiment method of the present invention, a predetermined volume of blood to be analyzed is introduced into the reaction chamber 94 of each test cell 66 A- 66 F, thereby dissolving reagent composition 80 . The resulting blood mixture is then allowed to react at a sufficient temperature and for a sufficient period of time to facilitate interaction between the platelets and restoration agent, thereby maximizing the restoration of platelet function. Preferably, the blood sample and reagent composition 80 are incubated at a temperature of between about 36° C. and about 38° C. and for a period of between about 1 second and about 2 minutes. During this incubation period, referred to herein as the pre-test recalcification step, the platelet function in the citrated blood sample is increased to a level which is generally comparable to the in vivo platelet function. Contemporaneously with the pre-test recalcification, the anticoagulant agent in the reagent composition 80 combines with certain components within the blood sample to inhibit pre-test coagulation and coagulation-related reactions. Although in the presently preferred embodiment the restoration and anticoagulant agents are included as test reagents within the test cell 66 , it is anticipated that these novel reagents could be combined with the blood sample outside the test cell 66 . The resulting blood mixture may then be allowed to react outside the test cell 66 or, alternatively, transferred to the test cell for recalcification prior to the initiation of the ACT test. The present invention thus includes these various modifications and alternate embodiments.
Following the pre-test recalcification step, the clotting reagent 90 in each reagent chamber 92 is introduced into the corresponding reaction chamber of each test cell 66 A- 66 F, and the clotting time is determined. The clot ratio is then calculated based on the clotting time for each test cell. Specifically, the clot ratio is defined as one minus the ratio of the average activated clotting time (i.e., the average clotting time of cells comprising the same concentration of platelet activating agent) to the average control clotting time (e.g., cells 66 A and 66 B). Platelet function (shown in FIGS. 2 and 4) is expressed as a percentage of the maximum clot ratio response observed in a normal population. This value of a normal population response is known and can be used to compute the clot ratio percentage, which is in turn indicative of the platelet functionality. As will be understood by those of skill in the art, any appropriate desired calculation may be made from the relative clotting times in each cell. The platelet functionality can in turn be utilized to estimate the risk of blood loss during or after surgery and the need for a transfusion of blood components. The platelet functionality may further assist in managing heparin therapy during invasive cardiology procedures.
Although the present invention is exemplified using coagulation-related platelet assays, including those described in U.S. Pat. Nos. 5,314,826 and 5,925,319, the invention can be applied to other, non-exemplified platelet function assays carried out on citrated blood. Such platelet function assays include, for example, platelet function tests to measure the platelet release reaction and platelet aggregation, and assay for von Willebrand's Factor. The present invention may also be readily modified to accommodate a variety of specialized coagulation tests, including specific coagulation factor assays, tests for disseminated intravascular coagulation, and the heparin-independent, high sensitivity platelet function evaluation technique described in U.S. Pat. No. 6,010,911, issued on Jan. 4, 2000 which is assigned to the assignee of the present invention and incorporated herein by reference. As will be understood by those of skill in the art, the present invention can be practiced with any platelet function assay, including the above-referenced techniques, by including a pre-test recalcification step, i.e., by incubating the restoration agent and anticoagulant agent in the citrated blood sample prior to commencing the test.
Referring now to FIGS. 5, 6 and 7 , the presently preferred embodiment of an apparatus 62 and a plunger sensor cartridge 64 may be used together in order to perform a platelet function test using two unique reagents, i.e. a substance to restore the platelets to their normal in vivo condition and an anticoagulant to inhibit pre-test coagulation-related activities. Although the invention is exemplified using a 6-cell cartridge (cartridge 64 in FIGS. 5 and 6 ), the invention can be practiced using any multiple-cell cartridge, for example, using the alternate 4-cell cartridge (cartridge 65 ) shown in FIG. 5 . In general, the ACT test of the invention can be achieved by comparing the clotting times of two test cells, one without a platelet activating agent and the other with an appropriate (generally high) amount of platelet activating agent. Preferably, the ACT test is performed in duplicate or triplicate, with the platelet function calculations being based on the average clotting time for each concentration of platelet activating agent.
In general, the ACT test, platelet function test, and heparin-protamine titration tests which may be performed using the apparatus 62 and the cartridges 64 , 65 have previously been described in the assignee's aforementioned patents and applications, including U.S. Pat. Nos. 4,599,219 and 5,925,319, the disclosures of which are incorporated herein by reference. Accordingly, many of the details of functionality will be generalized herein with the understanding that the assignee's prior patents and applications disclose many of these details to a greater extent. It is anticipated that coagulation-related testing techniques other than the plunger techniques may also be used to perform an ACT test using these novel reagents, in accordance with this invention. It is anticipated that similar results and effects as those obtained from using the assignee's plunger sensor technique will also be obtainable by practicing the present invention using other well known methods and devices.
In general, the cartridges 64 , 65 as shown in FIGS. 5 and 6 include a plurality of test cells 66 (shown in FIG. 7 ), each of which is formed generally as a downward extending truncated tube-like member 68 . Each of the tube-like members 68 is connected to an upper shelf portion 70 . A plunger assembly 72 (also shown in FIG. 7) extends downward from an upper open end of each test cell 66 into the tube-like member 68 . Each plunger assembly 72 includes at least one and preferably a pair of flags 74 at the upper end located at a position above the shelf portion 70 . The plunger assembly 72 also includes a shaft 76 which extends from the flags 74 downward to a lower end upon which a disk member 78 is attached. The disk member 78 is formed of resilient material and includes a center, generally cylindrical main body portion 82 and an annular flange 84 located above and extending outward from the main body portion 82 . The annular flange 84 includes slots or openings (not shown) formed therein at outer circumferential locations.
As shown in FIG. 7, prior to using the plunger sensor cartridge 64 or 65 in the apparatus 62 , the disk member 78 is positioned with its main body portion 82 located in and sealed against an opening formed by a partition 86 extending inwardly from the tube-like member 68 . The partition 86 is located between the upper and lower open ends of the tube-like member 68 . A resilient flexible plug 88 is positioned in the interior of the tube-like member at its lower open end. The plug 88 seals against the inner side walls of the tube-like member 68 and confines a quantity of clotting reagent 90 (discussed above) in a reagent chamber 92 between the partition 86 and the plug 88 . The clotting reagent 90 may be a liquid or a solid powder. A reaction chamber 94 is generally defined by that portion of the open tube-like member 68 above the partition 86 . A predetermined amount of a reagent composition 80 , the contents of which have been described in detail above, is provided in the reaction chamber 94 as either a liquid or a solid powder.
The plunger sensor cartridge 64 or 65 is inserted into a receiving block (not shown) in the apparatus 62 to conduct the test. Each of the test cells 66 extends into a receptacle 98 of the receiving block. Each receptacle 98 has a configuration adapted to receive a test cell 66 , while the shelf portion 70 of the cartridge 64 or 65 sits on top of the receiving block.
The apparatus 62 is generally formed of subassemblies. A dispensing subassembly 104 of the apparatus 62 automatically supplies a sample of blood to each test cell 66 of the cartridge 64 or 65 . The reagent composition 80 is dissolved in the blood sample when the blood sample is introduced into the reaction chamber 94 . A plunger lifting assembly 99 of the apparatus 62 controls the lifting movement of the plunger assembly 72 , and a reagent drive subassembly 100 of the apparatus 62 moves the plug 88 to force the clotting reagent 90 into the reaction chamber 94 , thereby mixing the clotting reagent 90 with the reagent composition 80 . An optical sensing system (not shown) senses the physical descent of the plunger assembly 72 through the blood sample and reagent mixture in the reaction chamber 94 in order to detect coagulation condition.
The sample of blood is supplied to the reaction chamber 94 from a syringe 102 having a blunt needle 103 attached thereto. The syringe 102 is manually attached to the dispensing subassembly 104 of the apparatus 62 . The body of the syringe 102 contains blood, preferably fresh drawn from the patient, upon which the ACT test is to be performed. Of course, prior to attachment of the syringe 102 to the dispensing subassembly 104 , all air or other voids in the blood within the syringe 102 and the blunt needle 103 is removed in the conventional manner. A plunger 106 located within the body of the syringe 102 is engaged with a drive wheel 108 . Rotation of the drive wheel 108 forces the syringe plunger 106 downward and expels a predetermined amount of blood from the lower end of the blunt needle 103 . The extent to which the syringe plunger 106 is moved downward determines the quantity of blood expelled from the needle.
The dispensing subassembly 104 includes a movement frame 110 which is moved laterally in the horizontal direction along guide rods 112 . The degree of lateral movement is controlled by the microprocessor (not shown) of the apparatus 62 in accordance with programmed information, thereby locating the blunt needle 103 directly above the open upward ends of each test cell 66 of the cartridge 64 or 65 . After attaining the proper lateral location, the movement frame 110 moves the syringe 102 vertically downward to insert the lower end of the blunt needle 103 into each of the test cells 66 . The desired amount of blood sample is automatically dispensed into the test cell 66 . Thereafter, the blunt needle 103 is withdrawn from the test cell 66 by the movement frame 110 , and the next lateral position over a test cell 66 is assumed. The sequence again repeats itself, thereby injecting into each test cell 66 of the plunger sensor cartridge 64 or 65 that predetermined amount of blood sample needed for conducting the ACT test.
A portion of the plunger lifting subassembly 99 is shown in FIG. 5, and includes at least one and preferably a plurality of lift wires 114 . The lift wires 114 are positioned in a lowermost location, and in that position a horizontal segment of the lift wires 114 fits underneath the flags 74 of the plunger assembly 72 . Upward movement of the lift wires 114 lifts each of the plunger assemblies 72 upward, thereby removing the disk member 78 from its sealed location in the opening 84 of the partition 86 . A fluid communication passageway through the opening 84 between the reagent chamber 92 and the reaction chamber 94 is thereby established. The reagent drive subassembly 100 includes a plurality of plug driver shafts 116 (shown in FIG. 7 ). Thereafter, or simultaneously with the upward movement of the plunger assembly 72 , the plug driver shafts 116 of the reagent drive subassembly 100 move upward, forcing each plug 88 upward collapsing the reagent chamber 92 and forcing its contents 90 into the reaction chamber 94 .
At the commencement of the ACT test, a sample of blood upon which the test is to be performed is introduced into the reaction chamber 94 . The reagent composition 80 is then dissolved in the sample of blood and allowed to mix therewith for a sufficient period of time to effect recalcification of the blood sample. Following completion of the recalcification step, the lift wires 114 of the subassembly 99 lift the plunger assembly 72 to withdraw the disk member 78 from its seated engagement with the opening in the partition 86 . The plug 88 is pushed upward against the partition 86 by the plug driver shafts 116 of the subassembly 100 . The clotting reagent 90 from the reagent chamber 92 is forced through the opening into the reaction chamber 94 . The clotting reagent 90 is mixed with the blood and reagent mixture in the reaction chamber 94 , by reciprocating the plunger assembly 72 . The lift wires 114 of the subassembly 99 continue to lift the plunger assembly 72 , which descends by the force of gravity through the pool of fluid in the reaction chamber 94 . Throughout the test, the activation of platelets by shear stress in the blood sample is kept to a minimum, as described in U.S. Pat. No. 5,314,826. As the plunger assembly 72 descends through the fluid it is resisted by a property of the fluid in the reaction chamber 94 , such as the viscosity, which changes as a result of the onset or occurrence of a coagulation-related activity, e.g., platelet activation and aggregation followed by coagulation resulting in fibrin formation. The descent rate of the plunger assembly 72 therethrough is changed, which indicates the occurrence of a coagulation-related activity. The clotting time of a blood sample is determined as described in detail in the assignee's aforementioned patents and applications, including U.S. Pat. Nos. 4,599,219 and 5,925,319.
It will be appreciated that clinical trials may establish a quantitative correlation between platelet functionality and any medical treatment to be administered. For example, during heart bypass surgery the platelets of blood circulated in an extracorporeal circuit may become activated by the materials present in the extracorporeal circuit. This activation may be reversible or irreversible. Once platelets are irreversibly activated they lose their ability to function further. A deficiency of functional platelets in the blood may be indicative of an increased probability of a post-operative bleeding problem. Such a deficiency, and the, resulting post-operative bleeding risk, could be remedied by a transfusion of platelet concentrate. The platelet functionality test can identify a deficiency of platelets or functional platelets and aid the attending physician in ascertaining when to administer a platelet concentrate transfusion. Such a test is further useful in ascertaining the efficacy of a platelet transfusion. By performing the platelet functionality test following a platelet transfusion it is possible to determine if additional platelet concentrate transfusions are indicated. Because the present invention is not dependent upon the amount of the time which has elapsed since the sample was drawn, it is especially useful for situations which require that the sample be transported from the patient to a different location for evaluation, i.e., where an automated coagulation detection apparatus is not readily available. For example, it is often desirable to perform a platelet function test after a patient has been moved from the operating room to the intensive care unit. In such a case, the blood sample must be transported back to the operating room or to another location such as a clinical laboratory for testing. The present invention thus provides a convenient alternative to bedside testing, by allowing hospital personnel to transport blood samples for testing without concern for distance from the laboratory and without the need for recording time of draw and instructions regarding the timing of the test.
The invention is further described by the following examples which are illustrative of specific modes of practicing the invention and are not intended as limiting the scope of the invention as defined by the appended claims.
EXAMPLES
All solvents and reagents employed in the examples were used as received from the manufacturer. Bovine serum albumin (BSA) was purchased from Sigma Chemical Co. (St. Louis, Mo.; Sigma Product #A-3803); bovine lung heparin was purchased from The Upjohn Company (Kalamazoo, Mich.); PAF was purchased from Sigma Chemical Co. (St. Louis, Mo.; Sigma Product #P-9525); calcium chloride dihydrate was purchased from Fisher Scientific (A.C.S. certified; Prod. No. C79-500); and kaolin was obtained from Charles Crystal, Inc. (St. Austell, Cornwall, UK). The coagulation detection apparatus used to perform the ACT tests in the examples was manufactured by Medtronic Hemotec, Inc. (Englewood, Colo.; Prod. No. 305-02).
Example 1
Preparation of Test Cells Comprising Reagent Composition 80 and Clotting Reagent 90
This example demonstrates the preparation of test cells to perform an ACT test on a sample of citrated whole blood which is independent of the amount of time which has elapsed since the sample was drawn, in accordance with the present invention. The procedure for preparing the test cells comprises the following steps:
1. Clotting Reagent: Weigh out 4 g Kaolin. Add 5 ml of 1.0 M calcium chloride solution. Dilute mixture to 100 ml with hydroxyethyl-piperazine ethanesulfonic acid (HEPES) buffer. This provides 4% w/v suspension of kaolin in HEPES buffer, 0.05 M calcium, pH 7.3. Add 0.088 ml of this kaolin mixture into the reagent chamber 92 of each cell 66 in the test cartridge.
2. Reagent Stock Solutions:
1) BSA/NaCl diluent. Combine 250 mg BSA and 876 mg NaCl, and bring to 100 ml with deionized water. This solution is 0.25% BSA (wt/vol) and 0.15 M NaCl.
2) Heparin reagent stock. Prepare 1050 units/ml heparin stock solution by bringing 1.05 ml of 10,000 units/ml heparin to a final volume of 10 ml with HEPES buffer.
3) Calcium stock. Prepare 1 M calcium stock by dissolving 3.675 grams of calcium chloride dihydrate in 25 ml BSA/NaCl diluent.
4) PAF stock. Using a Hamilton syringe, pipette 50 μl platelet activating factor (PAF) into a clean vial and allow the chloroform solvent to evaporate. Add 2 ml BSA/NaCl diluent and stir continuously for at least 1 hour. This provides a 100 μM working stock of PAF.
3. Baseline Reagent. Combine 0.5 ml heparin reagent stock, 2.625 ml 1M calcium stock, and 6.875 ml BSA/NaCl diluent to provide 10 ml baseline reagent (3 units/ml heparin; 15 mM calcium).
4. Platelet Activation Reagent. Combine 0.5 ml heparin reagent stock, 2.625 ml 1M calcium stock, 6.7875 ml BSA/NaCl diluent, and 0.0875 ml PAF stock to provide 10 ml platelet activation reagent (3 units/ml heparin; 15 mM calcium; and 50 nM PAF).
5. Cartridge preparation.
1) Baseline clotting time cell(s). To determine the baseline (non-activated) clotting time, add 0.02 ml of baseline reagent to each of the “baseline clotting time” cells (e.g., cells 66 A-B or cells 66 A-C of cartridge 64 ).
2) “Activated” clotting time cell(s). To determine the activated clotting time, add 0.02 ml of platelet activation reagent to each of the “activated clotting time” cells (e.g., cells 66 C-F or cells 66 D-F of cartridge 64 ).
6. The water is allowed to evaporate, leaving a dry fill in each cell.
7. Using a sample of normal blood from a voluntary donor, and a cartridge prepared as described above, 0.35 ml aliquots of blood are added to each cell and the clotting time of the blood in each cell is determined and plotted as previously described.
The titration curve can be normalized by converting the clotting times to ratios. The average clotting time of Cell A and Cell B, with no platelet activating factor present, is the cell clotting time to which all other cell clotting times are compared. The ratio is calculated by dividing the average of Cell A and Cell B clotting time in seconds by each other cell clotting time in seconds. A clot ratio is then calculated as 1 minus the ratio of the average of Cell A and Cell B clotting time to other cell clotting times (1—average of CellA&Btime/CellXtime). Data can also be presented in terms of platelet function as a percentage of normal. This is calculated from the clot ratio by multiplying the clot ratio by 100 and then by a factor which is determined by measuring the maximum platelet activating factor response from at least 20 normal donors. These donors had no known platelet dysfunction and were taking no known medications.
The test cartridge and method described herein are useful for providing a simple and rapid platelet function assay. This assay can identify patients with low platelet function. This is useful for those patients with excessive post-cardiopulmonary bypass blood loss (due to a platelet-related disorder) so that appropriate platelet transfusion can be administered. In addition, those patients experiencing excessive post-cardiopulmonary bypass blood loss who are found to have normal platelet function can be treated appropriately, thus avoiding the need for expensive platelet therapy and the health risks associated with blood component transfusion.
Example 2
Preparation of Test Cells for Comparing Activated Clotting Times and Calculated Platelet Function of Whole Blood Samples
This example demonstrates the preparation of test cells to perform platelet function and ACT tests on samples of freshly drawn whole blood, citrated whole blood, and heparinized whole blood. The test cells were prepared essentially as described above in Example 1, except for the following modifications:
Cartridge Preparation
1) Baseline clotting time cell(s). Prepared as described in Example 1, paragraph 2(1). Add 0.02 ml to each of cells 66 A and 66 B.
2) “Activated” clotting time cell(s). To prepare cells with varying concentrations of platelet activating agent, dilute a volume of PAF stock (prepared as described in Example 1) using BSA/NaCl diluent (also prepared as described in Example 1) to the indicated final volume, as follows:
Cell
Volume of PAF Stock
Final Volume
66C
0.01095
ml
50 ml
66D
0.02735
ml
25 ml
66E
0.0547
ml
25 ml
66F
0.65625
ml
25 ml
Add 0.02 ml of each of the above PAF solutions to the appropriate cell (cells 66 C- 66 F).
A. Heparinized Blood Samples
Heparinized blood samples were tested in cartridge 64 using the PAF solutions (cells 66 C- 66 F) as described above.
B. Citrated Blood Samples without Additional Calcium
Citrated blood samples were tested in cartridge 64 comprising the PAF solutions (cells 66 C- 66 F), as described above, and 3 units/ml heparin. Test cells were prepared essentially as described above, except that 0.01 ml of a heparin solution (described below) was added to each cell and allowed to dry. The heparin solution was prepared by bringing 1.05 ml heparin (10,000 units/ml) to a final volume of 100 ml with HEPES buffer.
C. Citrated Blood Samples with Additional Calcium
Test cells were prepared essentially as described above for the citrated samples without additional calcium, except that additional calcium chloride was added prior to testing as follows. Prepare 1 M calcium stock in HEPES buffer by dissolving 14.7 grams of calcium chloride dihydrate in 100 ml HEPES buffer. Prepare a diluted calcium stock by bringing 13.125 ml of 1 M calcium stock to a final volume of 25 ml with HEPES buffer. Add 0.01 ml of the diluted calcium stock to each cell (i.e., final calcium concentration is 15 mM per cell). Allow to dry. 0.35 ml aliquots of blood were added to each cell and the clotting time of the blood was determined and plotted as described above.
The results of platelet function tests on whole blood are shown in FIGS. 1 and 3. Data can also be presented in terms of platelet function as a percentage of normal, as shown in FIGS. 2 and 4.
The foregoing description is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and process shown as described above. Accordingly, all suitable modifications and equivalents may be resorted to falling within the scope of the invention as defined by the claims which follow.
|
An improved apparatus and method for evaluating platelet functionality of a blood sample. The apparatus includes a plurality of test cells. Each of the cells includes a platelet function restoration agent, an anticoagulant agent, and a clotting reagent. At least one of the cells also includes a platelet activating agent. The clotting time is determined for each of the aliquot portions, and the relative clotting times of the aliquot portions in the cells are determinative of the platelet functionality of the sample. The method includes the steps of combining a platelet function restoration agent, an anticoagulant agent, a platelet activating agent, and the sample of blood to be tested to form a test mixture. The platelets of the sample are activated by adding a clotting reagent to the test mixture at the start of the activated clotting time test, and the activated clotting time test is terminated upon detecting a predetermined change in a property of the test mixture. The activated clotting time of the sample of blood is calculated based on the elapsed time.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to U.S. Pat. No. 7,367,394 (“the '394 patent”), entitled “FORMATION EVALUATION WHILE DRILLING,” filed Dec. 19, 2005, and issued May 6, 2008, the entire disclosure of which is hereby incorporated herein by reference.
[0002] This application is also related to U.S. patent application Ser. No. 11/942,796 (“the '796 application”), entitled “FORMATION EVALUATION WHILE DRILLING,” filed Nov. 20, 2007, which is a continuation-in-part of the '394 patent.
[0003] This application is also related to U.S. patent application Ser. No. 12/355,956, entitled “FORMATION EVALUATION WHILE DRILLING,” filed Jan. 19, 2009, which is a continuation of the 796 application.
[0004] This application is also related to U.S. patent application Ser. No. ______ (Attorney Docket No. 24.0952C1), entitled “Formation Evaluation While Drilling,” and filed concurrently herewith.
[0005] This application is also related to U.S. patent application Ser. No. ______ (Attorney Docket No. 24.0952C2), entitled “Formation Evaluation While Drilling,” and filed concurrently herewith.
BACKGROUND OF THE DISCLOSURE
[0006] Wellbores are drilled to locate and produce hydrocarbons. A downhole drilling tool with a bit at and end thereof is advanced into the ground to form a wellbore. As the drilling tool is advanced, a drilling mud is pumped from a surface mud pit, through the drilling tool and out the drill bit to cool the drilling tool and carry away cuttings. The fluid exits the drill bit and flows back up to the surface for recirculation through the tool. The drilling mud is also used to form a mudcake to line the wellbore.
[0007] During the drilling operation, it is desirable to perform various evaluations of the formations penetrated by the wellbore. In some cases, the drilling tool may be provided with devices to test and/or sample the surrounding formation. In some cases, the drilling tool may be removed and a wireline tool may be deployed into the wellbore to test and/or sample the formation. See, for example, U.S. Pat. Nos. 4,860,581 and 4,936,139. In other cases, the drilling tool may be used to perform the testing and/or sampling. See, for example, U.S. Pat. Nos. 5,233,866; 6,230,557; 7,114,562 and 6,986,282. These samples and/or tests may be used, for example, to locate valuable hydrocarbons.
[0008] Formation evaluation often requires that fluid from the formation be drawn into the downhole tool for testing and/or sampling. Various fluid communication devices, such as probes, are typically extended from the downhole tool and placed in contact with the wellbore wall to establish fluid communication with the formation surrounding the wellbore and to draw fluid into the downhole tool. A typical probe is a circular element extended from the downhole tool and positioned against the sidewall of the wellbore. A rubber packer at the end of the probe is used to create a seal with the wellbore sidewall.
[0009] Another device used to form a seal with the wellbore sidewall is referred to as a dual packer. With a dual packer, two elastomeric rings expand radially about the tool to isolate a portion of the wellbore therebetween. The rings form a seal with the wellbore wall and permit fluid to be drawn into the isolated portion of the wellbore and into an inlet in the downhole tool.
[0010] The mudcake lining the wellbore is often useful in assisting the probe and/or dual packers in making the seal with the wellbore wall. Once the seal is made, fluid from the formation is drawn into the downhole tool through an inlet by lowering the pressure in the downhole tool. Examples of probes and/or packers used in downhole tools are described in U.S. Pat. Nos. 6,301,959; 4,860,581; 4,936,139; 6,585,045; 6,609,568; 6,719,049; and 6,964,301.
[0011] In cases where a sample of fluid drawn into the tool is desired, a sample may be collected in one or more sample chambers or bottles positioned in the downhole tool. Examples of such sample chambers and sampling techniques used in wireline tools are described in U.S. Pat. Nos. 6,688,390; 6,659,177; and 5,303,775. Examples of such sample chambers and sampling techniques used in drilling tools are described in U.S. Pat. Nos. 5,233,866 and 7,124,819. Typically, the sample chambers are removable from the downhole tool as shown, for example, in U.S. Pat. Nos. 6,837,314; 4,856,585; and 6,688,390.
[0012] Despite these advancements in sampling technology, there remains a need to provide sample chamber and/or sampling techniques capable of providing more efficient sampling in harsh drilling environments. It is desirable that such techniques are usable in the limited space of a downhole drilling tool and provide easy access to the sample. Such techniques preferably provide one or more of the following, among others: selective access to and/or removal of the sample chambers; locking mechanisms to secure the sample chamber; isolation from shocks, vibrations, cyclic deformations and/or other downhole stresses; protection of sample chamber sealing mechanisms; controlling thermal stresses related to sample chambers without inducing concentrated stresses or compromising utility; redundant sample chamber retainers and/or protectors; and modularity of the sample chambers. Such techniques are also preferably achieved without requiring the use of high cost materials to achieve the desired operability.
SUMMARY OF THE DISCLOSURE
[0013] In at least one aspect, the present disclosure relates to a sample module for a sampling while drilling tool positionable in a wellbore penetrating a subterranean formation is provided. The tool includes a drill collar, at least one sample chamber, at least one flowline and at least one cover. The drill collar is operatively connectable to a drill string of the sampling while drilling tool. The drill collar has at least one opening extending through an outer surface thereof and into a cavity. The drill collar has a passage therein for conducting mud therethrough. The sample chamber is positionable in the cavity of the drill collar. The flowline in the drill collar, the at least one flowline operatively connectable to the sample chamber for passing a downhole fluid thereto. The cover is positionable about the at least one opening of the drill collar whereby the sample chamber is removably secured therein.
[0014] In another aspect, the disclosure relates to a downhole sampling while drilling tool positionable in a wellbore penetrating a subterranean formation. The sampling tool includes a fluid communication device, a drill collar, at least one sample chamber, at least one flowline and at least one cover. The fluid communication device is operatively connectable to a drill string of the sampling while drilling tool and extendable therefrom for establishing fluid communication with the formation. The fluid communication device has an inlet for receiving formation fluid. The drill collar is operatively connectable to a drill string, the drill collar having at least one opening extending through an outer surface thereof and into a cavity. The drill collar has a passage therein for conducting mud therethrough. The sample chamber is positionable in the cavity of the drill collar. The flowline is in the drill collar. The flowline is fluidly connectable to inlet and the sample chamber for passing a downhole fluid therebetween. The cover is positionable about the at least one opening of the drill collar whereby the sample chamber is removably secured therein.
[0015] Finally, in another aspect, the disclosure relates to a method of sampling while drilling via a downhole sampling while drilling tool positionable in a wellbore penetrating a subterranean formation. The method involves positioning a sample chamber through an opening in an outer surface of a drill collar of the sampling while drilling tool and into a cavity therein, positioning a cover over the opening of the drill collar, deploying the downhole sampling while drilling tool into the wellbore, establishing fluid communication between the sampling while drilling tool and the formation, drawing a formation fluid into the sampling while drilling tool via an inlet in the sampling while drilling tool and passing the formation fluid from the inlet to the sample chamber.
[0016] Other aspects of the disclosure may be discerned from the description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present disclosure is best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
[0018] FIG. 1 is an schematic representation of a wellsite having a downhole tool positioned in a wellbore penetrating a subterranean formation, the downhole tool having a sampling while drilling (“SWD”) system.
[0019] FIG. 2A is a longitudinal cross-sectional representation of a portion of the downhole tool of FIG. 1 depicting a sample module of the SWD system in greater detail, the sample module having a fluid flow system and a plurality of sample chambers therein.
[0020] FIG. 2B is a horizontal cross-sectional representation of the sample module of FIG. 2A , taken along section line 2 B- 2 B.
[0021] FIG. 3 is a schematic representation of the fluid flow system of FIGS. 2A and 2B .
[0022] FIG. 4A is a partial sectional representation of the sample module of FIG. 2A having a removable sample chamber retained therein by a two piece cover.
[0023] FIG. 4B is a partial sectional representation of an alternate sample module having a removable sample chamber retained therein by a multi-piece cover.
[0024] FIG. 5A is a detailed sectional representation of a portion of the sample module of FIG. 4A depicting an interface thereof in greater detail.
[0025] FIG. 5B is an isometric representation, partially in section, of an alternate sample module and interface.
[0026] FIGS. 6A-6D are detailed sectional representations of a portion of the sample module of FIG. 4A depicting the shock absorber in greater detail.
[0027] FIG. 7 is an isometric representation of an alternative shock absorber having a retainer usable with the sample module of FIG. 4A .
[0028] FIG. 8A is an alternate view of the shock absorber of FIG. 7 positioned in a drill collar.
[0029] FIG. 8B is an exploded view of an alternate shock absorber and drill collar.
[0030] FIG. 8C is an isometric representation, partially in section, of an alternate shock absorber and drill collar.
DETAILED DESCRIPTION
[0031] It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact.
[0032] Certain terms are defined throughout this description as they are first used, while certain other terms used in this description are defined below:
[0033] “Electrical” and “electrically” refer to connection(s) and/or line(s) for transmitting electronic signals.
[0034] “Electronic signals” mean signals that are capable of transmitting electrical power and/or data (e.g., binary data).
[0035] “Module” means a section of a downhole tool, particularly a multi-functional or integrated downhole tool having two or more interconnected modules, for performing a separate or discrete function.
[0036] “Modular” means adapted for (inter)connecting modules and/or tools, and possibly constructed with standardized units or dimensions for flexibility and variety in use.
[0037] “Single phase” refers to a fluid sample stored in a sample chamber, and means that the pressure of the chamber is maintained or controlled to such an extent that sample constituents which are maintained in a solution through pressure only, such as gasses and asphaltenes, should not separate out of solution as the sample cools upon retrieval of the chamber from a wellbore.
[0038] FIG. 1 depicts a wellsite 1 including a rig 10 with a downhole tool 100 suspended therefrom and into a wellbore 11 via a drill string 12 . The downhole tool 10 has a drill bit 15 at its lower end thereof that is used to advance the downhole tool into the formation and form the wellbore.
[0039] The drillstring 12 is rotated by a rotary table 16 , energized by means not shown, which engages a kelly 17 at the upper end of the drillstring. The drillstring 12 is suspended from a hook 18 , attached to a traveling block (also not shown), through the kelly 17 and a rotary swivel 19 which permits rotation of the drillstring relative to the hook.
[0040] The rig is depicted as a land-based platform and derrick assembly 10 used to form the wellbore 11 by rotary drilling in a manner that is well known. Those of ordinary skill in the art given the benefit of this disclosure will appreciate, however, that the present invention also finds application in other downhole applications, such as rotary drilling, and is not limited to land-based rigs.
[0041] Drilling fluid or mud 26 is stored in a pit 27 formed at the well site. A pump 29 delivers drilling fluid 26 to the interior of the drillstring 12 via a port in the swivel 19 , inducing the drilling fluid to flow downwardly through the drillstring 12 as indicated by a directional arrow 9 . The drilling fluid exits the drillstring 12 via ports in the drill bit 15 , and then circulates upwardly through the region between the outside of the drillstring and the wall of the wellbore, called the annulus, as indicated by direction arrows 32 . In this manner, the drilling fluid lubricates the drill bit 15 and carries formation cuttings up to the surface as it is returned to the pit 27 for recirculation.
[0042] The downhole tool 100 , sometimes referred to as a bottom hole assembly (“BHA”), is preferably positioned near the drill bit 15 (in other words, within several drill collar lengths from the drill bit). The bottom hole assembly includes various components with capabilities, such as measuring, processing, and storing information, as well as communicating with the surface. A telemetry device (not shown) is also preferably provided for communicating with a surface unit (not shown).
[0043] The BHA 100 further includes a sampling while drilling (“SWD”) system 230 including a fluid communication module 210 and a sample module 220 . The modules are preferably housed in a drill collar for performing various formation evaluation functions (described in detail below). As shown in FIG. 1 , the fluid communication module 210 is preferably positioned adjacent the sample module 220 . The fluid communication module is depicted as having a probe with an inlet for receiving formation fluid. Additional devices, such as pumps, gauges, sensor, monitors or other devices usable in downhole sampling and/or testing may also be provided. While FIG. 1 is depicted as having a modular construction with specific components in certain modules, the tool may be unitary or select portions thereof may be modular. The modules and/or the components therein may be positioned in a variety of configurations throughout the downhole tool.
[0044] The fluid communication module 210 has a fluid communication device 214 , such as a probe, preferably positioned in a stabilizer blade or rib 212 . An exemplary fluid communication device that can be used is depicted in US patent Application No. 20050109538, the entire contents of which are hereby incorporated by reference. The fluid communication device is provided with an inlet for receiving downhole fluids and a flowline (not shown) extending into the downhole tool for passing fluids therethrough. The fluid communication device is preferably movable between extended and retracted positions for selectively engaging a wall of the wellbore 11 and acquiring a plurality of fluid samples from the formation F. As shown, a back up piston 250 may be provided to assist in positioning the fluid communication device against the wellbore wall.
[0045] Examples of fluid communication devices, such as probes or packers, that can be used, are described in greater detail in U.S. Patent/Application Nos. US 2005/0109538 and 5803186. A variety of fluid communication devices alone or in combination with protuberant devices, such as stabilizer blades or ribs, may be used.
[0046] FIGS. 2A and 2B depict a portion of the downhole tool 100 with the sample module 220 of FIG. 1 shown in greater detail. FIG. 2A is a longitudinal cross-section of a portion of the probe module 210 and the sample module 220 . FIG. 2B is a horizontal cross-sectional of the sample module 220 taken along section line 2 B- 2 B of FIG. 2A .
[0047] The sample module 220 is preferably housed in a drill collar 302 that is threadably connectable to adjacent drill collars of the BHA, such as the probe module 210 of FIG. 1 . The drill collar has a mandrel 326 supported therein. A passage 323 extends between the mandrel and the drill collar to permit the passage of mud therethrough as indicated by the arrows.
[0048] The sample chamber, drill collar and associated components may be made of high strength materials, such as stainless steel alloy, titanium or inconel. However, the materials may be selected to achieve the desired thermal expansion matching between components. In particular, it may be desirable to use a combination of low cost, high strength and limited thermal expansion materials, such as peek or kevlar.
[0049] Interface 322 is provided at an end thereof to provide hydraulic and/or electrical connections with an adjacent drill collar. An additional interface 324 may be provided at another end to operatively connect to adjacent drill collars if desired. In this manner, fluid and/or signals may be passed between the sample module and other modules as described, for example, in U.S. patent application Ser. No. 11/160,240. In this case, such an interface is preferably provided to establish fluid communication between the fluid communication module and the sample module to pass formation fluid received by the fluid communication module to the sample module.
[0050] Interface 322 is depicted as being at an uphole end of the sample module 220 for operative connection with adjacent fluid communication module 210 . However, it will be appreciated that one or more fluid communication and/or probe modules may be positioned in the downhole tool with one or more interfaces at either or both ends thereof for operative connection with adjacent modules. In some cases one ore more intervening modules may be positioned between the fluid communication and probe modules.
[0051] The sample module has fluid flow system 301 for passing fluid through the drill collar 302 . The fluid flow system includes a primary flow line 310 that extends from the interface and into the downhole tool. The flowline is preferably in fluid communication with the flowline of the fluid communication module via the interface for receiving fluids received thereby. As shown, the flowline is positioned in mandrel 326 and conducts fluid, received from the fluid communication module through the sample module.
[0052] As shown, the fluid flow system 301 also has a secondary flowline 311 and a dump flowline 260 . The secondary flowline diverts fluid from the primary flowline 310 to one or more sample chambers 314 for collection therein. Additional flowlines, such as dump flowline 260 may also be provided to divert flow to the wellbore or other locations in the downhole tool. As shown, a flow diverter 332 is provided to selectively divert fluid to various locations. One or more such diverters may be provided to divert fluid to desired locations.
[0053] The sample chambers may be provided with various devices, such as valves, pistons, pressure chambers or other devices to assist in manipulating the capture of fluid and/or maintaining the quality of such fluid. The sample chambers 314 are each adapted for receiving a sample of formation fluid, acquired through the probe 214 (see FIG. 1 ), via the primary flow line 310 and respective secondary flow lines 311 .
[0054] As shown, the sample chambers are preferably removably positioned in an aperture 303 in drill collar 302 . A cover 342 is positioned about the sample chambers and drill collar 302 to retain the sample chambers therein.
[0055] As seen in the horizontal cross-section taken along line 2 B- 2 B of FIG. 2A and shown in FIG. 2B , the sample module is provided with three sample chambers 314 . The sample chambers 314 are preferably evenly spaced apart within the body at 120° intervals. However, it will be appreciated that one or more sample chambers in a variety of configurations may be positioned about the drill collar. Additional sample chambers may also be positioned in additional vertical locations about the module and/or downhole tool.
[0056] The chambers are preferably positioned about the periphery of the drill collar 302 . As shown the chambers are removably positioned in apertures 303 in the drill collar 302 . The apertures are configured to receive the sample chambers. Preferably, the sample chambers fit in the apertures in a manner that prevents damage when exposed to the harsh wellbore conditions.
[0057] Passage 318 extends through the downhole tool. The passage preferably defines a plurality of radially-projecting lobes 320 . The number of lobes 320 is preferably equal to the number of sample chambers 314 , i.e., three in FIG. 2B . As shown, the lobes 320 project between the sample chambers 314 at a spacing interval of about 60° therefrom. Preferably, the lobes expand the dimension of the passage about the sample chambers to permit drilling fluid to pass therethrough.
[0058] The lobed bore 318 is preferably configured to provide adequate flow area for the drilling fluid to be conducted through the drillstring past the sample chambers 314 . It is further preferred that the chambers and/or containers be positioned in a balanced configuration that reduces drilling rotation induced wobbling tendencies, reduces erosion of the downhole tool and simplifies manufacturing. It is desirable that such a configuration be provided to optimize the mechanical strength of the sample module, while facilitating fluid flow therethrough. The configuration is desirably adjusted to enhance the operability of the downhole tool and the sampling while drilling system.
[0059] FIG. 3 is a schematic representation of the fluid flow system 301 of the sample module 220 of FIGS. 2A-2B . As described above, the fluid flow system 301 includes a flow diverter 332 for selectively diverting flow through the sample module and a plurality of sample chambers 314 . The flow diverter selectively diverts fluid from primary flowline 310 to secondary flowlines 311 leading to sample chambers 314 and/or a dump flowline 260 leading to the wellbore.
[0060] One or more flowlines valves may be provided to selectively divert fluid to desired locations throughout the downhole tool. In some cases, fluid is diverted to the sample chamber(s) for collection. In other cases, fluid may be diverted to the wellbore, the passage 318 or other locations as desired.
[0061] The secondary flowlines 311 branch off from primary flowline 310 and extend to sample chambers 314 . The sample chambers may be any type of sample chamber known in the art to capture downhole fluid samples. As shown, the sample chambers preferably include a slidable piston 360 defining a variable volume sample cavity 307 and a variable volume buffer cavity 309 . The sample cavity is adapted to receive and house the fluid sample. The buffer cavity typically contains a buffer fluid that applies a pressure to the piston to maintain a pressure differential between the cavities sufficient to maintain the pressure of the sample as it flows into the sample cavity. Additional features, such as pressure compensators, pressure chambers, sensors and other components may be used with the sample chambers as desired.
[0062] The sample chamber is also preferably provided with an agitator 362 positioned in the sample chamber. The agitator may be a rotating blade or other mixing device capable of moving the fluid in the sample chamber to retain the quality thereof.
[0063] Each sample chamber 314 is shown to have container valves 330 a, 330 b. Container valves 330 a are preferably provided to selectively fluidly connect the sample cavity of the sample chambers to flowline 311 . The chamber valves 330 b selectively fluidly connect the buffer cavity of the sample chambers to a pressure source, such as the wellbore, a nitrogen charging chamber or other pressure source.
[0064] Each sample chamber 314 is also associated with a set of flowline valves 328 a, 328 b inside a flow diverter/router 332 , for controlling the flow of fluid into the sample chamber. One or more of the flowline valves may be selectively activated to permit fluid from flowline 310 to enter the sample cavity of one or more of the sample chambers. A check valve may be employed in one or more flow lines to restrict flow therethrough.
[0065] Additional valves may be provided in various locations about the flowline to permit selective fluid communication between locations. For example, a valve 334 , such as a relief or check valve, is preferably provided in a dump flowline 260 to allow selective fluid communication with the wellbore. This permits formation fluid to selectively eject fluid from the flowline 260 . This fluid is typically dumped out dump flowline 260 and out the tool body's sidewall 329 . Valve 334 may also be is preferably open to the wellbore at a given differential pressure setting. Valve 334 may be a relief or seal valve that is controlled passively, actively or by a preset relief pressure. The relief valve 334 may be used to flush the flowline 310 before sampling and/or to prevent over-pressuring of fluid samples pumped into the respective sample chambers 314 . The relief valve may also be used as a safety to prevent trapping high pressure at the surface.
[0066] Additional flowlines and valves may also be provided as desired to manipulate the flow of fluid through the tool. For example, a wellbore flowline 315 is preferably provided to establish fluid communication between buffer cavities 309 and the wellbore. Valves 330 b permit selective fluid communication with the buffer chambers.
[0067] In instances where multiple sample modules 220 are run in a tool string, the respective relief valves 334 may be operated in a selective fashion, e.g., so as to be active when the sample chambers of each respective module 220 are being filled. Thus, while fluid samples are routed to a first sample module 220 , its corresponding relief valve 334 may be operable. Once all the sample chambers 314 of the first sample module 220 are filled, its relief valve is disabled. The relief valve of an additional sample module may then be enabled to permit flushing of the flow line in the additional sample module prior to sample acquisition (and/or over-pressure protection). The position and activation of such valves may be actuated manually or automatically to achieve the desired operation.
[0068] Valves 328 a, 328 b are preferably provided in flowlines 311 to permit selective fluid communication between the primary flowline 310 and the sample cavity 307 . These valves may be selectively actuated to open and close the secondary flow lines 311 sequentially or independently.
[0069] The valves 328 a, b are preferably electric valves adapted to selectively permit fluid communication. These valves are also preferably selectively actuated. Such valves may be provided with a spring-loaded stem (not shown) that biases the valves to either an open or closed position. In some cases, the valves may be commercially available exo or seal valves.
[0070] To operate the valves, an electric current is applied across the exo washers, causing the washers to fail, which in turn releases the springs to push their respective stems to its other, normal position. Fluid sample storage may therefore be achieved by actuating the (first) valves 328 a from the displaced closed positions to the normal open positions, which allows fluid samples to enter and fill the sample chambers 314 . The collected samples may be sealed by actuating the (second) valves 328 b from the displaced open positions to the normal closed positions.
[0071] The valves are preferably selectively operated to facilitate the flow of fluid through the flowlines. The valves may also be used to seal fluid in the sample chambers. Once the sample chambers are sealed, they may be removed for testing, evaluation and/or transport. The valves 330 a (valve 330 b may remain open to expose the backside of the container piston 360 to wellbore fluid pressure) are preferably actuated after the sample module 220 is retrieved from the wellbore to provide physical access by an operator at the surface. Accordingly, a protective cover (described below) may be equipped with a window for quickly accessing the manually-operable valves—even when the cover is moved to a position closing the sample chamber apertures 313 ( FIG. 4 ).
[0072] One or more of the valves may be remotely controlled from the surface, for example, by using standard mud-pulse telemetry, or other suitable telemetry means (e.g., wired drill pipe). The sample module 220 may be equipped with its own modem and electronics (not shown) for deciphering and executing the telemetry signals. Alternatively, one or more of the valves may be manually activated. Downhole processors may also be provided for such actuation.
[0073] Those skilled in the art will appreciate that a variety of valves can be employed. Those skilled in the art will appreciate that alternative sample chamber designs can be used. Those skilled in the art will appreciate that alternative fluid flow system designs can be used.
[0074] FIGS. 4A and 4B depict techniques for removably positioning sample chambers in the downhole tool. FIG. 4A depicts a sample chamber retained with the downhole tool by a cover, such as a ring or sleeve, slidably positionable about the outer surface of the drill collar to cover one or more openings therein. FIG. 4B depicts a cover, such as a plate or lid, positionable over an opening in the drill collar.
[0075] FIG. 4A is a partial sectional representation of the sample module 220 , showing a sample chamber 314 retained therein. The sample chamber is positioned in aperture 303 in drill collar 302 . The drill collar has a passage 318 for the passage of mud therethrough.
[0076] Cover 342 is positioned about the drill collar to retain the sample chamber in the downhole tool. The sample chambers 314 are positioned in the apertures 303 in drill collar 302 . Cover 342 is preferably a ring slidably positionable about drill collar 302 to provide access to the sample chambers 314 . Such access permits insertion and withdrawal of sample chamber 314 from the drill collar 302 .
[0077] The cover 342 acts as a gate in the form of a protective cylindrical cover that preferably fits closely about a portion of the drill collar 302 . The cover 342 is movable between positions closing (see FIG. 4A ) and opening (not shown) the one or more apertures 303 in the drill collar. The cover thereby provides selective access to the sample chambers 314 . The cover also preferably prevents the entry of large particles, such as cuttings, from the wellbore into the aperture when in the closed position.
[0078] The cover 342 may comprise one or more components that are slidable along drill collar 302 . The cover preferably has an outer surface adapted to provide mechanical protection from the drilling environment. The cover is also preferably fitted about the sample chamber to seal the opening(s) and/or secure the sample chamber in position and prevent damage due to harsh conditions, such as shock, external abrasive forces and vibration.
[0079] The cover 342 is operatively connected to the drill collar 302 to provide selective access to the sample chambers. As shown, the cover has a first cover section 342 a and a second cover section 342 b. The first cover section 342 a is held in place about drill collar 302 by connection means, such as engaging threads 344 , for operatively connecting an inner surface of the first cover section 342 a and an outer surface of the drill collar 302 .
[0080] The cover may be formed as a single piece, or it may include two or more complementing sections. For example, FIG. 4A illustrates a two-piece cover 342 with first and second cover sections 342 a, 342 b. Both the first cover section 342 a and second cover section 342 b are preferably slidably positioned about an opening 305 the tool body 302 . The first cover section 342 b may be slid about the drill collar until it rests upon an downwardly-facing shoulder 347 of the body. A shim 345 , or a bellows, spring-washer stack or other device capable of axial loading of the bottle to secure it in place, may be positioned between the shoulder 347 and the first cover section 342 b. The second cover section 342 a may also be slidably positioned about the drill collar 302 . The cover sections have complementing stops (referenced as 348 ) adapted for operative connection therebetween. The second cover section may be operatively connected to the first cover section before or after positioning the covers sections about the drill collar. The first cover section is also threaded onto the drill collar at threaded connection 344 .
[0081] The cover sections may then be rotated relative to the drill collar 302 to tighten the threaded connection 344 and secure the cover sections in place. Preferably, the covers are securably positioned to preload the cover sections and reduce (or eliminate) relative motion between the cover sections and the tool body 302 during drilling.
[0082] The cover 342 may be removed from drill collar 302 to access the sample chambers. For example, the cover 342 may be rotated to un-mate the threaded connection 344 to allow access to the sample chamber. The cover 342 may be provided with one or more windows 346 . Window 346 of the cover 342 may be used to access the sample chamber 314 . The window may be used to access valves 330 a, 330 b on the sample chamber 314 . Window 346 permits the manual valve 330 a to be accessed at the surface without the need for removing the cover 342 . Also, it will be appreciated by those skilled in that art that a windowed cover may be bolted or otherwise operatively connected to the tool body 302 instead of being threadably engaged thereto. One or more such windows and/or covers may be provided about the drill collar to selectively provide access and/or to secure the sample chamber in the drill collar.
[0083] The sample chamber is preferably removably supported in the drill collar. The sample chamber is supported at an end thereof by a shock absorber 552 . An interface 550 is provided at an opposite end adjacent flowline 311 to operatively connect the sample chamber thereto. The interface 550 is also preferably adapted to releasably secure the sample chamber in the drill collar. The interface and shock absorbers may be used to assist in securing the sample chamber in the tool body. These devices may be used to provide redundant retainer mechanisms for the sample chambers in addition to the cover 342 .
[0084] FIG. 4B depicts an alternate sample module 220 ′. The sample module 220 ′ is the same as the sample module 220 of FIG. 4A , except that the sample chamber 314 ′ is retained in drill collar 302 by cover 342 ′, an interface 550 ′ and a shock absorber 552 . The cover 342 ′ includes a plurality of cover portions 342 c and 342 d.
[0085] Cover 342 d is slidably positionable in opening 305 of the drill collar 302 . Cover 342 ′ is preferably a rectangular plate having an overhang 385 along an edge thereof. The cover may be inserted into the drill collar such that the overhang 385 engages an inner surface 400 of the drill collar. The overhang allows the cover to slidingly engage the inner surface of the drill collar and be retained therein. One or more covers 342 d are typically configured such that they may be dropped into the opening 305 and slid over the sample chamber 314 (not shown) to the desired position along the chamber cavity opening. The covers may be provided with countersink holes 374 to aid in the removal of the cover 342 d. The cover 342 d may be configured with one or more windows, such as the window 346 of FIG. 4A .
[0086] Cover 342 c is preferably a rectangular plate connectable to drill collar 302 about opening 305 . The cover is preferably removably connected to the drill collar by bolts, screws or other fasteners. The cover may be slidably positionable along the drill collar and secured into place. The cover may be provided with receptacles 381 extending from its sides and having holes therethrough for attaching fasteners therethrough.
[0087] The covers as provided herein are preferably configured with the appropriate width to fit snuggly within the opening 305 of the drill collar. One or more such covers or similar or different configurations may be used. The covers may be provided with devices to prevent damage thereto, such as the strain relief cuts 390 in cover 342 of FIG. 4B . In this manner, the covers may act as shields.
[0088] FIG. 5A is a detailed representation of a portion of the sample module of FIG. 4A depicting the interface 550 in greater detail. The interface includes a hydraulic stabber 340 fluidly connecting the sample chamber 314 disposed therein to one of the secondary flow lines 311 . The sample chamber 314 has a conical neck 315 having an inlet for passing fluids therethrough. The upper portion of the hydraulic stabber 340 is in fluid-sealing engagement with the conical neck 315 of the sample chamber 314 , and the lower portion of the hydraulic stabber in fluid-sealing engagement with the secondary flow line 311 of the drill collar 302 .
[0089] Such retainer mechanisms are preferably positioned at each of the ends of the sample chambers to releasably retain the sample chamber. A first end of the sample chamber 314 may be laterally fixed, e.g., by sample chamber neck 315 . An opposite end typically may also be provided with a retainer mechanism. Alternatively, the opposite end may be held in place by shock absorber 552 ( FIG. 4A ). These retainer mechanisms may be reversed or various combinations of retainer mechanisms may be used.
[0090] The conical neck 315 of the sample chamber 314 is supported in a complementing conical aperture 317 in the tool body 302 . This engagement of conical surfaces constitutes a portion of a retainer for the sample chamber. The conical neck may be used to provide lateral support for the sample chamber 314 . The conical neck may be used in combination with other mechanisms, such as an axial loading device (described below), to support the sample chamber in place. Preferably, little if any forces are acting on the hydraulic stabber 340 and its O-ring seals 341 to prevent wear of the stabber/seal materials and erosion thereof over time. The absence of forces at the hydraulic seals 341 preferably equates to minimal, if any, relative motion at the seals 341 , thereby reducing the likelihood of leakage past the seals.
[0091] FIG. 5B is a detailed view of a portion of the sample module 220 ′ of FIG. 4B with an alternate interface to that of FIG. 4A . The sample chamber 314 ′ of FIG. 5B is equipped with double-wedge or pyramidal neck 315 ′ that engages a complementing pyramidal aperture 317 ′ in the tool body 302 . Hydraulic stabber 340 ′ is positioned in an inlet in pyramidal neck 315 ′ for insertion into pyramidal aperture 317 ′ for fluidly coupling the sample chamber to flowline 311 . Hydraulic seals 341 ′ are preferably provided to fluidly seal the sample chamber to the drill collar.
[0092] This pyramidal engagement provides torsional support for the sample chamber, and prevents it from rotating about its axis within the sample chamber. This functionality may be desirable to ensure a proper alignment of manually operated valves 330 a ′ and 330 b ′ within the opening 313 of the sample chambers 314 .
[0093] FIGS. 6A-D illustrate a portion of the sample module 220 of FIG. 4A in greater detail. In these figures, the sample module 220 is provided with alternative configurations of retainers 552 a - d usable as the shock absorbers 552 and/or 552 ′ of FIGS. 4A-4B . These retainers assist in supporting sample chamber 314 within aperture 303 of drill collar 302 . Cover 342 also assists in retaining sample chamber 314 in position. The retainer and/or cover also preferably provide shock absorption and otherwise assist in preventing damage to the sample chamber.
[0094] As shown in FIG. 6A , the retainer 552 a includes an axial-loading device 1050 and a washer 852 . An adjustable setscrew 851 is also provided between the drill collar 302 and the retainer 552 a to adjustably position the sample chamber 314 within the drill collar. The washer may be a belleville stack washer or other spring mechanism to counteract drilling shock, internal pressure in the sample chamber and/or assist in shock absorption.
[0095] The sample chamber preferably has a tip 815 extending from an end thereof. The tip 815 is preferably provided to support washer 852 and axial loading device 1050 at an end of the sample chamber.
[0096] FIG. 6B shows an alternate shock absorber 552 b. The retainer 552 b is essentially the same as the retainer 552 a, but does not have a setscrew 851 . In this configuration, support is provided by cover 342 ′. Cover 342 ′ operates the same as covers 342 , but is provided with a stepped inner surface 343 . The stepped inner surface defines a cover shoulder 343 adapted to support sample chamber 314 within drill collar 302 .
[0097] Referring now to FIG. 6C , the shock absorber 552 c is the same as the shock absorber 552 a of FIG. 6A , but is further provided with a hydraulic jack 1051 . The hydraulic jack includes a hydraulic cylinder 1152 , a hydraulic piston 1154 , and a hydraulic ram 1156 that are operable to axially load the axial loading spacer 1050 .
[0098] When the cover 342 is open (not shown), the hydraulic jack may be extended under pressurized hydraulic fluid (e.g., using a surface source) to fully compress the spring member 852 . An axial lock (not shown) is then inserted and the pressure in the hydraulic cylinder 1152 may be released. The length of the axial lock is preferably dimensioned so that the counteracting spring force of the spring member is sufficient in the full temperature and/or pressure range of operation of the sample module, even if the sample module expands more than the sample chamber.
[0099] When the cover 342 is retracted (not shown), the hydraulic jack may be extended under pressurized hydraulic fluid (e.g., using a surface source) to fully compress the washer 852 . An axial lock 1158 may then be inserted and the pressure in the hydraulic cylinder 1152 released. The length of the axial lock 1158 is preferably dimensioned so that the counteracting spring force of spring member is sufficient to operate in a variety of wellbore temperatures and pressures.
[0100] FIG. 6D depicts an alternate shock absorber 552 d with an alternate jack 1051 ′. The shock absorber is the same as the shock absorber 552 c of FIG. 6C , except that an alternate jack is used. In this configuration, the jack includes opposing lead screws 1060 a and 1060 b, rotational lock 1172 and a jackscrew 1062 .
[0101] The jackscrew 1062 is engaged in opposing lead screws 1060 a and 1060 b. Opposing lead screws 1060 a and 1060 b are provided with threaded connections 1061 a and 1061 b for mating connection with threads on jackscrew 1062 . When the cover 342 is open (not shown), the distance between opposing lead screws 1060 a and 1060 b may be increased under torque applied to a central, hexagonal link 1171 until a desirable compression of the spring member 852 is achieved. Then a rotation lock 1172 may be inserted around the central, hexagonal link 1171 to prevent further rotation.
[0102] FIG. 7 illustrates an alternative retainer 552 e usable as the shock absorber for a sample chamber, such as the one depicted in FIG. 4A . The retainer 552 e includes an axial-loading spacer 1050 ′ and a head component 715 . Preferably, the axial load spacer has a flat sidewall 751 for engaging a complementing flat sidewall 752 of an end 815 ′ of the sample chamber 314 and preventing relative rotation therebetween. The head component 715 is insertable into the axial loading spacer 1050 ′ and the sample chamber to provide an operative connection therebetween. A spring member (not shown) may be provided about on a head component 815 of sample chamber 314 between the axial-loading spacer and the sample chamber.
[0103] FIGS. 8A-8C show alternative retainers usable with the sample chamber 314 of FIG. 7 . FIG. 8A depicts the retainer 552 e of FIG. 7 positioned in a drill collar 302 a. FIG. 8B depicts an alternate retainer 552 f having an axial-loading spacer 1050 ″ having a key 808 insertable into a drill collar 302 b ′. FIG. 8C depicts an alternate retainer 552 g having a radial retainer 860 operatively connected to a drill collar 302 c ′. The drill collars of these figures may be the same drill collar 302 as depicted in previous figures, except that they are adapted to receive the respective retainers. Preferably, these retainers and drill collars are adapted to prevent rotation and lateral movement therebetween, and provide torsional support.
[0104] As shown in FIG. 8A , the axial-loading spacers 1050 ′ of retainer 552 e has rounded and flat edge portions 804 and 805 , respectively. Drill collar 302 has a rounded cavity 806 adapted to receive the axial loading spacer 1050 ′.
[0105] In FIG. 8B , the retainer 552 e includes an axial-loading spacer 1050 ′ having a rectangular periphery 810 and a key 808 extending therefrom. The key 808 is preferably configured such that it is removably insertable into a cavity 812 in drill collar 302 b ′. As shown, the key has an extension 811 with a tip 814 at an end thereof. The tip 814 is insertable into cavity 812 , but resists removal therefrom. The dimension of cavity 812 is preferably smaller than the tip 814 and provides an inner surface (not shown) that grippingly engages the tip to resist removal. In some cases, it may be necessary to break the tip 814 to enable removal of the sample chamber when desired. Optionally, the tip may be fabricated such that a predetermined force is required to permit removal. In this manner, it is desirable to retain the sample chamber 314 in position in the drill collar during operation, but enable removal when desired.
[0106] FIG. 8C the alternative retainer 552 g includes an arm 950 operatively connected to drill collar 302 c ′. The arm 950 is preferably connected to drill collar 302 c ′ via one or more screws 951 . Preferably, the arm 950 is radially movable in a hinge like fashion. The arm 950 has a concave inner surface 955 adapted to engage and retain sample chamber 314 in place in drill collar 302 c′.
[0107] Preferably, the retainers provided herein permit selective removal of the sample chambers. One or more such retainers may be used to removably secure the sample chamber in the drill collar. Preferably, such retainers assist in securing the sample chamber in place and prevent shock, vibration or other damaging forces from affecting the sample chamber.
[0108] In operation, the sample module is threadedly connected to adjacent drill collars to form the BHA and drill string. Referring to FIG. 1 , the sample module may be pre-assembled by loading the sample chamber 314 into the aperture 303 of the drill collar 302 . The interface 550 is created by positioning and end of the sample chamber 314 adjacent the flowline 311 .
[0109] The interface 550 (also known as a pre-loading mechanism) may be adjusted at the surface such that a minimum acceptable axial or other desirable load is applied to achieve the required container isolation in the expected operating temperature range of the sample module 220 , thereby compensating for greater thermal expansion.
[0110] Retainer 552 may also be operatively connected to an opposite end of the sample chamber to secure the sample chamber in place. The cover 342 may then be slidably positioned about the sample chamber to secure it in place.
[0111] The interface 550 at the (lower) end with the hydraulic connection may be laterally fixed, e.g., by conical engagement surfaces 315 , 317 (see, e.g. FIG. 5A ) as described above. The retainer 552 at the opposite (upper) end typically constrains axial movement of the sample chamber 314 (see, e.g., FIGS. 6A-8C ). The two work together to hold the sample chamber within the drill collar 302 . The cover 342 is then disposed about the sample chamber to seal the opening 305 of the sample chamber as shown, for example in FIG. 4A .
[0112] One or more covers, shock absorbers, retainers, sample chambers, drill collars, wet stabbers and other devices may be used alone and/or in combination to provide mechanisms to protect the sample chamber and its contents. Preferably redundant mechanisms are provided to achieve the desired configuration to protect the sample chamber. As shown in FIG. 4 , the sample chamber may be inserted into the drill collar 302 and secured in place by interface 550 , retainer 552 and cover 342 . Various configurations of such components may be used to achieve the desired protection. Additionally, such a configuration may facilitate removal of the sample chamber from the drill collar.
[0113] Once the sample module is assembled, the downhole tool is deployed into the wellbore on a drillstring 12 (see FIG. 1 ). A sampling operation may then be performed by drawing fluid into the downhole tool via the probe module 210 ( FIG. 1 ). Fluid passes from the probe module to the sample module via flowline 310 ( FIG. 2A ). Fluid may then be diverted to one or more sample chambers via flow diverter 332 ( FIG. 3 ).
[0114] Valve 330 b and/or 330 a may remain open. In particular, valve 330 b may remain open to expose the backside of the chamber piston 360 to wellbore fluid pressure. A typical sampling sequence would start with a formation fluid pressure measurement, followed by a pump-out operation combined with in situ fluid analysis (e.g., using an optical fluid analyzer). Once a certain amount of mud filtrate has been pumped out, genuine formation fluid may also be observed as it starts to be produced along with the filtrate. As soon as the ratio of formation fluid versus mud filtrate has reached an acceptable threshold, a decision to collect a sample can be made. Up to this point the liquid pumped from the formation is typically pumped through the probe tool 210 into the wellbore via dump flowline 260 . Typically, valves 328 and 335 are closed and valve 334 is open to direct fluid flow out dump flowline 260 and to the wellbore.
[0115] After this flushing is achieved, the electrical valves 328 a may selectively be opened so as to direct fluid samples into the respective sample cavities 307 of sample chambers 314 . Typically, valves 334 and 335 are closed and valves 328 a, 328 b are opened to direct fluid flow into the sample chamber.
[0116] Once a sample chamber 314 is filled as desired the electrical valves 328 b may be moved to the closed position to fluidly isolate the sample chambers 314 and capture the sample for retrieval to surface. The electrical valves 328 a, 328 b may be remotely controlled manually or automatically. The valves may be actuated from the surface using standard mud-pulse telemetry, or other suitable telemetry means (e.g., wired drill pipe), or may be controlled by a processor (not shown) in the BHA 100 .
[0117] The downhole tool may then be retrieved from the wellbore 11 . Upon retrieval of the sample module 220 , the manually-operable valves 330 a, b of sample chamber 314 may be closed by opening the cover 342 to (redundantly) isolate the fluid samples therein for safeguarded transport and storage. The closed sample cavities 312 are then opened, and the sample chambers 314 may be removed therefrom for transporting the chambers to a suitable lab so that testing and evaluation of the samples may be conducted. Upon retrieval, the sample chambers and/or module may be replaced with one or more sample modules and/or chambers and deployed into the wellbore to obtain more samples.
[0118] It will be understood from the foregoing description that various modifications and changes may be made in the preferred and alternative embodiments of the present invention without departing from its true spirit.
[0119] This description is intended for purposes of illustration only and should not be construed in a limiting sense. The scope of this invention should be determined only by the language of the claims that follow. The term “comprising” within the claims is intended to mean “including at least” such that the recited listing of elements in a claim are an open set or group. Similarly, the terms “containing,” having,” and “including” are all intended to mean an open set or group of elements. “A,” “an” and other singular terms are intended to include the plural forms thereof unless specifically excluded. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words “means for” together with an associated function.
[0120] <next-to-last paragraphs—one paragraph for each independent claim, each paraphrasing the claim; additional paragraphs or sentences for dependent claims, if desired>
[0121] The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure.
[0122] The Abstract at the end of this disclosure is provided to comply with 37 C.F.R. §1.72(b) to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
|
An apparatus comprising a fluid communication device configured to extend from a drill string and establish fluid communication with a subterranean formation penetrated by a wellbore in which the drill string is positioned, wherein the drill string comprises a passage configured to conduct drilling mud and an opening extending through an outer surface thereof and into a cavity. A sample chamber is coupled within the cavity and is in selectable fluid communication with the formation via the fluid communication device. A retainer is configured to absorb lateral loading of the sample chamber within the cavity.
| 4
|
CROSS-REFERENCE OF RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 12/424,390, filed Apr. 15, 2009, which is a continuation of U.S. patent application Ser. No. 10/867,990, filed Jun. 15, 2004, now U.S. Pat. No. 7,524,286, which is a continuation of U.S. patent application Ser. No. 10/085,321, filed Feb. 28, 2002, now U.S. Pat. No. 6,856,821, which is a continuation-in-part of U.S. patent application Ser. No. 09/579,755, filed May 26, 2000, now abandoned, which claims the benefit of U.S. Provisional Application No. 60/136,293, filed May 27, 1999. All of the above-referenced applications are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the monitoring of blood gases during vacuum assisted wound healing. More particularly, the invention relates to a method and system for the transcutaneous monitoring of blood gases wherein said monitoring is enhanced by application of a vacuum pressure in the region of skin under evaluation, and during which negative pressure therapy is being applied to an adjacent or proximal wound site.
BACKGROUND OF THE INVENTION
[0003] Transcutaneous blood gas monitoring is known in the relevant arts as a method by which measurements of skin-surface gas pressures may be utilized to estimate arterial partial pressures of the gas of interest. In particular, skin surface oxygen or carbon dioxide pressure PO 2 or PCO 2 , respectively, is measured by a locally applied, electrochemically based device in order to develop an estimate of arterial partial pressure of oxygen or carbon dioxide P a O 2 or P a CO 2 , respectively. The obtained estimate is then made available to the clinician as an aid for the routine or emergency assessment of any of a variety of known cardiopulmonary functions.
[0004] In practice, a condition of hyperperfusion is indicated in the region of skin adjacent, the applied device in order to enhance the flow of arterial blood gases toward and through the skin surface. To date, this hyperperfusion condition has been established by local heating of the skin with an electrode in order to distend the arterial capillaries. Unfortunately, such local heating carries with it an increased risk for tissue injury—erythema, blisters, burns and skin tears being among the documented complications. In addition, some debate exists within the art as to whether the increased local metabolic rate concomitant the application of heat counteracts the intended perfusion effect. If so, false readings may result, which may ultimately lead to inappropriate treatment of the patient.
[0005] The use of transcutaneous blood gas monitoring can be particularly advantageous when used in conjunction with negative pressure therapy for vacuum induced healing of open wounds or other tissue damage. Vacuum induced healing of open wounds has recently been popularized by Kinetic Concepts, Inc. of San Antonio, Tex., by its commercially available V.A.C.® product line. The vacuum induced healing process has been described in commonly assigned U.S. Pat. No. 4,969,880 issued on Nov. 13, 1990 to Zamierowski, as well as its continuations and continuations in part, U.S. Pat. No. 5,100,396, issued on Mar. 31 1992, U.S. Pat. No. 5,261,893, issued Nov. 16, 1993, and U.S. Pat. No. 5,527,293, issued Jun. 18, 1996, the disclosures of which are incorporated herein by this reference. Further improvements and modifications of the vacuum induced healing process are also described in U.S. Pat. No. 6,071,267, issued on Jun. 6, 2000 to Zamierowski and U.S. Pat. Nos. 5,636,643 and 5,645,081 issued to Argenta et al. on Jun. 10, 1997 and Jul. 8, 1997 respectively, the disclosures of which are incorporated by reference as though fully set forth herein. Additional improvements have also been described in U.S. Pat. No. 6,142,982, issued on Nov. 7, 2000 to Hunt, et al.
[0006] The use of transcutaneous blood gas monitoring in conjunction with V.A.C.® therapy allows for monitoring of blood gases within and around the wound bed. Blood gases can be an indicative factor of wound healing progression. Crucial information can be ascertained as to the progression of the wound without disturbing the wound dressing.
[0007] It is therefore a primary object of the present invention to improve over the prior art by providing a method and apparatus for the transcutaneous monitoring of blood gases wherein local heating for hyperperfusion is eliminated, thereby eliminating a significant patient hazard and wherein the concomitant metabolic effects of local heating are likewise eliminated, thereby reducing the likelihood for misdiagnosis leading to inappropriate treatment regimen.
[0008] Hyperperfusion through local heating also requires a prolonged warm up and stabilization time following electrode placement in order for equilibration and calibration of the electrochemical transducer. As a result, operator time is generally wasted in the administration of a transcutaneous blood gas evaluation. Additionally, transcutaneous blood gas monitors are either not available for emergency use or must be made available with an operated in a standby mode. Such a standby mode requires additional hardware and generally shortens the electrode lifecycle.
[0009] It is therefore a further object of the present invention to improve over the prior art by providing a method and apparatus for the transcutaneous monitoring of blood gases wherein the apparatus is available for full operation on short notice without requirement for additional and/or lifecycle shortening hardware.
[0010] It is still a further object of the present invention to provide a system and method that combines the advantages of a non-invasive blood gas monitoring device with the effectiveness of negative pressure therapy upon wounds, so as to further improve the efficacy of negative pressure therapy on the treatment of wounds and other tissue treatments.
[0011] Finally it is still a further object of the present invention to improve over the prior art by providing a method and apparatus for the transcutaneous monitoring of blood gases wherein the above-described objects are implemented without sacrifice to patient safety or device efficacy, but wherein unnecessary hardware and software is nonetheless avoided, thereby conserving the ever more limited healthcare dollar.
SUMMARY OF THE INVENTION
[0012] In accordance with the foregoing objects, the present invention—a method and system for the transcutaneous monitoring of blood gases and vacuum assisted wound closure-generally comprises a blood gas data acquisition device, a vacuum source and a blood gas transducer unit. The blood gas transducer is adapted for application to a patient's skin and administration of a local vacuum at the area of patient application. It further comprises an electrochemical blood gas transducer, well known to those of ordinary skill in the art, which is disposed entirely within the local vacuum at the area of patient application. The transducer may also be disposed within a wound site, or an area immediately adjacent a wound site that is being treated by negative pressure therapy. The use of negative pressure therapy may include a porous, semi-rigid screen placed within a wound bed, a cover for maintaining a negative pressure within the wound bed that is placed over the screen and wound bed, and a vacuum source in fluid communication with the screen. Additionally, a canister may be disposed between the screen and vacuum source, for the collection of fluids that may emanate from the wound during application of negative pressure by the vacuum source. A flexible tube or similar device is used to communicate between the screen and vacuum source.
[0013] It is contemplated that the transducer may be incorporated within the screen, or alternatively placed as a separate element below the screen to be in direct contact with the wound bed, within a depression or cut-out of the screen, above the screen, or separate from the screen but immediately adjacent the wound bed.
[0014] The blood gas transducer unit is in fluid communication with the vacuum source through an interposed vacuum hose and in electrical communication with the blood gas data acquisition device through an interposed electrical cable. The vacuum source, which comprises a vacuum pump operated by a pump motor is placed in fluid communication with the blood gas transducer unit in order to induce a condition of hyperperfusion in the locality of the electrochemical blood has transducer. Under the control of the microcontroller, or equivalent means, the blood gas data acquisition device is then utilized to capture this measure to arrive at an estimate of arterial partial pressure of oxygen or carbon dioxide, accordingly. Because vacuum induced perfusion produces the requisite condition of hyperperfusion without local heating and, therefore, without acceleration of the local metabolic function, the present invention results in more accurate than previously available estimates of partial blood gas pressures and does so while eliminating a significant risk for injury to the patient.
[0015] The same vacuum source, or alternatively a second vacuum source, may be utilized to provide negative pressure at the wound site by communicating with the screen placed within the wound site, by means of a tube or similar device.
[0016] Because the application of vacuum perfusion to the patient presents at least some risk for contamination of the vacuum source and blood gas data acquisition device, the preferred embodiment of the present invention further comprises a transducer interface module particularly adapted for the reduction or elimination of contamination risk. According to the invention, the transducer interface module comprises a male and female interface pair, wherein the male portion is adapted into the female portion and thereby establishes communication between the blood gas transducer unit and the vacuum source and blood gas data acquisition device.
[0017] In implementing the male plug, a hydrophobic membrane filter—known to those of ordinary skill in the art—is interposed in the vacuum hose, thereby eliminating the opportunity for contaminants to pass from the patient to the vacuum source or blood gas data acquisition device. While the preferred embodiment of the present invention comprises a throw-away male plug, vacuum hose, electrical cable and blood gas transducer unit, those of ordinary skill in the art will recognize that each of these components can be made reusable with implementation of proper, known sterilization techniques. In this latter case, the hydrophobic membrane filter is preferably replaceable.
[0018] Finally, many other features, objects and advantages of the present invention will be apparent to those of ordinary skill in the relevant arts, especially in light of the foregoing discussions and the following drawings and exemplary detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and other features and advantages of the invention will now be described with reference to the drawings of certain preferred embodiments, which are intended to illustrate and not to limit the invention, and wherein like reference numbers refer to like components, and in which:
[0020] FIG. 1 shows, in perspective view, the preferred embodiment of the transcutaneous blood gas monitoring apparatus of the present invention, as employed with a human subject;
[0021] FIG. 2 shows, in schematic block diagram, details of the apparatus of FIGS. 1 ; and
[0022] FIG. 3 shows, in schematic block diagram, a transcutaneous blood gas monitoring device utilized in conjunction with a negative pressure therapy device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Although those of ordinary skill in the art will readily recognize many alternative embodiments, especially in light of the illustrations provided herein, this detailed description is exemplary of the preferred embodiment of the present invention, the scope of which is limited only by the claims that may be drawn hereto.
[0024] Referring now to FIG. 1 , the preferred embodiment of the transcutaneous blood gas monitoring system 10 of the present invention is shown to generally comprise a blood gas data acquisition device 11 , a vacuum source 12 and a blood gas transducer unit 13 . As shown in FIG. 1 , the blood gas transducer unit 13 is adapted for application to a patient's skin 14 . In alternative embodiments, not shown, the blood gas transducer may be applied within a wound bed 30 or disposed within a screen 32 placed within the wound bed 30 . As will be better understood further herein, the blood gas transducer unit 13 is also adapted for administration of a local vacuum at the area of the patient application. Finally, the blood gas transducer unit 13 comprises an electrochemical blood gas transducer 15 , well known to those of ordinary skill in the art, which is disposed entirely within the local vacuum at the area of patient application.
[0025] As also depicted in FIG. 1 , the blood gas transducer unit 13 is in fluid communication with the vacuum source 12 through an interposed vacuum hose 16 and in electrical communication with the blood gas data acquisition device 11 through an interposed electrical cable 17 . Although those of ordinary skill in the art will recognize many substantial equivalents, the preferred embodiment of the present invention comprises a unitary hose and cable pair 18 . Such a unitary pair 18 serves to reduce clutter in the patient care environment, thereby reducing the likelihood of either the hose 16 or cable 17 becoming entangled with other tubes, cables or equipment. Further, and as will be better understood further herein, such a unitary pair 18 is especially adapted for use with the preferred embodiment of the novel transducer interface module 19 of the present invention.
[0026] According to the preferred embodiment of the present invention, the vacuum source 12 comprises a vacuum pump 20 operated by a pump motor 21 . Those of ordinary skill in the art, however, will recognize many substantially equivalent embodiments for the vacuum source 12 including, for example, a central hospital vacuum or suction source or an integral pump and motor. In any case, all such equivalents are considered within the scope of the invention, which requires only a vacuum source 12 of the character otherwise described herein, and which is capable of providing suction in the range of about 50 mmHg through 250 mmHg.
[0027] In operation, the vacuum source 12 is placed in fluid communication with the blood gas transducer unit 13 in order to induce a condition of hyperperfusion in the locality of the electrochemical blood gas transducer 15 . Under the control of a microcontroller 22 , or equivalent means, the blood gas data acquisition device 11 is then utilized to capture a measure of skin surface oxygen or carbon dioxide pressure. The microcontroller 22 can then utilize this measure to arrive at an estimate of arterial partial pressure of oxygen or carbon dioxide, accordingly. Because vacuum induced perfusion produces the requisite condition of hyperperfusion without local heating and, therefore, without acceleration of the local metabolic function, the present invention results in more accurate than previously available estimates of partial blood gas pressures and does so while eliminating a significant risk for injury to the patient.
[0028] Because the application of vacuum to the patient presents at least some risk for contamination of the vacuum source 12 and blood gas data acquisition device 11 , the preferred embodiment of the present invention further comprises a transducer interface module 19 particularly adapted for the reduction or elimination of contamination risk. According to the invention, the transducer interface module 19 comprises a male 23 and female 24 interface pair, wherein the male portion 23 is adapted to plug into the female portion 24 and thereby establish communication between the blood gas transducer unit 13 and the vacuum source 12 and blood gas acquisition device 11 .
[0029] In implementing the male plug 23 , a hydrophobic membrane filter 25 —known to those of ordinary skill in the art—is interposed in the vacuum hose 16 , thereby eliminating the opportunity for contaminants to pass from the patient 14 to the vacuum source 12 or blood gas data acquisition device 11 . While the preferred embodiment of the present invention comprises a throw-away male plug 23 , vacuum hose 16 , electrical cable 17 and blood gas transducer unit 13 , those of ordinary skill in the art will recognize that each of these components can be made reusable with implementation of proper, known sterilization techniques. In this latter case, the hydrophobic membrane filter 25 is preferably replaceable.
[0030] Referring now to FIG. 3 , a collection canister 34 may be interposed between the vacuum source 12 and the screen 32 . As suction is applied, fluids may be drawn from the wound 30 and collected in the canister 34 . A common vacuum source 12 may be utilized to provide vacuum perfusion to the blood gas transducer 13 and negative pressure to the wound site 30 . A seal 36 is adhered over the screen 32 in order to maintain negative pressure within the wound site 30 . The seal 36 may be comprised of an elastomeric material. The screen 32 is preferably comprised of poly-vinyl alcohol foam, or alternatively a polyurethane porous sheet. It is to be understood that any semi-rigid and porous material may be utilized as a screen 32 within the wound bed 30 . The tube 16 may be in direct fluid communication with the screen 32 (not shown), or connected to an adapter 38 that is adhered over an opening 40 in the seal 36 . It is preferable that the tube 16 is bifurcated at a position between the vacuum source 12 and the canister 34 so that fluids being drawn from the wound site 30 do not interfere with the vacuum perfusion of the blood gas transducer 13 .
[0031] In an alternate embodiment, not shown, a separate vacuum source may be utilized to provide negative pressure to the wound site 30 and another vacuum source utilized to provide vacuum perfusion to the blood gas transducer 13 .
[0032] While the foregoing description is exemplary of the preferred embodiment of the present invention, those of ordinary skill in the relevant arts will recognize the many variations, alterations, modifications, substitutions and the like as are readily possible, especially in light of this description and the accompanying drawings. For example, a membrane or other like switch pad 26 may be implemented for user control of the transcutaneous blood gas monitor 10 and/or a display, printer or other output device 27 may be provided for monitoring and/or recording of estimated partial pressures. Likewise, a pressure transducer 28 may be, and preferably is, provided for monitoring and control of the vacuum applied to the patient 14 . In any case, because the scope of the present invention is much broader than any particular embodiment, the foregoing detailed description should not be construed as a limitation of the scope of the present invention, which is limited only by the claims that may be drawn hereto.
|
A system for administering negative pressure therapy to a wound includes a screen adapted to be positioned at the wound. A reduced pressure source is in fluid communication with the screen, and a Hood gas transducer is exposed to a reduced pressure provided by the reduced pressure source. The reduced pressure supplied by the reduced pressure source induces hyperperfusion of a blood gas at the wound.
| 0
|
CROSS REFERENCE
[0001] This application claims the benefit of International Patent Application No. PCT/US2013/057485, filed on 30 Aug. 2013, for Transosseous Attachment Method and Instruments and U.S. Provisional Patent Application No. 62/025,044, filed on 16 Jul. 2014, for Passive Retrieving Interosseous Suture Passing Device, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to techniques and instruments for surgical transosseous attachments, for example, the attachment of ligaments, tendons, fascia, and muscle to an adjacent bone to effect a repair of a joint. Typical joints subjected to repair are the hands, feet, ankle, knee and shoulder.
[0003] Transosseous attachment instruments of the type presently described, are generally referred to as a tunneler as they are not only utilized for the transosseous passing of suture, but in addition, are generally utilized to also guide bone tunneling procedures. Tunneler instruments of the prior art are at a disadvantage in that they require excessive procedural step to form the intersecting tunnels and transosseously pass suture through the intersecting tunnels. In addition, the prior art tunneler instruments cannot assure quick and effective transosseous placement and passing of the suture on each and every attempt, and in addition, the prior tunneler instruments are generally single use instruments which cannot be readily disassembled, disinfected and reused.
[0004] Tunneler instruments of the prior art such as illustrated in U.S. Pat. No. 8,449,552, issued on May 28, 2013, for Surgical Drill Guide with Awl and Method of Use, do not provide a passive means for capturing the suture and therefore quick and effective transosseous placement, and passing of the suture cannot be assured on each and every attempt. With this and other prior art tunnelers, in order to capture the suture passed through a suture retrieving element, additional active manipulation of the suture retrieving element must be taken in order to effect capture of the suture to be retrieved, and assured capture of the suture upon active manipulation of the suture retrieving element cannot be guaranteed.
[0005] It is therefore an object of the present invention to provide an intersosseous suture passing tunneling device which possesses passive retrieving capabilities in the suture retrieving element of the tunneler and which absolutely assures quick and effective transosseous placement and passing of the suture on each and every attempt.
SUMMARY OF THE INVENTION
[0006] The passive retrieving intersosseous suture passing instrument of the present invention includes a guide handle having a proximal end for manual grasping and a distal end for engagement with a bone to which suture is to be attached, the bone being provided with a first tunnel. A suture retrieving arm is carried at the distal end of the guide handle and it is provided with a distal tip which is dimensioned to be received in this first bone tunnel. The retrieving arm is also provided with a window therethrough which is aligned with a central guide bore passing through the handle for receiving a bone tunneling implement, such as a drill or awl, to form a second intersecting tunnel in the bone which passes through the window.
[0007] A suture passing awl is provided which is dimensioned and configured to be received in the central guide bore of the guide handle and to carry and pass suture through the window for capture and retention in the window of the suture retrieving arm. The instrument of the present invention is characterized by a passive suture capture device in the window which is adapted to passively engage suture carried on the awl under a pinching spring biased engagement sufficient to prevent withdrawal of the suture from the window when the awl is withdrawn, thus always insuring effective transosseous placement and passing of the suture on each and every attempt.
[0008] The passive suture capture device may take on various forms. In one of the more preferred embodiments, the passive suture capture device is comprised of a spaced pair of nitinol wires having their free distal ends depending into the window and positioned for passage of the suture passing awl therebetween under spring biased engagement of the nitinol wires against the suture being carried on the awl. Preferably the nitinol wires are replaceable and the suture retrieving arm carrying the nitinol wires includes spring clips for retaining the proximal ends of the replaceable nitinol wires.
[0009] The awl is keyed to the guide handle for guided orientation relative to the handle when fully seated therein to ensure proper orientation of the suture carried on the awl for engagement with the passive suture capture device. The awl is also preferably pointed at its distal end for creating a bone tunnel while simultaneously carrying the suture, which is exposed on the sides of the awl.
[0010] In a different embodiment, the suture capture device may consist of a flexable and penetrable capture wall confined within the window of the suture retrieving arm, such as a wall or sleeve of silicone or a wall of one or more layers of a fine mesh, such as a metal or plastic mesh. Alternatively the suture capture choice may consist of a metal trap door configuration.
[0011] The suture retrieving arm of the instrument may be constructed of one piece or may be constructed of two pieces which are interconnected and include a detachable oriented bone tunneling spike at the forward distal end of the suture retrieving arm, and wherein the spike carries the suture passing window at its distal end.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Other objects and advantages appear hereinafter in the following description and claims. The accompanying drawings show, for the purpose of exemplification, without limiting the scope of the present invention or the appended claims, certain practical embodiments of the present invention wherein:
[0013] FIG. 1 is a side view of one embodiment of the tunneler instrument of the present invention showing the suture pushing awl partially inserted into the instrument;
[0014] FIG. 2 is a side view of the tunneler shown in FIG. 1 illustrating the suture pushing awl fully inserted and engaged within the tunneler instrument;
[0015] FIG. 3 is a perspective view of the tunneler instrument shown in FIG. 1 as seen from the front;
[0016] FIG. 4 is an enlarged view in side elevation of the passive suture retrieving arm which is positioned on the forward end of the tunneler instruments shown in FIGS. 1, 2 and 3 ;
[0017] FIG. 5 is a front view of the passive suture retrieving arm shown in FIG. 4 ;
[0018] FIG. 6 is a perspective rear view of the passive suture retrieving arm shown in FIG. 4 ;
[0019] FIG. 7 is an enlarged perspective view of the forward end of the tunneler instrument of the present invention shown as detached from the handle portion of the tunneler instrument of the present invention thereby illustrating in part how the instrument may be disassembled for cleaning and sterilization;
[0020] FIG. 8 is a perspective view of the tunneler instrument of the present invention showing and illustrating the internal parts to further illustrate the inner workings of the instrument and its capability to be fully disassembled for cleaning and sterilization;
[0021] FIG. 9 is an enlarged perspective view of the forward end of the suture pushing awl loaded with a suture;
[0022] FIG. 10 is an enlarged perspective view of the forward end of the suture pushing awl shown in an inverted position with the suture removed;
[0023] FIG. 11 is a side view in partial section illustrating the application of the tunneler instrument of the present invention to a humeral head;
[0024] FIG. 12 is an enlarged view in side elevation of the passive suture retrieving arm illustrated in FIG. 4 with the addition of steel spring clips retaining the proximal ends of the replaceable nitinol wires utilized for the passive suture capturing device;
[0025] FIG. 13 is an enlarged front view of the passive suture retrieving arm incorporating another embodiment of the passive suture capture device in the retrieving arm window in the form of a metal trap door;
[0026] FIG. 14 is an enlarged front view of the passive suture retrieving arm illustrating another embodiment of the passive suture capture device in the suture passing window of the arm in the form of one or more layers of a fine metal or plastic mesh; and
[0027] FIG. 15 is an enlarged perspective view of the forward end of the tunneler instrument of the present invention illustrating the suture retrieving arm including a bone tunneling spike attached to its forward end and illustrating yet another embodiment of the passive suture capture device in the form of a wall or sleeve of silicone.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0028] The following illustrated examples depict instruments and techniques to pass a suture through a portion of the head of the humeral bone at the shoulder of a human patient to repair damaged soft tissue associated with the shoulder joint. However, instruments and techniques according to the present invention may be used to pass a suture through any joint bone.
[0029] Referring to the drawings, the tunneler instrument 10 is utilized for the creation of converging tunnels in bone (transosseous tunneling) both arthroscopically or with open techniques. For illustration purposes only, the tunneler 10 of the present invention is illustrated in the creation of tunnels in the humeral head 11 shown in FIG. 11 to allow for the repair of a torn rotator cuff
[0030] The tunneler instrument 10 consists of a guide handle 13 having at its forward end a passive suture retrieving arm 12 , and a suture pusher awl 14 . These elements work together to assist in creating two converging tunnels of different length and angles within bone and transosseously pass suture through the tunnels utilizing a passive suture capture or retrieving device on the distal end of suture retrieving arm 12 which interacts with the forward distal end of suture passer awl 14 . The tunneler instrument 10 transosseously passes and passively captures and retrieves suture 22 through the lateral tunnel 21 and medial tunnel 15 respectively, with fewer steps and greater reliability and repeatability than is possible through the use of current techniques.
[0031] An awl or drill (not shown) is first used to create the first or medial tunnel 15 ( FIG. 11 ) in the humeral head 11 . The passive suture retriever arm 12 is constructed of surgical stainless steel or other suitable material and is provided with a sharp distal tip 17 for piercing tissue, such as the percutaneous penetration of the deltoid and to also penetrate the rotator cuff, if desired, thereby eliminating a step. Window 20 is provided in the distal end of arm 12 to allow passage of the complimentary pusher awl 14 , which is used to create the second converging lateral tunnel 21 , as well as for passing suture 22 through the lateral tunnel. With specific reference to FIGS. 9 and 10 , suture pusher awl 14 has a special “shark mouth” geometry such that a slot 48 is created in the distal tip allowing it to retain a loop of the suture 22 in slot 48 and in side grooves 47 while creating the tunnel 21 , but releases the suture 22 as it is withdrawn from the tunnel 21 .
[0032] The head 18 of passive suture retrieving arm 12 is provided with two side by side passages 23 to receive and tightly retain the upper ends of nitinol wires 35 which have their free distal ends depending downwardly into open window 20 for passively capturing and retrieving suture 22 from the distal end of awl 14 .
[0033] Nitinol wires 35 are spaced side by side as best illustrated in FIG. 5 and their bottom free ends are disposed within window 20 . Thus when awl pusher 14 is keyed to handle 13 for proper orientation as shown, and is loaded with suture 22 and then penetrated into the bone head 11 to form the lateral tunnel 21 and pushed forward sufficiently to the final position as illustrated in FIG. 2 . The distal tip 17 of awl 14 passes between nitinol wires 35 and spreads them and flexes them slightly forward as illustrated in FIG. 10 whereby the nitinol wires 35 tightly engage and capture the suture 22 on both sides of awl 14 to passively capture and retrieve suture 22 from awl 14 when awl 14 is thereafter retracted and withdrawn. The nitinol wires 35 have a bristled surface which captures the suture 22 therebetween under the spring bias of the wires 35 .
[0034] Nitinol has been selected for the wires 35 as it is a metal alloy of nickel and titanium which exhibits the unique properties of shape, memory and super elasticity. It also may be provided with many different surface finishes. For example, it may be provided with a bristled surface for secure engagement of the suture as by chemical etching or sandblasting, or alternatively may be provided with coated polymers.
[0035] Other passive suture capturing and retrieval mechanisms may be substituted for nitinol wires 35 , such as a metal trap door, wire mesh, silicone mesh, suture mesh or any other substance that is capable of passively capturing and retrieving the suture 22 from awl 14 such as described hereinafter.
[0036] After awl 14 is withdrawn, the captured suture 22 remains clamped between nitinol wires 35 and the distal end of arm 12 may then be withdrawn from medial tunnel 15 pulling the captured suture 22 with it.
[0037] Before awl 14 is forced through head 11 to form lateral tunnel 21 , inner guide 41 is advanced forward under the bias of spring 31 ( FIG. 8 ) as controlled with knob 42 so that the forward pointed tip 43 of guide 41 ( FIGS. 3 and 11 ) engages the bone of head 11 at the desired position to maintain the instrument 10 in position for advancement of the awl 14 .
[0038] The tunneler instrument 10 is modular in construction and may be easily disassembled for cleaning and sterilization for reuse. As seen in FIG. 8 , the forward collar 39 may be unscrewed in order to detach the forward end of the tunneler 10 as shown in FIG. 7 . This also permits removal of the remaining internal parts. Knob 42 may be unscrewed thereby releasing the internal guide 41 and spring 31 for cleaning and sterilization.
[0039] Different passive suture retrieval guide arms 12 may be substituted in order to provide guide tips with different morphologies, which guide tips may be interchangeable intraop to allow lower or different positions on the bone, or to adapt to certain intraop situations.
[0040] Referring to FIG. 12 , the nitinol wires 35 are replaceable for reuse of the instrument. In this embodiment the distal ends 50 are engaged by stainless steel ribbon spring 51 to temporarily but firmly engage and retain nitinol wires 35 in position. Ribbon spring 51 is retained in position by machine screw 52 .
[0041] Referring next to FIG. 13 , a metal trap doors passive suture capture device 35 ′ is illustrated in substitution of the nitinol wires previously described. In this embodiment the trap door 35 ′ consists of two side by side vertical sheets of stainless steel which are respectively retained at the side edges of window 20 . The two sheets are separate from each other and meet or adjoin at the middle joint 53 .
[0042] Accordingly, when the forward tip 17 of awl 14 engages the trap door 35 ′, tip 17 penetrates through and between the two side by side metal plates or sheets, thereby separating them and flexing them forward whereby the inner side edges of the metal sheets at 53 engage awl 14 under a pinching spring biased engagement sufficient to prevent withdrawal of suture 22 from the window 20 when awl 14 is withdrawn from window 20 .
[0043] Yet another embodiment of the passive suture capture device is illustrated in FIG. 14 is a flexible and percutaneously penetrable wall of one or more layers of a fine mesh 35 ″. In this embodiment, the fine mesh 35 ″ permits penetration of the tip 17 of awl 14 through the mesh causing the fibers of the mesh to spread and engage the awl tip with a tight pinching engagement for assured passive capture of the suture 22 carried on awl 14 .
[0044] Referring to FIG. 15 , the suture retrieving arm 12 in this embodiment consists of two interconnected elements, namely the forward arm 27 which is interconnected with the distal tunneling spike 16 which contains the window 20 . In this arrangement, the spike 16 is first driven into the humeral bone to form a first or medial tunnel and then the forward end of arm 27 is secured to the head 18 of spike 16 . Thereafter in the afore described fashion, the lateral tunnel is then made with awl 14 , which passes through window 20 .
[0045] In this embodiment the passive suture capture device is provided in the form of a capture wall of silicone 35 ″′ which is flexible and percutaneously penetrable, will engage awl 14 under spring bias thereby pinching the suture 22 against awl 14 sufficiently to prevent withdrawal of the suture 22 from window 20 when awl 14 is withdrawn or retracted.
[0046] The head 18 of suture retriever spike 16 is cannulated axially as indicated at 23 and slotted radially at 24 to allow for mounting of the spike 16 into the distal connecting end 25 to temporarily to a driver (not shown) for driving spike 16 into the bone 11 .
[0047] A long loop 30 of suture or wire is secured via passages 43 to head 18 of spike 16 and permits the surgeon or assistant to pull the spike 16 out of the bone 11 when desired to retrieve suture 22 . The end of this loop 30 stays well outside of the body at all times, allowing the surgeon or assistant to readily grab it with their hand and pull.
[0048] In the embodiment of FIG. 15 , the suture retrieving arm 12 is pivotal as indicated by arrow 28 which allows for vertical pivotal rotation of pitch of the guide handle 13 relative to the spike 16 . To the contrary, in the previous embodiments, the suture retrieving arm 12 is fixed relative to the guide handle 13 .
|
A passive retrieving interosseous suture passing instrument ( 10 ) having a guide handle ( 13 ) with a proximal end for grasping and a distal end for engagement with a bone ( 11 ) to which suture ( 22 ) is to be attached. The bone ( 11 ) is provided with a first tunnel ( 15 ), and a suture retrieving arm ( 12 ) carried at the distal end of the guide handle ( 13 ) is provided with a distal tip dimensioned to be received in the first tunnel ( 15 ).
| 0
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a surge energy transfer circuit related to surge suppression techniques, and more particularly to an integrated circuit that can not only absorb surge energy but also convert the remaining surge energy into usable voltage form that also completely protects power facilities.
[0003] 2. Description of the Related Art
[0004] Surge vulnerability interference arises from the large energies involved, making it a major source of surge interference. Lighting flash surge (LFS) is a typical source of surge interference. As a practical matter, power facilities are prone to failure when confronted with LFS due to insufficient surge protection.
[0005] As for adequate surge protection schemes used for securing normal operations of power facilities, many patents have been disclosed, such as U.S. Pat. No. 5,353,189 “Surge protector for vehicular traffic monitoring equipment”, U.S. Pat. No. 5,617,284 “Power surge protection apparatus and method”, U.S. Pat. No. 5,038,245 “Method and apparatus for suppressing electrical transients”, U.S. Pat. No. 4,677,518 “Transient voltage surge suppressor”, U.S. Pat. No. 4,584,622 “Transient voltage surge suppressor”, and the like. All of these patents basically employ a structure that emphasizes on the use of a clamping voltage or remnant surge voltage suppression while lacking an adequate consideration of processing surge energy.
[0006] Remnant surge voltage is not the main cause leading to power facility failures. Remnant surge energy generated by a residual current flowing in the power equipment must be taken into account as well. According to ANSI/IEEE C62.41 standard “Recommended Practice on Characterization of Surges in Low-Voltage (1000 V and Less) AC Power Circuits”, outdoor power facilities are classified as C category devices for surge interference. A combination waveform surge test in accordance with the C3 category is 20 kV 1.2/50 μSec and 10 kA 8/20 μSec. The energy generated by the combination waveform surge can go up to more than 1,000 Joules and easily destroy power facilities.
[0007] The reason that methods of the prior art are ineffective in processing surge energy lies in using circuits built around a surge protection device, a gas tube choke, to process the surge and targeted at reducing the remnant surge voltage of the power supply end of power facilities. However, as the current withstanding capability of the choke is low, there are no methods explaining how to reduce the remnant surge energy of the power supply end of power facilities. In fact, methods or techniques for reducing remnant surge voltage fail to effectively process surge energy, with the result that surge energy may still easily destroy power equipment.
[0008] To overcome the shortcomings of the prior, the inventor has disclosed an effective alternative in US Patent Application No. 2009/0109585 A1, entitled “Series surge suppression structure”, that is, a method that takes the clamping voltage and energy storage into account, to significantly reduce remnant surge voltage and remnant energy entering power facilities, thereby achieving a superior protection result.
[0009] In pursuit of constant betterment, a surge energy transfer circuit is further developed to absorb and transfer surge energy by means of a parameter adjustment design, significantly lowering the surge energy entering power facilities and reducing remnant surge voltages, and ensuring to substantially protect power facilities and enhance surge immunity within power facilities.
SUMMARY OF THE INVENTION
[0010] An objective of the present invention is to provide a surge energy transfer circuit that not only absorbs surge energy but also converts the remaining surge energy into a usable form to thoroughly protect power facilities.
[0011] To achieve the foregoing objective, a surge energy transfer circuit has an input terminal, an output terminal, an energy absorption unit, a surge energy transfer unit, a surge energy charge and discharge unit and an equipotential grounding unit.
[0012] The surge absorption unit is connected to the input terminal and has two surge protection devices (SPD) for absorbing a percentage of input surge energy.
[0013] The surge energy transfer unit is connected to the surge absorption unit, and is formed by at least two inductors having an identical inductance or at least two groups of inductors having an identical inductance for temporarily storing a remaining percentage of the input surge energy and converting the remaining percentage of the input surge energy into a usable voltage, in which the percent of the converted surge energy out of the input surge energy is equal to the percent of a figure obtained by subtracting the input surge energy absorbed by the surge absorption unit from the input surge energy out of the input surge energy.
[0014] The surge energy charge and discharge unit is connected to the surge energy transfer unit and the output terminal, and has at least one high voltage capacitor or at least one group of high voltage capacitors to charge and discharge the voltage converted from the remaining percentage of the inputted surge energy, in which a time duration elapsing for charging or discharging is determined by a magnitude of the selected high voltage capacitor.
[0015] The equipotential grounding unit is connected to the surge absorption unit, the surge transfer unit, the surge energy charge discharge unit, the input terminal and the output terminal, and has at least two SPDs having identical characteristics so as to maintain a constant voltage at the output terminal when the input surge energy is coupled to ground, thereby significantly reducing the input surge energy and a remnant surge voltage represented by the converted form of voltage by serially connecting a circuit formed by the foregoing units to a path through which a surge passes.
[0016] The surge energy transfer circuit has the following advantages:
[0017] 1. The SPD, inductors and high voltage capacitors are employed to reduce the remnant surge voltage, convert surge energy into a voltage form superimposed on the operating power to slightly increase the operating voltage. Given this approach, the lifetime of the SPD is extended and the surge immunity of power facilities is also increased.
[0018] 2. The SPD and gas tube are serially connected with the input terminal to form a two-stage surge suppression unit that effectively enhances surge suppression capabilities.
[0019] 3. A two-port structure, one port being the input terminal and the other being the output terminal for protecting power facilities, protects the power facilities by way of a serial connection.
[0020] 4. The input terminal is connected with an external power source, and the output terminal is connected to a power facility. The surge energy transfer circuit can be serially connected to an external wire and the power facility to form a surge energy transferring means, thereby substantially increasing the surge immunity of power facilities.
[0021] More importantly, adopting the present invention not only converts surge energy into a usable voltage form and calculates the operating voltage rise range and the lasting time duration, but also builds products in compliance with customized demand. Accordingly, the present invention can be extensively applied to various types of power facilities to effectively avoid surge interference and keep power facilities operating normally.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a functional block diagram of a surge energy transfer circuit in accordance with the present invention;
[0023] FIG. 2 is a circuit diagram of the surge energy transfer circuit in FIG. 1 ;
[0024] FIG. 3 is a test diagram showing normal mode coupling for the surge energy transfer circuit in FIG. 1 ;
[0025] FIG. 4 is a test diagram showing common mode coupling to ground for the transfer circuit in FIG. 1 ;
[0026] FIG. 5 is a circuit diagram of a multi-stage circuit composed of multiple surge energy transfer circuits in FIG. 2 ;
[0027] FIG. 6 is a perspective view showing different circuit modules formed by the surge energy transfer circuit in FIG. 2 ;
[0028] FIG. 7 is a perspective view showing the circuit modules in FIG. 6 having a respective cover;
[0029] FIG. 8 is a functional block diagram of a three-phase Y-connected product built with three modules shown in FIGS. 6 and 7 ; and
[0030] FIG. 9 is a functional block diagram of a three-phase Δ-connected product built with three modules shown in FIGS. 6 and 7 .
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present invention will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for the purpose of illustration and description only; it is not intended to be exhaustive or to be limited to the precise form disclosed.
[0032] With reference to FIGS. 1 and 2 , a surge energy transfer circuit 10 in accordance with the present invention has an input terminal 12 , an output terminal 34 , a surge absorption unit 1 , a surge energy transfer unit 2 , a surge energy charge and discharge unit 3 , and an equipotential grounding unit 4 .
[0033] The surge absorption unit 1 is connected to the input terminal 12 , and includes two or more surge protection devices (SPD) 11 having functionally identical characteristics and serving to absorb a percent of the input surge energy. Additionally, to facilitate to mark reference numerals in the description while not disobeying word meaning, the relevant SPD is relocated ahead of the surge protection device 11 .
[0034] The surge energy transfer unit 2 is connected to the surge absorption unit 1 , and includes at least two inductors 21 having an equal inductance or two groups of inductors 21 having an equal inductance (despite two inductors being illustrated in FIG. 2 , the number of inductors is not so limited when the surge energy transfer unit is implemented) for temporarily storing a remaining percentage of the input surge energy exceeding a specific percentage thereof and for converting the remaining percentage of the input surge energy into a usable voltage form, in which the percentage of the converted surge energy out of the entire input surge energy is equal to the percent of the figure subtracting the surge energy absorbed by the surge absorption unit 1 from the input total surge energy out of the entire input surge energy.
[0035] The surge energy charge and discharge unit 3 is connected to the surge energy transfer unit 2 and an output terminal 34 , and includes at least one high voltage capacitor 31 or at least one group of high voltage capacitors (despite a high voltage capacitor illustrated in FIG. 2 , the number of high voltage capacitors is not so limited when the surge energy charge and discharge unit is implemented) to charge and discharge the voltage converted from surge energy, in which the time duration for charging or discharging is determined by the magnitude of the selected high voltage capacitor 31 .
[0036] The equipotential grounding unit 4 is connected to the surge absorption unit 1 , the surge transfer unit 2 , the surge energy charge discharge unit 3 , the input terminal 12 and the output terminal 34 , and includes at least two SPDs 41 having functionally identical characteristics so that the surge energy transfer circuit can generate an equipotential effect to a surge coupled through ground.
[0037] With reference to FIGS. 1 and 2 , when implemented, the surge energy transfer circuit 10 may have a two-port structure. One port is the input terminal 12 connected with a power source or a signal line, and the other port is the output terminal 12 serving as a protection terminal for a power facility.
[0038] The two or two groups of inductors 21 are parallelly connected between the input terminal 12 and the output terminal 34 . The one or one group of high voltage capacitors 31 is/are connected with one end of each of the two inductors 21 that are connected to the output terminal 34 . The surge absorption unit 1 has two SPDs 11 crossly connected with the two inductors 21 . Two ends of each of the two SPDs 11 are respectively connected to one end of one of the two inductors 21 and one end of the other of the two inductors 21 . The surge absorption unit 1 is intersected with the two inductors 21 at nodes C 1 , C 2 adjacent to the input terminal 12 and nodes C 3 and C 4 adjacent to the output terminal 34 . The equipotential grounding unit 4 has four SPDs 41 having functionally identical characteristics. Each of the four SPDs 41 is connected between each of the four nodes C 1 , C 2 , C 3 , C 4 and ground.
[0039] When being implemented, the surge energy transfer circuit 10 further includes a SPD 51 and a gas tube 52 serially connected to the input terminal 12 to constitute a two-stage surge suppression structure for higher surge suppression effect.
[0040] Given the foregoing structure, the surge energy transfer circuit 10 can be serially connected between an external connection wire and a power facility to create a surge energy transfer and protection effect, thereby substantially reducing the surge energy that enters the power facility to maintain normal operations of the power facility and extend the life duration of the power facility. Specifically, the life durations of the SPDs 11 , 41 , 51 are extended and the surge immunity of the power facility is enhanced so that the power facility can keep operating when encountering surges from the environment.
[0041] The present invention further includes a method for how to calculate surge energy with a voltage form converted from the surge energy so as build a practical product in accordance with a customized voltage rise margin and lasting time duration.
[0042] With reference to FIG. 2 , the surge energy transfer circuit 10 has three SPDs 11 , 41 , 51 , a gas tube 52 , an inductor 21 and a high voltage capacitor 31 . The converted surge energy entering the power facility and the resulting suppression effect can be expressed by the following equations.
[0043] The SPDs 11 , 41 , 51 used in the mathematical derivation of the method in accordance with the present invention are designed based on various clamping voltages V clamping . The higher the V clamping is, the lower a residual current I r flowing through the SPD 11 is, and the lower the V clamping is, the higher the residual current I r flowing through the SPD 11 is. The mathematical derivation of the method of the present invention adopts a design framework letting values of residual currents flowing through the SPD between C 1 , C 4 be k, and a value of a residual current flowing through the inductor 21 be 1−k, in which the value of k is in a range from 0.1 to 0.9.
[0044] 1. With reference to FIGS. 2 and 3 , when an operating voltage is applied to the input terminal 12 and a vulnerability interference surge enters the input terminal 12 , normal mode coupling occurs.
[0045] Given a voltage V 34 of the output terminal 34 of the surge energy transfer circuit 10 for protecting the power facility, energy E L is stored in two inductors 21 , and an inductance L and a voltage V L of the inductor 21 , an energy E (L) is momentarily stored in the inductor 21 and a transient voltage V (L) of the inductor 21 when a surge current I L flows through the inductor 21 can be respectively expressed as follows:
[0000] E (L) =2×(½)× L ( I L ) 2 =L [(1− k )× I r ] 2
[0000] V (L) =L ( dI L /dt )=(1− k )× L ( dI r /dt )
[0046] A remnant surge voltage of the output terminal 34 , V r , is expressed by:
[0000]
V
r
=
V
clamping
-
V
(
△
L
)
=
V
clamping
-
(
1
-
k
)
×
L
(
I
r
/
t
)
(
1
)
[0047] where k is in a range of 0.1 to 0.9.
[0048] As known from equation (1), the magnitude of the inductor 21 (L) is inversely proportional to the remnant surge voltage Vr. The less the remnant surge voltage decreases when the value of the inductor 21 (L) increases, and increases when the value of the inductor 21 (L) decreases. By varying the magnitude of the inductor 21 (L), the value of the remnant surge voltage Vr can be precisely controlled. Such an approach has a more definite and substantial suppression effect than conventional surge voltage suppression approaches.
[0049] After a residual current passes through the inductor 21 , energy E (L) momentarily stored in the inductor 21 is released to the high voltage capacitor 31 and the SPD 11 connected to C 3 and C 2 . A k proportion of the residual current flows through the SPD 11 connected to C 3 and C 2 . The remaining (1-2 k) proportion of the residual current flows through the high voltage capacitor 31 . The voltage increment of the output terminal 34 , V (34) , is expressed by:
[0000] V (34) =(1 /C )∫(1−2 k ) I r dt (2)
[0050] where C is a value of the high voltage capacitor and k is in a range of 0.1 to 0.9.
[0051] As indicated by Equation (2), the voltage increment V (34) is reversely proportional to the value C of the high voltage capacitor 31 . The V (34) decreases when the value C of the high voltage capacitor 31 increases, and increases when the V (34) decreases.
[0052] A power frequency is a frequency constituted by the inductor 21 and the high voltage capacitor 31 . Thus, after the residual current passes through the output terminal 34 , the transient total voltage of the output terminal 34 rises to V T
[0000]
V
T
=V
34
+V
(34)
[0053] The transient total energy Ec momentarily stored in the high voltage capacitor connected with the output terminal 34 can be expressed as follows:
[0000]
E
c
=
1
2
CV
c
2
=
E
34
+
E
(
△34
)
=
∫
t
0
t
1
(
V
34
×
I
34
)
t
+
(
1
-
2
k
)
∫
t
0
t
1
(
V
△
34
×
I
r
)
t
[0054] where t 0 -t 1 is a lasting time duration of a waveform of the residual current I r .
[0000]
(
1
-
2
k
)
∫
t
0
t
1
(
V
△
34
×
I
r
)
t
=
1
2
CV
(
△34
)
2
=
1
2
QV
(
△34
)
=
1
2
(
1
-
2
k
)
(
I
r
×
t
)
V
(
△
34
)
;
CV
(
△
34
)
=
(
1
-
2
k
)
(
I
r
×
t
)
[0055] A lasting time duration of the voltage increment V (34) is t
[0000]
t
=
1
(
1
-
2
k
)
I
r
CV
(
△
34
)
(
3
)
[0056] As indicated by Equation (3), the lasting time duration t of the voltage increment V (34) is proportional to the value C of the high voltage capacitor 31 . The lasting time duration t of the voltage increment V (34) is longer when the value C of the high voltage capacitor 31 is larger, and is shorter when the value C of the high voltage capacitor 31 is smaller.
[0057] From Equations (1), (2) and (3), the remnant surge voltage Vr of the output terminal 34 of the surge energy transfer circuit 10 , the inductance of the inductor 21 , the value of the high voltage capacitor, and low voltage increment of the output terminal V (34) and long lasting time duration t or high voltage increment of the output terminal V (34) and short lasting time duration t can be effectively and precisely planned and designed to meet different customized demands and raise surge immunity of power facilities.
[0058] With reference to FIG. 3 , an actual testing diagram (L-N) for common mode coupling of the surge energy transfer circuit 10 is shown. An operating voltage AC 110V is applied to the power input terminal 12 . A combination wave surge combined by 10 KV 1.2/50 μS and 5 k A 8/20 μS is coupled to the input terminal 12 . The test results show that a peak value of the operating voltage at the output terminal 34 rises from 145 V to 154V, which represents an increase rate of 6.2%. After lasting for 58 mSec (3.5 cycles), the operating voltage at the output terminal 34 returns to 145V (note: the voltage attenuation ratio in FIG. 3 is 100). It is evident that the present invention has a good surge energy transfer and suppression effect.
[0059] Moreover, as there are many nonlinear loads in an actual operating environment, the resulting power waveform is distorted accordingly. The power frequency constituted by the inductor 21 and the high voltage capacitor 31 in the surge energy transfer circuit 10 of the present invention can be employed to completely improve the distortion of the power waveform during the lasting time duration of the voltage increment V (34) after the residual current passes through.
[0060] 2. With reference to FIGS. 2 and 4 , when an operating voltage is applied to the input terminal, a vulnerability interference surge enters the input terminal 12 through ground to form a common mode coupling for the surge.
[0061] Transient voltage increments for 4 SPDs 41 connected between ground and C 1 , C 2 , C 3 , C 4 and having a functionally identical characteristics are V( 1G ), V( 2G ), V( 3G ) and V( 4G ) respectively. When a surge current flows through, a transient total voltage of the output terminal 34 , V C can be expressed as follows:
[0000] V C =V 34 +( V (Δ1G) −V (Δ2G) )+( V (Δ3G) −V (Δ4G) ) (4)
[0062] Since the four SPDs 41 have the same characteristics, V (Δ1g) =V (Δ2G) , V (Δ3G) =V (Δ4G) . The four SPDs 41 serve to mutually cancel the surge voltage. Therefore, the output terminal 34 is maintained in an equipotential effect to suppress the common mode coupling of the surge.
[0063] With reference to FIG. 4 , an actual testing diagram (L, N-G common mode coupling) of the surge energy transfer circuit 10 is shown. When an operating AC voltage of 220V is applied to the input terminal 12 , a combination wave surge, 10 kV, 1.2/50 μS, 5 k A, 8/20 μS enters the input terminal 12 and is coupled to ground; a test result shows that a peak value of the operating voltage at the output terminal 34 rises from 291V to 308V and indicates an increase rate of 5.8%. After lasting 25 mS (1.5 cycles), the operating voltage at the output terminal 34 returns to 291V (note: the voltage attenuation ratio in FIG. 4 is 100, and a current and voltage output transfer ratio is 1V/100 A). It is evident that the equipotential grounding design of the present invention has superior surge energy transfer and suppression effect.
[0064] Moreover, FIGS. 3 and 4 show a significant aspect. A surge suppression effect generated by the surge energy transfer circuit 10 can be clearly derived from the foregoing equations (1), (2), (3) and (4). A combined suppression effect for enhancing surge immunity and penetration suppression of protected power facilities can be definitely addressed to effectively improve the drawbacks of conventional approach.
[0065] Additionally, customized requirements can be easily achieved by utilizing equations (1), (2), (3) and (4). In accordance with different operating voltages (AC and DC) of power facilities, the specifications of the corresponding SPD 11 , the inductor 21 , and the high voltage capacitor 21 can be obtained from simple calculations to build a product in compliance with practical requirements.
[0066] With reference to FIG. 2 , not only can the surge energy transfer circuit 10 of the present invention be used to provide a single-stage circuit but can also be used to provide a multi-stage circuit with several single-stage circuits serially connected as shown in FIG. 5 or, as shown in FIGS. 6 and 7 , to practically provide various products using a module 100 based on standard requirements. Furthermore, with reference to FIGS. 8 and 9 , three of the modules 100 can be integrated in accordance with consumer demand to build three-phase products that are Y-connected and Δ-connected with the input terminal 12 and the output terminal 34 to provide a diversified and extensive product range.
[0067] Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only. Changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
|
A surge energy transfer circuit comprises a surge protection device, gas tube, inductor and high voltage capacitor for significantly reducing surge energy entering a power facility, lowering a remnant surge voltage to convert the surge energy in a voltage form. The converted voltage is superimposed to an operating power to slightly cause a rise of a peak value of the operating voltage. After the surge energy is converted in tens of mS, the operating power returns to a normal voltage value. Accordingly, the lifetime of the surge protection device can be extended and the surge immunity of the power facility can be improved to normal under surge interference situations.
| 7
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a control apparatus for a robot, and in particular in an industrial robot, to a method of outputting a stop signal for the periphery of the robot and to the configuration of a safety circuit for generating the stop signal when the robot is stopped in case of abnormality in the periphery of the robot.
[0003] 2. Description of the Related Art
[0004] An industrial robot is provided with emergency stop switches in order to secure the safety of both the operator of the robot and the workers in the periphery of the robot. Since these emergency stop switches are electrically connected to a safety circuit in series, the operation of any emergency stop switch causes the switching OFF of a servo power supply for driving a motor in the robot body.
[0005] These emergency stop switches indicate those switches for detecting the occurrence of a factor harmful to the safety, and include: an emergency stop switch provided in the body of the control apparatus; a door open-close switch provided in a safety fence for insuring a safety region in the periphery of the robot; an external emergency stop switch in a peripheral system; and an over travel switch for the robot body. Each switch is configured in linkage with the driving circuit of the servo power supply so as to control the switching ON permission and the switching OFF of the servo power supply. A prior art safety apparatus for an industrial robot is described below with reference to FIG. 8.
[0006] In a safety circuit of a robot body 1 shown in FIG. 8, disposed in series are switches 21 to 2 n each corresponding to a factor inhibiting the switching ON of a servo power supply 4 to the robot body 1 . One end of the switch 21 is supplied with a 24 V voltage, while the last end of the switch 2 n is provided with a relay 3 for controlling the switching ON and switching OFF of the servo power supply, whereby a first signal line is formed. Further, a signal of servo switching ON permission is provided from a control apparatus 5 to the servo power supply 4 . Without a factor inhibiting the switching ON of the servo power supply to the robot body 1 , each switch 21 to 2 n is closed thereby to provide the 24 V voltage on the first signal line. A relay coil 31 is then excited thereby to close a relay contact 32 . Then, finally, a servo power supply switching ON circuit in the servo power supply 4 is driven. When switched ON, the servo power supply starts to energize (control) a motor 11 included in the robot body 1 , while a lock (brake 12 ) circuit of a shaft of the motor 11 is switched OFF.
[0007] In this state, when at least one of the switches 21 to 2 n is operated (to become open) due to occurrence of a factor inhibiting the switching ON of the servo power supply, the first signal line is switched OFF, and the 24 V voltage is not supplied. At that time, by monitoring the potential in the end point on the relay 3 side of each switch with a control apparatus 5 , it is known which switch is open. Further, the relay coil 31 becomes unexcited thereby to open the relay contact 32 . The servo power supply is then switched OFF thereby to stop to energize (control) the motor 11 in the robot body 1 , while the brake 12 of the shaft of the motor 11 is switched ON.
[0008] As such, as is described in Japanese Laid-Open Patent Publication No. Hei 10-217180, when any of the switches 21 to 2 n becomes open, the first signal line which is the servo power supply switching ON permission line is switched OFF, whereby the servo power supply is switched OFF thereby to cause immediate stop of the robot.
[0009] In the prior art safety apparatus for an industrial robot as described above, a signal for sending the emergency stop to external devices is output by the open-close of the relay contact 32 . Further, in a production line in which each of a plurality of robots is disposed in each work area, the emergency stop of each work area is monitored using the above-mentioned signal. Accordingly, even when a trouble occurs only in some of the work areas, the robots in all of the areas are immediately stopped. Therefore, even when a work area is to be stopped to ensure the safety in the work area in case of a trouble (such as a change of expendable parts) which concerns the work area alone and does not affect the other work areas, the whole line is stopped in accordance with the prior art configuration. This causes the problem of reducing the work efficiency.
[0010] Further, since the switching OFF of the servo power supply for the industrial robot is carried out by breaking the switch contact of a limit switch and the like of each switch 21 to 2 n , in case of occurrence of a contact fusion in any switch, the servo power supply is not properly switched OFF even in case of occurrence of the emergency stop factor corresponding to the switch. Furthermore, the control apparatus 5 can not detect the occurrence position of the fusion, and hence the reliability of the safety circuit of the control apparatus 5 is not secured.
[0011] An object of the present invention is to provide a control apparatus for a robot in which the work efficiency is improved in the whole robot peripheral system including the robot, and in which considering the increase in the consciousness of safety such as the standardization of safety apparatuses, both the reliability of the safety circuit of the control apparatus for a robot and the ensuring of the safety are improved.
SUMMARY OF THE INVENTION
[0012] A control apparatus for a robot in accordance with the present invention comprises a switch circuit consisting of a plurality of emergency stop switches interconnected in series, wherein a servo power supply is switched ON or OFF by the switch circuit, and wherein each of the plurality of switches is provided with an intermediate output signal line for extracting the operation signal, or the emergency stop signal thereof.
[0013] In accordance with the control apparatus for a robot in accordance with the present invention, by connecting the intermediate output signal lines to peripheral devices outside the robot, a factor to cause the stop of the robot body alone can be distinguished from a factor to cause the stop of both the robot body and the peripheral devices. This permits the safety circuit of the whole robot system to be configured with flexibility, and accordingly the work efficiency can be improved without degrading the safety.
[0014] A control apparatus for a robot in accordance with the present invention comprises a switch circuit consisting of a plurality of emergency stop switches interconnected in series, wherein a servo power supply is switched ON or OFF by the switch circuit, wherein each of the plurality of switches comprises a first open-close contact and a second open-close contact both operating simultaneously, wherein every first open-close contact of each of the plurality of the switches is interconnected in series by a first signal line, while every second open-close contact of each of the plurality of the switches is interconnected in series by a second signal line, and wherein an intermediate output signal line for extracting the operation signal or the emergency stop signal of each of the plurality of switches is connected to at least one of the first signal line and the second signal line.
[0015] In accordance with the control apparatus for a robot in accordance with the present invention, a case to stop the whole system including the robot body, a case to cause the stop of the robot body and a part of peripheral devices, and a case to cause the stop of the robot body alone can be distinguished with each other. This permits the safety circuit of the whole robot system to be configured with flexibility, and accordingly the work efficiency can be improved without degrading the safety.
[0016] A control apparatus for a robot in accordance with the present invention comprises a switch circuit consisting of a plurality of emergency stop switches interconnected in series, wherein a servo power supply is switched ON or OFF by the switch circuit, wherein each of the plurality of switches comprises a first open-close contact and a second open-close contact both operating simultaneously, wherein every first open-close contact of each of the plurality of the switches is interconnected in series by a first signal line, while every second open-close contact of each of the plurality of the switches is interconnected in series by a second signal line, wherein each of the first signal line and the second signal line is provided with a voltage of an opposite polarity with each other relatively to the plurality of switches, and wherein a relay for extracting the operation signal or the emergency stop signal of the plurality of switches is connected to the end on the same side of each of the first signal line and the second signal line.
[0017] In accordance with the control apparatus for a robot in accordance with the present invention, in case of occurrence of a short circuit between the first signal line and the second signal line for controlling the switching ON and OFF of the servo power supply for driving the motor, the servo power supply can be immediately switched OFF. This improves the safety of the control apparatus for a robot.
[0018] A control apparatus for a robot in accordance with the above-mentioned present invention further comprises current interrupting means disposed in the end opposite to the relays in the first signal line and the second signal line and for interrupting a current greater than or equal to a predetermined value.
[0019] In accordance with the control apparatus for a robot in accordance with the present invention, in case of occurrence of a short circuit between the first signal line and the second signal line, the servo power supply can be immediately switched OFF, while the occurrence of the short circuit can be detected by the control apparatus. As such, since the control apparatus can detect the occurrence of abnormality and the occurrence position of abnormality in the signal lines, the repair work of the control apparatus is speeded up.
[0020] In a control apparatus for a robot in accordance with the above-mentioned present invention, a fuse is used as the current interrupting means.
[0021] Further, in a control apparatus for a robot in accordance with the present invention, the plurality of switches are disposed in the order of priority.
[0022] In accordance with the control apparatus for a robot in accordance with the present invention, the disposing of the plurality of switches in the order of priority permits the optimal setting depending on the system to be used, for example, when a case to stop the whole system including the robot body, a case to cause the stop of the robot body and a part of peripheral devices, and a case to cause the stop of the robot body alone are to be distinguished with each other.
[0023] In a control apparatus for a robot in accordance with the above-mentioned present invention, an intermediate output signal line for extracting the operation signal or the emergency stop signal of each of the plurality of switches is connected to at least one of the first signal line and the second signal line.
[0024] In accordance with the control apparatus for a robot in accordance with the present invention, the disposing of the plurality of switches in the order of priority permits the optimal setting depending on the system to be used when a case to stop the whole system including the robot body, a case to cause the stop of the robot body and a part of peripheral devices, and a case to cause the stop of the robot body alone are to be distinguished with each other. Further, in case of occurrence of a short circuit between the first signal line and the second signal line, the servo power supply can be immediately switched OFF, while the occurrence of the short circuit can be detected by the control apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 is a block diagram showing a first embodiment of the present invention, and is used also for describing a fourth embodiment of the present invention.
[0026] [0026]FIG. 2 is a block diagram showing a second embodiment of the present invention.
[0027] [0027]FIG. 3 is a block diagram describing the effect of a second configuration of the present invention.
[0028] [0028]FIG. 4 is a block diagram showing a third embodiment of the present invention, and is used also for describing a fourth embodiment of the present invention.
[0029] [0029]FIG. 5 is a block diagram used for describing the operation in the case of occurrence of a short circuit in a third embodiment of the present invention.
[0030] [0030]FIG. 6 is a block diagram showing a specific example of a third embodiment of the present invention.
[0031] [0031]FIG. 7 is a block diagram showing a fifth embodiment of the present invention.
[0032] [0032]FIG. 8 is a block diagram showing a control apparatus for a robot in accordance with the prior art.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0033] A first embodiment of the present invention is described below with reference to FIG. 1.
[0034] [0034]FIG. 1 shows the configuration of a first embodiment of the present invention. In a safety circuit of a robot body 1 , each of n switches 21 to 2 n each assigned to a factor of emergency stop comprises a first open-close contact and a second open-close contact both operating simultaneously. The first open-close contacts are interconnected electrically in series by a first signal line for controlling the switching ON and OFF of a servo power supply 4 , while the second open-close contacts are interconnected electrically in series by a second signal line for controlling the switching ON and OFF of the servo power supply 4 . Each of one ends of the signal lines is supplied with a 24 V voltage, while each of the other ends is grounded through a relay 3 . In a normal state without any factor inhibiting the switching ON of the servo power supply, all of the n switches 21 to 2 n are closed, and hence the first and second signal lines are in the ON voltage state with 24 V.
[0035] Thus, the relay coil 31 of each relay 3 is excited thereby to close the relay contact 32 . By connecting this open-close status of the relay contact 32 into a driving circuit for switching ON and OFF of the servo power supply in the servo power supply 4 , the switching ON and OFF of the servo power supply can be controlled in hardware by switching ON and OFF the switches 21 to 2 n , or alternatively in software by a signal such as servo power supply switching ON permission from the control apparatus 5 .
[0036] When switched ON, the driving circuit of the servo power supply 4 starts to energize the motor 11 of the robot body 1 , and switches OFF the lock (brake 12 ) circuit of the shaft of the motor 11 .
[0037] Further, the potential of the end on the servo power supply 4 side of each of the n switches 21 to 2 n is output to the control apparatus 5 . Similarly, an intermediate output of emergency stop is output from each end to external devices. Since every switch is interconnected in series on each of the first and the second signal lines, when any switch is opened for emergency stop, the signal line is interrupted at the open switch thereby to cause a potential drop from 24 V to 0 V. Accordingly, the control apparatus 5 can detect which switch is open. Further, in the emergency stop signals being output to the external devices, no change in the potential is caused by any switch on the servo power supply 4 side (the other end side) of the selected intermediate output signal, whereas a change in the potential is caused by any switch disposed on the opposite side (one end side).
[0038] Accordingly, a factor of emergency stop can be selected for each peripheral device by selecting an intermediate output signal of emergency stop signal located on the 24 V side (one end side) of the switch corresponding to the factor in question and by connecting it to the peripheral device not to be stopped by the emergency stop of the robot body 1 .
[0039] Further, since the first open-close contact and the second open-close contact both operating simultaneously are connected to the first signal line and the second signal line, respectively, even in case of occurrence of fusion in one of the contacts, the open-close contact suffering from the fusion can be detected by the control apparatus 5 by comparing the potential of one contact with the potential of the other contact of each switch 21 to 2 n in the first and the second signal lines.
[0040] A second embodiment of the present invention is described below with reference to FIGS. 2 and 3. FIG. 2 shows the second embodiment of the present invention. A like numeral designates a configuration, an action, and the like identical to that of the first embodiment, and the description is omitted.
[0041] In a safety circuit of a robot body 1 , n switches 21 to 2 n each assigned to a factor of emergency stop are interconnected electrically in series thereby to form a first signal line and a second signal line. One ends of the first signal lines is supplied with a 24 V voltage, while the other end is grounded through a relay 3 . Further, one ends of the second signal lines is grounded, while the other end is supplied with a 24 V voltage. In a relay coil 61 of a relay 6 , one end is supplied with a 24 V voltage, while the opposite end is connected to the second signal line. In a normal state without any factor inhibiting the switching ON of the servo power supply, all of the n switches 21 to 2 n are closed, and hence the second signal line is in the ON voltage state with 24 V.
[0042] Thus, the relay coil 61 of the relay 6 connected to the second signal line is excited thereby to close the relay contact 62 . This open-close status of the relay contact 62 is connected into a driving circuit for switching ON and OFF of the servo power supply in the servo power supply 4 . As such, by supplying the 24 V voltage to the one end of the first signal line and by grounding the one end of the second signal line, an equivalent circuit of a signal line supplied with a 24 V voltage is formed from the one end of the first signal line to the one end of the second signal line. Accordingly, in case of occurrence of a short circuit between the first signal line and the second signal line as shown in FIG. 3, the voltage level of the second signal line is pulled up to 24 V at the position of occurrence. As a result, the relay coil 61 of the relay 6 becomes unexcited thereby to open the relay contact 62 . The servo power supply is accordingly switched OFF by the relay 6 . When the one end of the second signal line is not grounded but supplied with a 24 V voltage similarly to the first signal line, the short circuit does not cause the above-mentioned switching OFF of the servo power supply. Further, in case of occurrence of a fusion in the contact of a switch 21 , 22 on the one end side from the short circuit position of the signal line, all of the switches obviously do not work correctly.
[0043] A third embodiment of the present invention is described below with reference to FIGS. 4 to 6 . FIG. 4 shows the third embodiment of the present invention. A like numeral designates a configuration, an action, and the like identical to that of the second embodiment, and the description is omitted.
[0044] Current interrupting means 7 for interrupting a current greater than or equal to a predetermined value is provided in the one end side of the second signal line.
[0045] In case of occurrence of a short circuit between the first signal line and the second signal line, since the switches 21 , 22 used are contact switches, the line formed by the switches 21 , 22 via the short circuit point as shown in FIG. 5 has almost no load, and hence an extreme current flows. This over-current can be avoided using the current interrupting means 7 . Further, by sending the status of the current interrupting means 7 to the control apparatus 5 , the occurrence of a short circuit between the signal lines can be detected.
[0046] The current interrupting means can obviously be implemented by using a fuse as shown in FIG. 6.
[0047] A fourth embodiment of the present invention is described below with reference to FIGS. 1 and 5. A like numeral designates a configuration, an action, and the like identical to that of the first embodiment, and the description is omitted.
[0048] In a safety circuit of a robot body 1 as shown in FIG. 1, n switches 21 to 2 n each assigned to a factor of emergency stop are interconnected electrically in series thereby to form a first signal line and a second signal line. Each of one ends of signal lines is supplied with a 24 V voltage, while each of the other ends is grounded through a relay 3 . In FIG. 5, in place of the second signal line, another second signal line is formed by grounding the one end and by supplying the 24 V voltage to the other end.
[0049] A priority is assigned to each factor of emergency stop to be assigned to each of then switches 21 to 2 n , and then disposed in the order starting from the switch 21 . As a result, the emergency stop signal by the switch assigned to the factor having the highest priority is output from all of the emergency stop intermediate outputs. Further, in the descending order of priority, each emergency stop intermediate output can be selected. Furthermore, the configuration of the signal lines as shown in FIG. 5 obviously improves the safety and the reliability of the safety circuit.
[0050] A fifth embodiment of the present invention is described below with reference to FIG. 7. FIG. 7 shows the fifth embodiment of the present invention. A like numeral designates a configuration, an action, and the like identical to that of the first, second, or third embodiment, and the description is omitted.
[0051] In the figure, in place of the second signal line shown in FIG. 1, another second signal line is formed by grounding the one end and by supplying the 24 V voltage to the other end. Further, current interrupting means 7 is provided in the one end of the second signal line. Furthermore, a priority is assigned to each of the n switches 21 to 2 n corresponding to each factor of emergency stop in the descending order of priority starting from the switch 21 . As a result, the emergency stop signal by the switch 21 is output from every intermediate output. In contrast, the emergency stop output by the switch having the lowest priority is output solely from the last end (most the other end side) intermediate output. Further, occurrence of a short circuit obviously causes immediate switching OFF of the servo power supply.
[0052] In the first embodiment, the first signal line and the second signal line have been provided, whereby intermediate output signal lines have been connected to each signal line. However, a single signal line may be provided, whereby an intermediate output signal line is connected to each switch.
[0053] Further, intermediate output signal lines shown in Figure have been omitted in the second to fourth embodiments. However, intermediate output signal lines may be connected between the one end and the other end of at least one of the first signal line and the second signal line.
|
An object of the present invention is to provide a control apparatus for a robot in which the work efficiency is improved in the whole robot peripheral system including the robot, and in which considering the increase in the consciousness of safety such as the standardization of safety apparatuses, both the reliability of the safety circuit of the control apparatus for a robot and the ensuring of the safety are improved.
By connecting, to peripheral devices outside the robot, each intermediate output signal line for extracting the operation signal or the emergency stop signal of each of the plurality of switches each assigned to a factor causing the stop of the robot, a factor to cause the stop of the robot body alone can be distinguished from a factor to cause the stop of both the robot body and the peripheral devices.
| 1
|
TECHNICAL FIELD
[0001] The present invention relates to a hand joint supporter which can support wearer's daily motion, and particularly, to a hand joint supporter having a taping function of improving stability of the hand joints, thereby reducing the burden on the hand joints and also preventing an inflammation of the tendons of the hand.
BACKGROUND ART
[0002] A supporter for wrist restraint in the related art has a supporter main body which is formed in an approximately tubular shape, can expand and contract at least in the circumferential direction among the circumferential direction and the longitudinal direction, and can cover a site from the vicinity of the wrist of the forearm section to at least the vicinity of the bases of the four fingers except for the thumb, an opening portion for the thumb formed in the supporter main body, and a support which extends along the longitudinal direction on the little finger side of the supporter main body inserted into a pocket, wherein the support is provided so as to be able to extend from at least the vicinity of the wrist of the forearm section on which the support is mounted, to the side portion on the little finger side of the palm over a pisiform bone site (refer to PTL 1, for example).
CITATION LIST
Patent Literature
[0000]
[PTL 1] JP-A-2005-549
SUMMARY OF INVENTION
Technical Problem
[0004] The supporter for wrist restraint in the related art is a supporter for restraining the movement of the wrist as a conservative therapy in a case where a bruise, a sprain, or an inflammation of the tendon develops in the wrist, and is not provided with a support on the thumb side and the back side of the hand and the palm side of the hand. In particular, in the supporter for wrist restraint in the related art, as the support, a support which bends when an external force or a load is added thereto is also included. However, it is regarded as being formed so that the fixed feeling is not lost by the bending, and is formed of, for example, synthetic resin, metal, carbon fiber, glass fiber, wood, or the like.
[0005] For this reason, in the supporter for wrist restraint in the related art, there is a problem in that after the approximately tubular supporter main body is formed, a process of attaching the support to the supporter main body by sewing, tack fixing, attachment, adhesion, or the like is required, so that the manufacturing process is complicated.
[0006] The present invention has been made to solve the problem as described above and has an object to provide a hand joint supporter in which the manufacturing process of disposing a support that is a separate body from a supporter main body to the supporter main body is not required, while reducing the burden on the hand joints, so that it is possible to prevent an inflammation of the tendons of the hand.
Solution to Problem
[0007] A hand joint supporter according to the invention includes: a first anchor section which is knitted to go around one end of a tubular knitted fabric and makes the tubular knitted fabric tighten on the forearm of the wearer; a second anchor section which is knitted to go around the other end of the tubular knitted fabric, surrounds portions corresponding to the second metacarpal bone, the third metacarpal bone, the fourth metacarpal bone, and the fifth metacarpal bone in the vicinity of the metacarpophalangeal joints of the wearer, and makes the tubular knitted fabric tighten on the palm and the back of the hand of the wearer; a hole anchor section which is formed as an approximately circular through-hole in the vicinity of the second anchor section in the tubular knitted fabric to insert the thumb of the hand of the wearer therethrough; and a supporting section which is knitted to extend in the length direction of the tubular knitted fabric over portions corresponding to the carpometacarpal joints of the wearer on the front face and/or back face side of the tubular knitted fabric and is connected to the first anchor section and the hole anchor section, thereby supporting the hand joints of the wearer, wherein the stretch resistance of the first anchor section in the circumferential direction of the tubular knitted fabric is larger than the stretch resistance of a base fabric section in the circumferential direction of the tubular knitted fabric, and the stretch resistance of the supporting section in the length direction of the tubular knitted fabric is larger than the stretch resistance of the base fabric section in the length direction of the tubular knitted fabric.
Advantageous Effects of Invention
[0008] In the hand joint supporter according to the invention, the hand joints of the wearer are stabilized by performing the inhibiting of the palmar flexion and/or the dorsal flexion of the hand joints, and a load which is applied to a tendon that is located at the hand joints is reduced, so that an inflammation of the tendons of the hand can be prevented.
BRIEF DESCRIPTION OF DRAWINGS
[0009] FIG. 1( a ) a front view showing a schematic configuration of a hand joint supporter related to the first embodiment, FIG. 1( b ) is a back view of the hand joint supporter shown in FIG. 1( a ), FIG. 1( c ) is a left side view of the hand joint supporter shown in FIG. 1( a ), FIG. 1( d ) is a right side view of the hand joint supporter shown in FIG. 1( a ), and FIG. 1( e ) is a plan view and bottom view of the hand joint supporter shown in FIG. 1( a ).
[0010] FIG. 2 is a perspective view showing a wearing state of the hand joint supporter shown in FIG. 1 .
[0011] FIG. 3( a ) is an explanatory diagram for describing the joints and the bones of the hand, FIG. 3( b ) is an explanatory diagram for describing the position of a supporting section with respect to the hand of a wearer, FIG. 3( c ) is an explanatory diagram for describing another position of the supporting section with respect to the hand of the wearer, and FIG. 3( d ) is an explanatory diagram for describing still another position of the supporting section with respect to the hand of the wearer.
[0012] FIG. 4 is an explanatory diagram for describing sites for measuring elongation rates in the hand joint supporter shown in FIG. 1( a ).
[0013] FIG. 5( a ) is an explanatory diagram for describing an experimental motion, FIG. 5( b ) is graphs showing the verification results by a surface electromyogram of the flexor carpi ulnaris muscle in the hand joint supporter shown in FIG. 1 , FIG. 5( c ) is graphs showing the verification results by a surface electromyogram of the flexor carpi radialis muscle in the hand joint supporter shown in FIG. 1 , and FIG. 5( d ) is graphs showing the verification results by a surface electromyogram of the biceps brachii muscle in the hand joint supporter shown in FIG. 1 .
[0014] FIG. 6( a ) is a graph showing the measurement results of the amount of work of a hand joint palmar flexion moment with respect to each test subject for verifying the operation and effects of the hand joint supporter shown in FIG. 1 , and FIG. 6( b ) is a graph showing the average value of the measurement results shown in FIG. 6( a ).
[0015] FIG. 7( a ) is a graph showing the measurement results of the amount of work of a hand joint dorsal flexion moment with respect to each test subject for verifying the operation and effects of the hand joint supporter shown in FIG. 1 , and FIG. 7( b ) is a graph showing the average value of the measurement results shown in FIG. 7( a ).
[0016] FIG. 8( a ) is a front view showing the schematic configuration of a hand joint supporter related to the second embodiment, FIG. 8( b ) is a back view of the hand joint supporter shown in FIG. 8( a ), FIG. 8( c ) is a left side view of the hand joint supporter shown in FIG. 8( a ), FIG. 8( d ) is a right side view of the hand joint supporter shown in FIG. 8( a ), and FIG. 8( e ) is a plan view and bottom view of the hand joint supporter shown in FIG. 8( a ).
[0017] FIG. 9( a ) is a front view showing the schematic configuration of another hand joint supporter related to the second embodiment, FIG. 9( b ) is a back view of the hand joint supporter shown in FIG. 9( a ), FIG. 9( c ) is a left side view of the hand joint supporter shown in FIG. 9( a ), FIG. 9( d ) is a right side view of the hand joint supporter shown in FIG. 9( a ), and FIG. 9( e ) is a plan view and bottom view of the hand joint supporter shown in FIG. 9( a ).
[0018] FIG. 10( a ) is a perspective view showing a wearing state of the hand joint supporter shown in FIG. 8 , and FIG. 10( b ) is a perspective view showing a wearing state of the hand joint supporter shown in FIG. 9 .
DESCRIPTION OF EMBODIMENTS
First Embodiment of the Invention
[0019] In FIGS. 1 and 2 , a hand joint supporter 10 is made of a tubular knitted fabric which is knitted by circular knitting by a hosiery knitting machine (for example, a type of knitting machine (the number of needles: 256) manufactured by Lonati Co.), and is a supporter which comes into close contact with the body surface of the wearer, thereby assisting the hand joints of the wearer.
[0020] The hand joint supporter 10 has a desired function such as a taping function by performing different knitting with respect to a base fabric section 1 that is a knitted fabric which is knitted in a plain stitch, a rib stitch, a tuck stitch, a float stitch, a pile stitch, or the like by using an upper thread, an under thread, and a rubber thread as knitting yarn. In addition, the base fabric section 1 related to this embodiment is a knitted fabric which is knitted in a tuck stitch (hereinafter referred to as tuck stitch knitted fabric).
[0021] Here, the tuck stitch knitted fabric is a knitted fabric in which a certain loop is not made temporarily when knitting the fabric and loops are made together when knitting the next course. In addition, in this embodiment, in consideration of a balance with density, the number of tucks is set to be twice. However, the number is not limited thereto.
[0022] The hand joint supporter 10 has a first anchor section 2 which is knitted to go around one end (an upper end 10 a ) of the tubular knitted fabric and makes the hand joint supporter 10 tighten on the forearm of a wearer.
[0023] The first anchor section 2 is knitted such that the stretch resistance thereof in the circumferential direction H of the hand joint supporter 10 (the tubular knitted fabric) is larger than the stretch resistance of the base fabric section 1 in the circumferential direction H of the hand joint supporter 10 . That is, when tension in a case where a certain elongation has been imparted to a material from a state where elongation is not imparted is set to be F, the tension of the base fabric section 1 in the circumferential direction H of the hand joint supporter 10 is set to be F H1 , and the tension of the first anchor section 2 in the circumferential direction H of the hand joint supporter 10 is set to be the first anchor section 2 has such a magnitude relationship of F H2 >F H1 that it has a strong tightening force in the circumferential direction H of the hand joint supporter 10 , compared to the base fabric section 1 .
[0024] Specifically, by making the first anchor section 2 be a knitted fabric knitted in a moss stitch (hereinafter referred to as a moss stitch knitted fabric), it is possible to make the stretch resistance thereof in the circumferential direction H of the hand joint supporter 10 large with respect to the base fabric section 1 that is the tuck stitch knitted fabric.
[0025] In addition, the moss stitch knitted fabric is a knitted fabric in which a plain stitch and a tuck (a structure in which no loop protrudes over a given course and a plurality of loops protrude over the subsequent course) appear alternately or every few courses in the course direction and the wale direction. For this reason, in the first anchor section 2 , the plain stitch and the tuck are used in combination, whereby it is possible to make protuberances or openwork stitches the surface of a knitted fabric and a mesh pattern, such as a moss, appears.
[0026] In this manner, the first anchor section 2 is knitted to surround the forearm of a wearer, and the stretch resistance of the first anchor section 2 in the circumferential direction H of the hand joint supporter 10 is larger than the stretch resistance of the base fabric section 1 in the circumferential direction H of the hand joint supporter 10 , whereby it is possible to fix the hand joint supporter 10 to the forearm of a wearer and suppress slipping-off of the upper end 10 a of the hand joint supporter 10 during palmar flexion of the hand joints. Further, the first anchor section 2 is connected to a supporting section 4 (described later), thereby also functioning as an anchor of the supporting section 4 .
[0027] Further, the hand joint supporter 10 has a second anchor section 3 which is knitted to go around the other end (a lower end 10 b ) of the tubular knitted fabric, surrounds portions corresponding to a second metacarpal bone 102 , a third metacarpal bone 103 , a fourth metacarpal bone 104 , and a fifth metacarpal bone 105 in the vicinity of metacarpophalangeal joints 110 of a wearer, and makes the hand joint supporter 10 tighten on the palm and the back of the hand of the wearer, as shown in FIG. 3( a ).
[0028] The second anchor section 3 is knitted such that the stretch resistance thereof in the circumferential direction H of the hand joint supporter 10 is larger than the stretch resistance of a buffer section 5 (described later) in the circumferential direction H of the hand joint supporter 10 . That is, when the tension of the second anchor section 3 in the circumferential direction H of the hand joint supporter 10 is set to be F H3 and the tension of the buffer section 5 in the circumferential direction H of the hand joint supporter 10 is set to be F H5 , the second anchor section 3 has such a magnitude relationship of F H3 >F H5 that it has a strong tightening force in the circumferential direction H of the hand joint supporter 10 , compared to the buffer section 5 .
[0029] Specifically, by making the second anchor section 3 be a moss stitch knitted fabric, it is possible to make the stretch resistance thereof in the circumferential direction H of the hand joint supporter 10 large with respect to the buffer section 5 that is a mesh stitch knitted fabric which will be described later.
[0030] In this manner, the second anchor section 3 is knitted to surround the palm and the back of the hand of a wearer and the stretch resistance of the second anchor section 3 in the circumferential direction H of the hand joint supporter 10 is larger than the stretch resistance of the buffer section 5 in the circumferential direction H of the hand joint supporter 10 , whereby it is possible to fix the hand joint supporter 10 to the palm and the back of the hand of a wearer and suppress slipping-off of the lower end 10 b of the hand joint supporter 10 during palmar flexion of the hand joints.
[0031] In addition, if a tightening force on the palm and the back of the hand of a wearer by the second anchor section 3 is too strong, the gaps between the fingers (the second finger (the index finger or the forefinger), the third finger (the middle finger), the fourth finger (the ring finger), and the fifth finger (the little finger)) of the hand of a wearer cannot be fully opened, thereby causing interference with work such as keyboard operation of a personal computer.
[0032] For this reason, the hand joint supporter 10 related to this embodiment is made such that the density of the second anchor section 3 is adjusted (for example, to make a tightening force thereof about 10% smaller with respect to the first anchor section 2 ), whereby the movement of the fingers of the hand with the hand joint supporter 10 worn thereon is not prevented. That is, it is preferable that the hand joint supporter 10 related to this embodiment have a magnitude relationship of F H2 >F H1 >F H3 >F H5 so as to have a moderate tightening force in the circumferential direction H of the hand joint supporter 10 .
[0033] A hole anchor section 11 is formed as an approximately circular through-hole in the vicinity of the second anchor section 3 in the hand joint supporter 10 to insert the first finger (the thumb or the big finger) of the hand of a wearer therethrough.
[0034] In addition, the hole anchor section 11 related to this embodiment is made by making a cut in the tubular knitted fabric which becomes the hand joint supporter 10 , folding a cut edge back to the inside of the tubular knitted fabric, and sewing it using a sewing machine. However, the hole anchor section 11 may also be formed by knitting without cutting out the tubular knitted fabric. In particular, it is preferable that a sewn section constituting the hole anchor section 11 be formed as flexible bellows by using a sewing thread having high stretch property and increasing the number of stitches per inch of the sewing machine, to reduce a pressing force which is imparted on the thumb of a wearer.
[0035] The hole anchor section 11 positions the hand joint supporter 10 with respect to the hand joints of the wearer by inserting the thumb of the hand of the wearer therethrough and also suppresses the rotational movement in the circumferential direction H or the parallel displacement in the length direction L of the hand joint supporter 10 , thereby being able to prevent a position shift. Further, the hole anchor section 11 is connected to the supporting section 4 (described later), thereby also functioning as an anchor of the supporting section 4 .
[0036] The supporting section 4 is knitted to extend in the length direction L of the hand joint supporter 10 over portions corresponding to carpometacarpal joints 120 of a wearer on the front face and/or back face side of the hand joint supporter 10 and is connected to the first anchor section 2 and the hole anchor section 11 , thereby supporting the hand joints of the wearer. That is, the supporting section 4 is locked at the first anchor section 2 on the forearm side of a wearer and locked at the hole anchor section 11 on the hand side of the wearer.
[0037] In addition, the supporting section 4 related to this embodiment is knitted in an approximately rectangular shape. However, as long as it extends in the length direction L of the hand joint supporter 10 over the portions corresponding to the carpometacarpal joints 120 of the wearer, the shape thereof is not limited thereto.
[0038] Further, the supporting section 4 is knitted such that the stretch resistance thereof in the length direction L of the hand joint supporter 10 is larger than the stretch resistance of the base fabric section 1 in the length direction L of the hand joint supporter 10 . That is, when the tension of the base fabric section 1 in the length direction L of the hand joint supporter 10 is set to be F L1 and the tension of the supporting section 4 in the length direction L of the hand joint supporter 10 is set to be F L4 , the supporting section 4 has such a magnitude relationship of F L4 >F L1 that it has a strong tightening force in the length direction L of the hand joint supporter 10 , compared to the base fabric section 1 .
[0039] Specifically, by making the supporting section 4 be a knitted fabric in which a tuck stitch and a plating stitch are used in combination (hereinafter referred to as a tuck stitch-plating stitch knitted fabric), it is possible to make the stretch resistance in the length direction L of the hand joint supporter 10 large with respect to the base fabric section 1 that is a tuck stitch knitted fabric.
[0040] In addition, in the tuck stitch-plating stitch knitted fabric, expansion and contraction of the supporting section 4 in the length direction L of the hand joint supporter 10 is moderately suppressed by additionally feeding another knitting yarn (for example, woolly nylon yarn) in addition to the ground knitting yarn of the tuck stitch, and another knitting yarn is cut at the boundary between the supporting section 4 and the base fabric section 1 (a cut boss).
[0041] In this manner, the supporting section 4 is knitted to extend in the length direction L of the hand joint supporter 10 over the portions corresponding to carpometacarpal joints 120 of the wearer on the front face and/or back face side of the hand joint supporter 10 , and the stretch resistance in the length direction L of the hand joint supporter 10 is larger than the stretch resistance of the base fabric section 1 in the length direction L of the hand joint supporter 10 . In this way, the supporting section 4 limits the palmar flexion and/or the dorsal flexion of the hand joints of a wearer, thereby being able to secure stability of the hand joints and also reduce the load that is applied to a tendon which is located at the hand joints.
[0042] In particular, in a case where the hand joint supporter 10 is not worn, if a pain is present in the hand joints, a burden is also applied to the elbow joint or the like which compensates for an overload on the hand joints, so that there is a fear that a secondary pain may be induced. For this reason, in a person for whom the frequency of using the fingers or the hand joints is high and pain is present in the elbow or the front of the shoulder joint, pains of the elbow and the shoulder joint, which result through a chain reaction from a pain of the hand joints, can be reduced by wearing the hand joint supporter 10 .
[0043] In addition, the supporting section 4 is disposed on the front face (the palm of the hand) side of the hand joint supporter 10 , thereby limiting the dorsal flexion of the hand joints of the wearer, and is disposed on the back face (the back of the hand) side of the hand joint supporter 10 , thereby limiting the palmar flexion of the hand joint of the wearer. For this reason, depending on pain of the hand joints of the wearer, in the case of wanting to limit the dorsal flexion of the hand joints, the hand joint supporter 10 in which the supporting section 4 is disposed only on the front face (the palm of the hand) side is also acceptable, and in the case of wanting to limit the palmar flexion of the hand joints, the hand joint supporter 10 in which the supporting section 4 is disposed only on the back face (the back of the hand) side is also acceptable.
[0044] In particular, it is preferable to dispose the supporting sections 4 on the front face and back face sides of the hand joint supporter 10 , because the front face and the back face of the hand joint supporter 10 become symmetrical, so that the hand joint supporter 10 can double as left-hand and right-hand supporters.
[0045] Further, in a case where the supporting section 4 along with the base fabric section 1 which is knitted between the supporting sections 4 that are on the front face and back face sides of the tubular knitted fabric extends only from the vicinity (the first anchor section 2 ) of radiocarpal joints 130 to the vicinity of the carpometacarpal joints 120 , as shown in FIG. 3( c ), a holding feeling of the wrist cannot be obtained and the above-described operation and effects by the supporting section 4 cannot be obtained.
[0046] In contrast to this, in a case where the supporting section 4 and the base fabric section 1 extend from the vicinity (the first anchor section 2 ) of the radiocarpal joints 130 to the vicinity (the second anchor section 3 ) of the metacarpophalangeal joints 110 , as shown in FIG. 3( d ), as well as being unable to fully open the gaps between the fingers of a wearer, the palm and the back of the hand of a wearer are tightened, thereby being accompanied by a pain.
[0047] Therefore, it is preferable that the supporting section 4 and the base fabric section 1 extend from the vicinity (the first anchor section 2 ) of the radiocarpal joints 130 to the metacarpal bone bodies (the approximate middles of the second metacarpal bone 102 , the third metacarpal bone 103 , the fourth metacarpal bone 104 , and the fifth metacarpal bone 105 ), as shown in FIG. 3( b ).
[0048] In addition, in the movement of the hand joints, in addition to the palmar flexion and the dorsal flexion, radial flexion and ulnar flexion are included, and the radial flexion and the ulnar flexion are motions which are frequently used in daily life, and according to the motion, the frequency of occurrence of De Quervain syndrome that is an inflammation of the tendons extending toward the thumb from the hand is high. In contrast to this, the supporting section 4 and the base fabric section 1 limit the radial flexion and the ulnar flexion of the hand joints of a wearer, whereby prevention and improvement of De Quervain syndrome can be expected.
[0049] The buffer section 5 is a knitted fabric surrounded by the second anchor section 3 , the hole anchor section 11 , the supporting section 4 , and the base fabric section 1 in the hand joint supporter 10 and is a knitted fabric making flexibility be provided between the second anchor section 3 and the supporting section 4 .
[0050] The buffer section 5 is knitted such that the stretch resistance thereof in the length direction L of the hand joint supporter 10 is smaller than the stretch resistance of the base fabric section 1 in the length direction L of the hand joint supporter 10 . That is, when the tension of the buffer section 5 in the length direction L of the hand joint supporter 10 is set to be F L5 , the buffer section 5 has such a magnitude relationship of F L1 >F L5 that it has a weak tightening force in the length direction L of the hand joint supporter 10 , compared to the base fabric section 1 .
[0051] Specifically, by making the buffer section 5 be a knitted fabric knitted in a mesh stitch that is a knitting structure having good air permeability (hereinafter referred to as a mesh stitch knitted fabric), it is possible to make the stretch resistance in the length direction L of the hand joint supporter 10 small with respect to the base fabric section 1 that is a tuck stitch knitted fabric.
[0052] In addition, the mesh stitch knitted fabric is a knitted fabric in which a certain loop is not made temporarily when knitting the fabric and loops are made together when knitting the next course and which stretches well by being knit in the form of a mesh.
[0053] In this manner, in the buffer section 5 , the stretch resistance thereof in the length direction L of the hand joint supporter 10 is smaller than the stretch resistance of the base fabric section 1 in the length direction L of the hand joint supporter 10 , whereby the buffer section 5 does not tighten the palm and the hack of the hand of the wearer, thereby preventing constriction of blood flow as well as allowing the gaps between the fingers of a wearer to be fully open, so that a feeling of discomfort is not caused to the wearer.
[0054] In addition, in the hand joint supporter 10 related to this embodiment, due to the knitted fabric of each site described above, the stretch resistance of the base fabric section 1 in the length direction L of the hand joint supporter 10 is larger than the stretch resistance of the first anchor section 2 in the length direction L of the hand joint supporter 10 . Further, the stretch resistance of the first anchor section 2 in the length direction L of the hand joint supporter 10 is larger than the stretch resistance of the second anchor section 3 in the length direction L of the hand joint supporter 10 . Further, the stretch resistance of the second anchor section 3 in the length direction L of the hand joint supporter 10 is larger than the stretch resistance of the buffer section 5 in the length direction L of the hand joint supporter 10 . Further, the stretch resistance of the supporting section 4 in the circumferential direction H of the hand joint supporter 10 is approximately equal to the stretch resistance of the base fabric section 1 in the circumferential direction H of the hand joint supporter 10 .
[0055] Therefore, the hand joint supporter 10 related to this embodiment satisfies a magnitude relationship shown by the following expression (1) in the tension F in the length direction L of the hand joint supporter 10 . However, in the following expression (1), F L2 is the tension of the first anchor section 2 in the length direction L of the hand joint supporter 10 , and F L3 is the tension of the second anchor section 3 in the length direction L of the hand joint supporter 10 .
[0056] [Expression 1]
[0000] F L4 >F L1 >F L3 >F L2 >F L5 (1)
[0057] Further, the hand joint supporter 10 related to this embodiment satisfies a magnitude relationship shown by the following expression (2) in the tension F in the circumferential direction H of the hand joint supporter 10 . However, in the following expression (2), F H4 is the tension of the supporting section 4 in the circumferential direction H of the hand joint supporter 10 .
[0058] [Expression 2]
[0000] F H2 >F H1 ˜F H4 >F H3 >F H5 (2)
[0059] In addition, in this embodiment, as ground knitting yarn which is used in the moss stitch, the tuck stitch, and the mesh stitch, an upper thread which is nylon yarn having a thickness of 70 deniers and composed of two pieces of knitting yarn, an under thread which is nylon yarn having a thickness of 30 deniers and is composed of two pieces of knitting yarn, and a rubber thread which is covering yarn (DCY: double covered yarn) in which two pieces of nylon winding yarn each having a thickness of 40 deniers are wound around a polyurethane core yarn having a thickness of 260 deniers are used. However, the threads are not limited to these materials.
[0060] For example, as the upper thread, it is preferable to select a natural fiber such as cotton, wool (cashmere, lamb, Angora, or the like), silk, or hemp, a chemical fiber such as acrylic, a material having a sweat absorbing, quick-drying, or body temperature adjusting function, or the like according to the cost of the hand joint supporter 10 or the needs of a wearer. Further, as the under thread, it is preferable to select an ester, FTY (filament twisted yarn), or an antibacterial, deodorant, or odor eliminating material according to the cost of the hand joint supporter 10 or the needs of a wearer.
[0061] Further, the woolly nylon yarn (pattern yarn) in the tuck stitch-plating stitch knitted fabric (the supporting section 4 ) is composed of two pieces of knitting yarn each having a thickness of 100 deniers.
[0062] Here, the results of measurement of elongation rates (the percentage of the difference between the length when elongated (an elongated dimension) and the original length (the original dimension) to the original length) measured with respect to the respective sites (refer to FIG. 4 ) of the hand joint supporter 10 made according to the above-described knitting yarn and knitted fabrics by using a stretch tester (tensile load: 4 kg) are shown in Table 1 below.
[0000]
TABLE 1
Original
Elongated
Elongation
dimension
dimension
rate
Measured site
[cm]
[cm]
[%]
Circled
Circumferential
8.5
22.0
158.8
number 1
direction H of
the first
anchor section 2
Circled
Circumferential
9.7
28.0
188.7
number 2
direction H of
the second
anchor section 3
Circled
Circumferential
9.0
24.0
166.7
number 3
direction H
ever the base
fabric section
1 and the
supporting
section 4
Circled
Length
7.2
10.0
3-9
number 4
direction L of
the base fabric
section 1
Circled
Length
7.2
9.0
25.0
number 5
direction L of
the supporting
section 4
[0063] In addition, since the elongation rates in Table 1 represents the fact that the larger the value, the more easily the knitted fabric is elongated and the tension F in the above-described expressions (1) and (2) represents the fact that the larger the value, the more difficult it is for the knitted fabric to be elongated (the larger the tightening force), an inequality sign showing the magnitude relationship of the elongation rates and an inequality sign showing the magnitude relationship of the tension F become opposite to each other.
[0064] Next, the result of verification of the operation and effects of the hand joint supporter 10 related to this embodiment will be described.
[0065] In the first experiment, in a case where the hand joint supporter 10 is worn on the right wrist (hereinafter referred to as the time of wear) of a test subject (a 26-years-old healthy male, no anamnesis in any of the four limbs) and a case where the hand joint supporter 10 is not worn (hereinafter referred to as the time of non-wear), a state where the test subject holds in the right hand a frying pan weighing 300 g with a 1 kg weight placed therein, and the brachium and the forearm of the right arm are approximately perpendicular to each other was maintained for 30 seconds ( FIG. 5( a )).
[0066] At this time, in the experiment, the myogenic potentials of the biceps brachii muscle (the muscle which bends the elbow) and the flexor carpi ulnaris muscle and the flexor carpi radialis muscle (the muscles which bend the wrist) for the final 5 seconds were measured by a surface electromyogram ( FIG. 5 ). In addition, “MyoResearch” manufactured by Noraxon, Inc. was used in the measurement of the surface electromyogram.
[0067] As shown in FIGS. 5( b ) and 5 ( c ), it can be seen that in the case of the time of wear, compared to the case of the time of non-wear, since the myogenic potentials (the average amplitudes and the muscle integrated values) of the flexor carpi ulnaris muscle and the flexor carpi radialis muscle are lowered, loads on the flexor carpi ulnaris muscle and the flexor carpi radialis muscle are reduced, so that the burden on the hand joints is reduced. In particular, the hand joint supporter 10 reduces the burden on the hand joints, thereby being able to prevent an inflammation of the tendons of the hand.
[0068] Further, as shown in FIG. 5( d ), it can be seen that in the case of the time of wear, compared to the case of the time of non-wear, since the myogenic potential (the average amplitude and the muscle integrated value) of the biceps brachii muscle is lowered, a load on the biceps brachii muscle is reduced, so that the burden on the hand joints is reduced.
[0069] In the second experiment, in a case where the hand joint supporters 10 are worn on the right wrists of three test subjects (healthy adult males, average age: 29±3.6-years-old, average height: 169.7±4.9 cm, and average weight: 64.3±11.9 kg) (the time of wear) and a case where the hand joint supporter 10 is not worn (the time of non-wear), the hand joints of the test subjects were palmar-flexed and dorsal-flexed in a state where the brachium of the right arm of each test subject is approximately vertical and the forearm of the right arm of each test subject is approximately horizontal. In the experiment, the amount of work of a hand joint palmar flexion moment of each test subject was measured ( FIG. 6 ), and the amount of work of a hand joint dorsal flexion moment of each test subject was measured ( FIG. 7 ).
[0070] As shown in FIGS. 6 and 7 , it can be found that in all the test subjects, at the time when the hand joint supporter 10 is worn, the amount of work of a hand joint palmar flexion moment and the amount of work of a hand joint dorsal flexion moment become large compared to the time of non-wear.
Second Embodiment of the Invention
[0071] FIG. 8( a ) is a front view showing the schematic configuration of a hand joint supporter related to the second embodiment, FIG. 8( b ) is a back view of the hand joint supporter shown in FIG. 8( a ), FIG. 8( c ) is a left side view of the hand joint supporter shown in FIG. 8( a ), FIG. 8( d ) is a right side view of the hand joint supporter shown in FIG. 8( a ), and FIG. 8( e ) is a plan view and bottom view of the hand joint supporter shown in FIG. 8( a ).
[0072] FIG. 9( a ) is a front view showing the schematic configuration of another hand joint supporter related to the second embodiment, FIG. 9( b ) is a back view of the hand joint supporter shown in FIG. 9( a ), FIG. 9( c ) is a left side view of the hand joint supporter shown in FIG. 9( a ), FIG. 9( d ) is a right side view of the hand joint supporter shown in FIG. 9( a ), and FIG. 9( e ) is a plan view and bottom view of the hand joint supporter shown in FIG. 9( a ). FIG. 10( a ) is a perspective view showing a wearing state of the hand joint supporter shown in FIG. 8 , and FIG. 10( b ) is a perspective view showing a wearing state of the hand joint supporter shown in FIG. 9 . In FIGS. 8 to 10 , the same symbol as that in FIGS. 1 and 2 denotes the same or equivalent section, and explanation thereof is omitted.
[0073] In each drawing described above, the hand joint supporter 10 related to this embodiment is configured to have, in addition to the configuration in the first embodiment, an anchor reinforcing section 12 which is made of a second tubular knitted fabric that is knitted by circular knitting continuously from the second anchor section 3 of the tubular knitted fabric and which spans between the palm and the back of the hand of a wearer in the webbing between the index finger and the middle finger of the wearer, the webbing between the middle finger and the ring finger, and/or the webbing between the ring finger and the little finger, thereby being engaged with the webbing of the wearer. In addition, in the anchor reinforcing section 12 , for example, a mesh stitch knitted fabric which stretches well is used as the second tubular knitted fabric, whereby a strong pressing force is not imparted to the webbing between the index finger and the middle finger of the wearer, the webbing between the middle finger and the ring finger, and/or the webbing between the ring finger and the little finger, so that a feeling of discomfort is not induced in the wearer.
[0074] It is conceivable that the anchor reinforcing section 12 related to this embodiment has, for example, two engagement portions (a first engagement portion 12 a and a second engagement portion 12 b ) which are engaged with the webbing between the index finger and the middle finger of a wearer and the webbing between the ring finger and the little finger, as shown in FIGS. 8 and 10( a ), or three engagement portions (a first engagement portion 12 a , a third engagement portion 12 c , and a second engagement portion 12 b ) which are engaged with the webbing between the index finger and the middle finger of a wearer, the webbing between the middle finger and the ring finger, and the webbing between the ring finger and the little finger, as shown in FIGS. 9 and 10( b ).
[0075] In particular, since compared to the hand joint supporter 10 shown in FIGS. 8 and 10( a ), the hand joint supporter 10 shown in FIGS. 9 and 10( b ) covers each finger up to the vicinity of the proximal interphalangeal joints of the index finger, the middle finger, the ring finger, and the little finger of a wearer and the number of engagements of the engagement portions of the anchor reinforcing section 12 with the webbings of a wearer is large, so that the contact area with the fingers of the wearer is large, it is possible to stably support the hand joints of the wearer.
[0076] In this manner, the hand joint supporter 10 related to this embodiment more reliably supports the hand joints of a wearer by hooking the engagement portions of the anchor reinforcing section 12 on a single or a plurality of webbings, so that the burden on the hand joints is reduced, whereby an inflammation of the tendons of the hand can be prevented.
[0077] In addition, the second embodiment is different from the first embodiment only in that the anchor reinforcing section 12 having a single or a plurality of engagement portions is newly disposed at the second anchor section 3 of the hand joint supporter 10 , and except the above-described operation and effects by the anchor reinforcing section 12 , the same operation and effects as those of the first embodiment are obtained.
REFERENCE SIGNS LIST
[0000]
1 : base fabric section
2 : first anchor section
3 : second anchor section
4 : supporting section
5 : buffer section
10 : hand joint supporter
10 a : upper end
10 b : lower end
11 : hole anchor section
12 : anchor reinforcing section
102 : second metacarpal bone
103 : third metacarpal bone
104 : fourth metacarpal bone
105 : fifth metacarpal bone
110 : metacarpophalangeal joint
120 : carpometacarpal joint
130 : radiocarpal joint
|
A hand joint supporter which can reduce the load on hand joints includes a first anchor section for tightening the wearer's forearm with a tubular knitted fabric, a second anchor section for tightening the palm and back of the wearer's hand with the fabric and a hole anchor section formed as a roughly circular through-hole in the vicinity of the second anchor section. A supporting section extends lengthwise in the fabric across the part covering the caprometacarpal joint and is joined to the first anchor section and the hole anchor section so as to support the wearer's hand joints. Stretch resistance, in the circumferential direction of the fabric of the first anchor part is larger than that of a base fabric section, and stretch resistance, in the length width direction of the fabric, of the supporting section is larger than that of the base fabric section.
| 3
|
This application is a divisional of application Ser. No. 09/067,876, filed Apr. 28, 1998 now U.S. Pat. No. 6,063,064.
This invention relates to female urinary incontinence appliances.
BACKGROUND OF THE INVENTION
Many women suffer from a condition known as urinary incontinence, resulting in partial or complete loss of bladder control. The typical non-surgical approach to managing this condition has been for such women to wear an external pad which absorbs and retains any urine lost from the bladder. Depending on the severity of the condition, a small pad or complete absorbent undergarment may be required to accommodate the urine loss.
Although such external absorbent perineal pads are effective at capturing lost urine and are simple to use, they have inherent disadvantages which many women find objectionable. Such pads tend to be bulky and for some uncomfortable to wear, especially when wet. Prolonged contact with such pads can irritate the delicate skin tissues in contact with the pad, causing chaffing, soreness, and general discomfort. Some individuals may develop skin allergies as a result of prolong use of such pads. In severe cases the user may no longer be able to wear such external pads. Other complaints often expressed about external absorbent pads is that they are unable to contain the odor of urine when wet.
The present invention overcomes or greatly minimizes all of the foregoing objections.
SUMMARY OF INVENTION
A urinary incontinence appliance constructed according to the invention includes hydrophilic absorbing media encased in a water-impermeable sheath having a closed end that is inserted into the vagina of the user and an open end external to the vagina that is form fit to cover the urethra of the user. The external open end portion acts to funnel any urine that may escape from the urethra into the interior of the sheath where it is captured and wicked by the absorbent media within the vagina.
The appliance may be a disposable device such that when the absorbent capacity of the media has been reached or when the vaginal bulk becomes uncomfortable to the wearer, she may simply replace the appliance with a fresh one.
One of the principal advantages of the invention is that the absorbent media which absorbs and holds the urine is internal to the vagina and encased in a water-impermeable sheath. The internal disposition and encasement of the media eliminates external bulk normally associated with the traditional external pads and absorbent undergarments as well as the urine odor associated with the use of such external pads and garments.
The invention has the further advantage of minimizing the amount of tissue exposed to a wet pad, since all but a small portion of the absorbent media at the opening of the sheath is accommodated within the vagina and encased by the water-impermeable sheath to shield the vaginal wall tissues of the wearer from contact with the absorbent media. The invention contemplates that such a minimal contact incontinence device may be utilized even by those patients who have allergies to traditional external pads and, importantly, may be utilized in the first instance by those susceptible to such skin allergies to prevent or at least minimize the occurrence of such allergies.
The invention contemplates various embodiments of the basic intravaginal incontinence appliance having features which aid in retaining the closed intravaginal portion of the appliance within the vagina. According to a particular embodiment, the closed end of the sheath may be somewhat flared such that as the absorbent media within the sheath absorbs urine and expands, the closed end of the appliance accommodated within the vagina expands disproportionately to that of the open end to effectively wedge the device within the vagina so that it is self-supporting against removal. A further advantage with this feature is that as the media collects more urine, its self-retaining wedging effect increases counteracting the force of the additional weight tending to withdraw the device from the vagina. Still yet another advantage is that the internal bulk of the absorbent media provides support to the bladder and urethra tube which, in some case, may serve to lessen the severity of the users incontinence where such condition is attributable to the loss of muscle or tissue support in those regions.
According to another particular feature, the closed intravaginal sheath may be fitted with a retaining device that, when the sheath is inserted in the vagina, expands to support and retain the appliance in place. The retainer may take the form of a pair of spaced arms internal to the sheath and extending toward its closed end and joined adjacent the closed end by an elastic member which applies a constant outward biasing force to the forks causing them to take on a divergent wedge-shaped form when extended into the vagina.
Other means for retaining the appliance in place may include a belt or strap worn about the hips of the user and connected to the appliance to effectively suspend the appliance in place. Another means contemplated for supplementing the support of the appliance is to wear it in combination with a thin pad which serves to apply and maintain upward pressure on the appliance to hold it in place.
Those skilled in the gynecological field will appreciate that the retaining system for the basic intravaginal device may take on these and various other forms and will depend a great deal on the needs of a particular wearer. For those individuals who have good intravaginal muscle support, the self-retaining construction may be all that is needed. Others with weakened muscle support may require the use of the supplemental retaining devices such as the flared sheath design, flared spring arms, the belt, or external pad to name a few.
THE DRAWINGS
A presently preferred embodiment of the invention is disclosed in the following description and in the accompanying drawings, wherein:
FIG. 1 is a perspective view of an incontinence appliance constructed in accordance with a first presently preferred embodiment of the invention;
FIG. 2 is a longitudinal cross-sectional view of the appliance of FIG. 1 shown installed in place within the vagina of a user;
FIG. 3 is a view like FIG. 2 but with the absorbent media expanded from absorption of urine;
FIG. 4 is a top cross-sectional view showing a supplemental retaining system for the appliance;
FIG. 5 is another embodiment of a supplemental retaining system of the invention; and
FIG. 6 is still a further embodiment of a supplemental retaining system of the invention.
DETAILED DESCRIPTION
Turning now in more detail to the drawings, FIG. 1 illustrates a female incontinence appliance 10 constructed in accordance with a presently preferred embodiment of the invention. The appliance 10 comprises a generally elongate tubular sheath 12 having a closed end 14 and an open end 16. Accommodated within the sheath 12 is a hydrophilic absorbent medium 18, only a small portion of which is exposed at the open end 16 of the sheath 12. The sheath 12 is fabricated of a water-impermeable material, such as latex, silastic, or other neutral, hypoallergenic elastic materials. The closed end portion 14 of the sheath 12 is preferably a thin walled construction and may be constructed much like a condom. The front open end portion 16 may be fabricated of the same or different material and preferably of a pliable, yet form fitting construction such that it provides an upwardly extending cup-shaped shield 20 and an opening or rim 22.
FIGS. 2 and 3 illustrate the appliance 10 in use. As shown, the closed end portion 14 is extended into the vaginal canal 24 of the user with the open end 16 remaining external such that the opening or rim 22 of the sheath 12 encompasses the urethral opening or meatus 26 of the wearer leading from the bladder 28. In this way, the absorbent medium 18 is primarily internal to the user and that which is external is sealed by the rim 22 of the sheath 12 about the urethra region 26.
Any urine that leaks from the bladder 28 is funneled into the interior of a sheath 12 through the opening 22. Such urine is wicked by the absorbent medium 18 and contained wholly within the sheath 12. The water-impermeable nature of the sheath 12 prevents fluids from being transmitted into or out of the sheath thereby retaining the urine and any odors associated therewith within the confines of the sheath 12.
FIG. 3 illustrates a preferred construction of the closed end region 14 which is caused to flare or enlarge disproportionally with the remainder of the appliance 10 as urine as absorbed. As illustrated, the sheath 12 is preferably constructed with a flared configuration at its closed end 14 such that as the urine is absorbed and wicked toward the closed end, the absorbent medium 18 in the vicinity expands and flares the closed end 14 to present a divergent wedge-shaped configuration to the appliance 10. Such shape helps retain the closed end 14 within the vagina 24, and the wedging effect is increased proportionally with the amount of urine absorbed. In this way, the appliance 10 increases its self-supporting properties as more urine is absorbed, counteracting the downward gravitational force acting on the appliance 10 as it becomes heavier with urine. By "wedge-shaped", it is meant to include any bulbous or enlarged configurations that serve to wedge or lodge the closed end 14 within the vagina 24.
The preferred absorbent media 18 provided within the sheath 12 is preferably of a super absorbent material, such as the hydrophilic gelling beads commonly used in children's diapers and is capable of expanding to many times its size when absorbing urine. A wicking pad 32 and overlying dry cloth layer 34 may be provided at the opening 22 such that the portion of the medium 18 in contact with the users skin is kept dry and free of urine. The construction and materials for the pad 32 and dry layer 34 may be any of various forms commonly used in diaper applications, sanitary napkins, and the like.
FIG. 4 illustrates a supplemental retaining system 36 that may be used in conjunction with the application 10 described above. As shown, the system 36 comprises a pair of spaced arms 38, 40 accommodated within the sheath 12 and extending generally the length of the closed end portion 14. The arms 38, 40 are joined at their ends adjacent the closed end 14 of the sheath by an elastic spring member 42 which acts on the arms 38, 40 biasing them constantly apart so that they diverge outwardly from one another in the direction of the closed end 14 to provide a wedge shape to the intravaginal portion 14. The spring 42 may comprise a rubber or plastics piece or a protected metal piece which spans the arms and in its unloaded state spreads them apart, yet is elastically yieldable to enable the user to pinch the arms 38, 40 toward one another to accommodate the insertion of the sheath 12 into the vagina 24. Upon releasing the arms, the spring 42 returns the arms to their divergent condition, thereby wedging the closed end portion 14 to the sheath 12 within the vagina 24.
FIG. 5 illustrates another means of retaining the appliance 10 within the vagina 24, and in this case is in the form of a belt or strap system 44 that may arranged about the waist or hips of the wearer to effectively suspend the appliance 10 in place. It is preferred that the appliance 10 be separable from the belt system 44 such that the same belt 44 may be used with different appliances 10.
FIG. 6 illustrates yet another retaining system that may be used in conjunction with the appliance 10. In this embodiment, the appliance 10 is installed and used in the same manner as described above except that a thin supplemental external pad 46 is worn between the appliance 10 and the undergarment 48 in order to apply upward pressure on the underside of the shield 20 to help hold the closed end portion 14 within the vagina 24. The pad 46 is preferably a thin panty liner type pad like any of a number of types presently in use. The invention contemplates that the pad 24 could be constructed as an integral part of the appliance 10 to provide an all-in-one unit with the pad 46 serving as a support device for the shield 12 and if desired as a secondary absorbent device in the unlikely event that urine were to escape pass the rim 22 of the sheath 12.
The disclosed embodiments are representative of presently preferred forms of the invention, but are intended to be illustrative rather than definitive thereof. The invention is defined in the claims.
|
A urinary incontinence appliance constructed according to the invention includes hydrophilic absorbing media encased in a water-impermeable sheath having a closed end that is inserted into the vagina of the user and an open end external to the vagina that is form fit to cover the urethra of the user. The external open end portion acts to funnel any urine that may escape from the urethra into the interior of the sheath where it is captured and wicked by the absorbent media within the vagina.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a double axis type transit which is capable of effecting repeated measurement of an angle to be measured.
2. Description of the Prior Art
The repetitive measuring method is effected to reduce the influence of the error resulting from the structural defect of the transit or the incompleteness of adjustment as well as the influence of the error resulting from the observation operation such as collimation or reading. The transit is comprised of a base, first and second rotational members coaxial with the base and rotatable, means for measuring the angle between the first rotational member and the second rotational member, and a collimator secured to the first rotational member. Accordingly, the repetitive measuring method, as shown in FIG. 1 of the accompanying drawings, comprises installing the transit at a point 0, fixing the base thereof, and rotating the first rotational member with the second rotational member to thereby collimate a point A by the collimator. Let it be assumed that the then angle of the first rotational member with respect to the base is α 0 . Subsequently, the first rotational member is made rotatable with the second rotational member remaining fixed to the base and a point B is collimated by the collimator to thereby measure an angle α 1 . Then, the first rotational member and the second rotational member are rotated together relative to the base and the point A is again collimated by the collimator, and subsequently the second rotational member is fixed to the base, while the first rotational member is made rotatable and the point B is collimated by the collimator to thereby measure the angle. The cumulative measured value when the space between the points A and B has been measured n times in this manner is defined as α n , and the angle α of <AOB is found from
α=(α.sub.n -α.sub.0)/n
Now, the transit disclosed in Japanese Laid-open Patent Application No. 165011/1983 comprises a base, a first rotational member having a collimator and supported on said base for rotation about a vertical axis, a second rotational member supported for rotation about said vertical axis relative to the base and the first rotational member, measuring means for measuring the relative angular displacement between said first rotational member and said second rotational member by a binary code, digital display means for displaying the measurement value of said measuring means, digital display clearing means for rendering the digital display means into a zero value when the measurement value of said measuring means has become 360°, and inhibiting means for selectively inhibiting the clearing function of said digital display clearing means, and has been designed such that the digital display means displays a right measurement value even when the measured angle by the repetitive measuring method or the like exceeds 360°.
However, in the above-described apparatus, the inhibition of the clearing function of the digital display clearing means by the inhibiting means is effected in a circuit-like fashion, and this has led to a disadvantage that the apparatus is complicated in structure.
Also, suppose a case where the maximum countable number of a counter for counting the binary code corresponding to the relative angular displacement is not integer times as great as 360°. When this counter counts the maximum countable number, e.g., 1000, the content of the counter returns to zero and therefore, when the counter counts down from this state, the content of the counter changes to 999, 998, . . . . However, where subtraction is effected from zero (it is to be understood that the angle changes by 1° each), the angle changes to 359, 358, . . . . Accordingly, where the maximum countable number of the counter is not integer times as great as 360°, the count number of the counter must be corrected, and this leads to a disadvantage that the apparatus becomes complicated.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a transit which is simple in structure.
To achieve the above object, the transit of the present invention for detecting the relative angular displacement between a first rotational member and a second rotational member is designed such that the detected angle is latched and the maximum latchable angle is integer times as great as 360°.
Further, the present invention is designed such that the detected angle is converted into a binary code, the converted binary code is counted, the maximum countable value is integer times as great as 360° and whether the result of the counting is to be displayed as being greater than 0° and less than 360° or to be intactly displayed is selected.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the principle of the repetitive measuring method.
FIG. 2 illustrates a digital transit according to an embodiment of the present invention.
FIG. 3 is an enlarged illustration of the angle display system of FIG. 2.
FIG. 4 is a block diagram of a first embodiment of the operation display circuit.
FIG. 5 shows the construction of a counter.
FIG. 6 is a flow chart of an operator.
FIG. 7 is a block diagram of a second embodiment of the operation display circuit.
FIG. 8 is a flow chart of the second embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Some embodiments of the present invention will hereinafter be described with reference to the drawings. The mechanism of a double axis type digital transit, as shown in FIG. 2, comprises a first rotational member 10 supporting a collimator 4 for rotation about a horizonal axis 6 and supported on a base 2 for rotation about a vertical axis 8, a second rotational member (upper board) 12 supported for rotation about the vertical axis 8 relative to the base 2 and the first rotational member 10, and an angle measuring system 14 (FIG. 3) for measuring the angular relative displacement between the first rotational member 10 and the second rotational member 12 by a binary code. The second rotational member 12 has a first clamp screw 16 for making the second rotational member 12 integral with the first rotational member 10, and a second clamp screw 18 for making the second rotational member 12 integral with the base 2. The angle measuring system 14 is a so-called rotary encorder as shown in FIG. 3 and comprises a light source 20, a condenser lens 22, an index slit 24 and two light-receiving elements 26, 28 mounted on the first rotational member 10, and a code plate 30 mounted on the second rotational member 12. The index slit 24 comprises two slit groups 24a and 24b disposed so that the output signals of the light-receiving elements 26 and 28 are 90° out of phase with each other. The technique of making the output signals of two light-receiving elements out of phase with each other by the arrangement of the code plate 30 and the index slit 24 is already known and is described, for example, in U.S. Pat. No. 3,826,318. However, this U.S. Patent is a technique regarding a linear encoder.
As regards a first embodiment of the operation display circuit of the outputs of the light-receiving elements 26, 28, the outputs of the light-receiving elements 27, 28 are connected to a direction discriminator 40 through amplifiers 32, 34 and comparators 36, 38, as shown in FIG. 4. The direction discriminator 40 puts out to a counter 42 a signal a indicative of the direction of rotation of the first rotational member 10 and the second rotational member 12 and a signal b indicative of the angle thereof. The counter 42 puts out to an operator 44 a signal of binary code indicative of the counted value, and the operator 44 processes the signal from the counter 42 and puts it out to a digital display device 46. The counter 42, as shown in FIG. 5, is so constructed that a counter group 420 (first counter) having 359°59'59" as a maximum count value and an N-nary counter 421 (second counter) are connected together, and the counter group 420 is comprised of a decimal counter 420a, a six-nary counter 420b, a decimal counter 420c, a six-nary counter 420d, a decimal counter 420e and a thirty-six-nary counter 420f, which are up/down counters. The counter group 420 has 359°59'59" as the maximum countable value and further, when it counts a pulse of the signal b corresponding to an angle 1", the counter group 420 inputs a pulse to the N-nary counter 421 and is reset. However, of course, the construction of the counters may be changed depending on the resolving power of the measured angle. The number N of the N-nary counter 421 is selected so that the counter 42 does not overflow by the angles accumulated by repeated measurement.
A select switch 45 capable of selecting the repetitive measuring method in its ON position and selecting the usual measurement in its OFF position is connected to the operator 44.
In the above-described circuit construction, two angle signals having a phase difference of 90° which have been detected by the light-receiving elements 26, 28 are amplified by the amplifiers 32 and 34 and converted into rectangular waves by the comparators 36 and 38 and further, the two angle signals are converted by the direction discriminator 40 into a signal a indicative of the count-up or count-down to the up/down counter 42 and a signal b generating a pulse for a change of the angle 1". The pulse count value counted by the counter 42 is supplied to the operator 44.
The operations of the counters 420-420f constituting the counter group 420 will now be described with respect typically, to the counters 420a and 420b. The decimal counter 420a counts the pulse number indicated by the signal b when the signal a is indicative of count-up, and counts up to 10 when it begins to count from zero, and renders the result of the count into zero and causes the six-nary counter 420b to generate a pulse. When the signal a is indicative of count-down, the content of the counter 420a is zero and when a pulse is input thereto, a pulse is generated in the six-nary counter 420b. The operations of the remaining counters 420c-420f are similar to the operations of the decimal counter and the six-nary counter with the exception that the maximum countable pulse number of the decimal counter is 10 and the maximum countable pulse number of the six-nary counter is 6. Also, the counters 420a-420f put out in parallelism binary signals indicative of the result of count.
The operator 44 comprises, for example, a microcomputer and the flow chart thereof is as shown in FIG. 6. At step 60, the operator 44 reads the output from the counter 42, and at step 61, it stores the output of the counter 42 as D x , and at step 62, it reads the ON or OFF of the select switch 45 and when the select switch 45 is OFF, the operator 44 subtracts as angle integer times as great as 360° from the pulse count value and converts the displayed value from 0° to a value less than 360° (steps 63 and 64) if the pulse count value exceeds 360°. This is similar to the operation of the conventional digital transit. Where the repetitive measuring method in which the accumulated angle value exceeds 360° is carried out, if the select switch 45 is brought into its ON position, the operator 44 does not effect the subtraction as described above even if the count value of the counter exceeds 360°, because this is the case of the repetitive measuring method, and the value indicated by the data D x is displayed on the digital display device 46 (step 65). The measured value may be found by dividing the accumulated angle value displayed on the digital display device 46 by the frequency of the repeated measurement.
In the above-described embodiment, the accumulated angle value is displayed on the digital display device 46 during the repeated measurement and therefore, it has been necessary to divide the displayed value by the frequency of the repeated measurement in order to find the measured value, but a second embodiment in which said measured value is directly displayed will now be described by reference to FIG. 7.
In the second embodiment, the light-receiving elements 26, 28, the amplifiers 32, 34, the comparators 36, 38, the discriminator 40, the counter 42 and the display device 46 are identical to those in the first embodiment and therefore need not be described. A setting circuit 71 for setting the frequency of the repeated measurement is connected to an operator 44a, and a measurement termination switch 70 is further connected to the operator 44a.
In the above-described circuit construction, the frequency k of the repeated measurement of 1 or 2 or more is set by the setting circuit 71. When the frequency k of the repeated measurement is set to 1 by the setting circuit 71, the operator 44a subtracts an angle integer times as great as 360° from the pulse count value if the pulse count value exceeds 360°. When the frequency k of the repeated measurement is set to 2 or more, in other words, when repeated measurement is to be effected, the operator 44a does not effect said subtraction. When a measurement termination signal is input by the ON of the measurement termination switch 70, the operator 44a reads the count value from the counter 42 and divides it by the frequency of the repeated measurement set by the setting circuit 71.
The result of that operation is the measured value, which is displayed on the digital display device 46. The flow chart of the operator 44a except the portions thereof which overlap the flow chart of FIG. 6 is shown in FIG. 8. When, at step 62, it is judged that the switch 45 is ON, whether the frequency k of the repeated measurement is 1 or 2 or more is judged at step 66 and, if the frequency k is 1, the operator may proceed to step 65 and, if the frequency k is 2 or more, the operator may proceed to step 65 via step 67 at which the data D x of the counter 42 is divided by the frequency k.
In any of the above-described embodiments, the counter group 420 may be constructed in any manner as required. That is, in the example of FIG. 5, the counter group 420 is constructed by combining chiefly decimal counters, but it may also be constructed by combining chiefly sixteen-nary counters to reduce the number of digits.
Also, if the counter group 420 of the construction as shown in FIG. 5 is used, the operator 44 may also be designed so as to effect subtraction by discarding the content of the N-nary counter 421 representative of integer times 360° from the count value of the counter 42 and put out only the value of the first counter group 420. Also, the counter 42 has been shown as comprising up/down counters connected together in series, but a time lag occurs between the transmission of pulse from counter to counter and the pulse of the actual signal b. Accordingly, to reduce this time lag, the up/down counters may be parallel-connected together.
Further, the measuring system 14 may be, for example, a potentiometer or a magnetic encoder.
|
A transit includes a first rotational member provided with a collimator and supported on the transit for rotation about a predetermined axis, a second rotational member supported on the transit for rotation about the predetermined axis, a detector for generating a pulse in accordance with a predetermined angle of displacement between the first rotational member and the second rotational member, a first counter for counting the number of pulses from the detector, the maximum countable pulse number of the first counter corresponding to the angle of 360°, the first counter generating a pulse in accordance with its counting of the maximum pulse number, and a second counter for counting the pulses from the first counter means up to a predetermined number.
| 6
|
BACKGROUND
[0001] 1. Field
[0002] This invention relates to the field of data and voice communications, and in particular, an apparatus to operate and manage a consumer network device.
[0003] 2. Related Art
[0004] Since the commercialization of the Internet in the 1990s, manufacturers have introduced consumer network products and services at a breathtaking pace. From more technology driven products like telephone modems, ADSL/Cable modems, Ethernet hubs/switches, consumer broadband gateways and routers, and wireless access points, manufactures are moving rapidly integrating networking technologies into more traditional consumer products such as IP telephony adaptors, network audio servers, network gaming consoles, network security devices. In the foreseeable future, there will be many new consumer network products and services, to improve the usefulness of current consumer technology products and services, or to enrich further the contemporary life styles. These emerging products and services create a new landscape for communications, productivity, and entertainment for consumers. Yet at the same time the products and services employ more and complex technologies than most consumers can comprehend. The proliferation of these consumer network devices creates a new set of problems because most consumers do not possess the necessary technical knowledge to operate and to manage the products.
[0005] These consumer network devices typically use Internet technologies. Today these devices require a connection to a personal computer for initial set-up, periodic operation and management, and troubleshooting. The difficulties, complexities and issues that arise due to the current state of the art for setting up, managing and operating such network devices are best illustrated by examples.
[0006] In one scenario, a user subscribes to a DSL broadband data service and has a DSL modem. Recently the consumer bought a second personal computer. In order to have Internet access to both personal computers, the consumer learns he can connect both personal computers to a broadband gateway. He buys a consumer broadband gateway. During the initial set-up of the consumer broadband gateway, the default IP address of consumer broadband gateway is factory set at 192.168.1.101 and the subnet mask at 255.255.255.0. His two personal computers however, have IP addresses of 10.122.11.123 and 10.122.11.124, with a subnet mask of 255.255.240.0. The consumer connects the WAN port of the consumer broadband gateway to the DSL modem, and both personal computers to the LAN ports of the consumer broadband gateway. Following the instruction manual of the consumer broadband gateway, The consumer launches the Web browser, at one of his personal computers, to access the URL “http://192.168.11.101/index.html” which would allow the consumer to access the consumer broadband gateway. Due to the incompatible settings, the Web browser returns an error message indicating the failure to access the URL. The consumer checks the consumer broadband gateway and sees several blinking LED's. According to the manual, the consumer broadband gateway indicates normal LAN port activities. However, the consumer becomes frustrated and he cannot get further information which step in the initial set-up he has a mistake. After a few hours of frustration, the consumer decides to return the consumer broadband gateway.
[0007] In another scenario, the consumer bought a wireless network access point and connected it to his consumer network at home. Fortunately, The consumer understood enough about his home network and was able to set-up the wireless network access point. However, the new wireless network access point includes a DHCP server and was interfering with the DHCP server running in an existing consumer broadband gateway in his consumer network. This interaction caused the network to malfunction after a couple of days. The consumer's personal computer was not able to reach the wireless network access point, the consumer broadband gateway, nor other consumer network devices in his consumer network. The consumer checked the wireless network access point and the consumer broadband gateway. The LEDs on the two devices indicate normal operation. After numerous calls to the customer support of the manufacturer of the wireless network access point, the manufacturer of the consumer broadband gateway, the manufacturer of the personal computer and the broadband service provider, The consumer suffered a lot of frustration as the problem remained unsolved. The consumer eventually returned the wireless network access point.
[0008] In a different embodiment, the consumer subscribed to an IP telephone service and brought home a new IP telephony adaptor. She connected the IP telephony adaptor to her consumer network, and connected her home phone to the telephone jack of the IP telephony adaptor. She faced the same problem as the consumer in the above embodiment that the factory preset IP address and subnet mask were incompatible to that of her consumer network. After great frustration and many service calls, the problem was eventually resolved by an onsite service person, a costly experience for the consumer as well as the IP telephone service provider.
[0009] The foregoing examples illustrate a need for a user-friendly solution for a consumer to set up, operate and manage consumer network devices that will reduce the amount of time, money and frustration to both the consumer and the manufacturer, service provider or reseller.
SUMMARY
[0010] Embodiments of the present invention include method and apparatuses for a Console Controller.
[0011] In one embodiment, a control console comprising a display module, an input module and console controller is incorporated into a network device such as, but not limited to, a DSL/Cable router, a switch, a hub, a DSL/Cable modem, Voice over Internet Protocol (VoIP) router, wireless access point, wireless router or residential gateway to facilitate the display, input, programming and configuration of network settings of said network device without the use of a separate device or computer. By providing for a means of retrieving and entering data about the network device on the actual network device, a console controller can greatly reduce the difficulty associated with current state of the art set up, management and operation of the network device.
[0012] In one embodiment, the control console can have one or more lines of graphical information display with one or more single purpose or multi purpose buttons, dials or touch pads.
[0013] In one embodiment, the control console can have audio notification or response capabilities. Such audio notification or response can include, but is not limited to, alarms for when network functionality or status changes or sounds played to confirm button operation or successful input of information.
[0014] Additional embodiments will be evident from the following detailed description and accompanying drawings, which provide a better understanding of the nature and advantages of the present invention.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. 1 is a block diagram illustrating a Network Application and Network Function Component according to one embodiment of the present invention.
[0016] FIG. 2 is a block diagram illustrating a Consumer Network Device with Control Console according to one embodiment of the present invention.
[0017] FIG. 3 is a representation of an Input Module and Display Module according to one embodiment of the present invention.
[0018] FIG. 4 is a block diagram illustrating a Console Controller State Machine according to one embodiment of the present invention.
[0019] FIG. 5 is a block diagram illustrating a Main Menu State Machine according to one embodiment of the present invention.
[0020] FIG. 6 is a representation of a Main_Menu_Line_Item according to one embodiment of the present invention.
[0021] FIG. 7 is a representation of a Display Module and Input Module for Main Menu State Machine in Main Menu State-A according to one embodiment of the present invention.
[0022] FIG. 8 is a block diagram illustrating a Status Menu State Machine according to one embodiment of the present invention.
[0023] FIG. 9 is a representation of a Status_Menu_Line_Item according to one embodiment of the present invention.
[0024] FIG. 10 is a representation of a Display Module and Input Module for Status Menu State Machine in Status Menu State-A according to one embodiment of the present invention.
[0025] FIG. 11 is a representation of a Display Module and Input Module for Status Menu State Machine in Status Menu State-B according to one embodiment of the present invention.
[0026] FIG. 12 is a block diagram illustrating a Set Menu State Machine according to one embodiment of the present invention.
[0027] FIG. 13 is a representation of a Set_Menu_Line_Item according to one embodiment of the present invention.
[0028] FIG. 14 is a representation of a Display Module and Input Module for Set Menu State Machine in Set Menu State-A according to one embodiment of the present invention.
[0029] FIG. 15 is a representation of a Display Module and Input Module for Set Menu State Machine in Set Menu State-B according to one embodiment of the present invention.
[0030] FIG. 16 is a representation of a Display Module and Input Module for Set Menu State Machine in Set Menu State-C according to one embodiment of the present invention.
[0031] FIG. 17 is a representation of a Display Module and Input Module for Set Menu State Machine in Set Menu State-D according to one embodiment of the present invention.
[0032] FIG. 18 is a representation of a Display Module and Input Module for Set Menu State Machine in Set Menu State-E according to one embodiment of the present invention.
[0033] FIG. 19 is a block diagram illustrating a Test Menu State Machine according to one embodiment of the present invention.
[0034] FIG. 20 is a representation of a Test_Menu_Line_Item according to one embodiment of the present invention.
[0035] FIG. 21 is a representation of a Display Module and Input Module for Test Menu State Machine in Test Menu State-A according to one embodiment of the present invention.
[0036] FIG. 22 is a representation of a Display Module and Input Module for Test Menu State Machine in Test Menu State-B according to one embodiment of the present invention.
DETAILED DESCRIPTION
[0037] Described herein are apparatuses for a Control Console for a network device. In the following description, for purposes of explanation, numerous examples and specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention as defined by the claims may include some or all of the features in these examples alone or in combination with other features described below, and may further include obvious modifications and equivalents of the features and concepts described herein.
[0038] FIG. 1 is a diagram illustrating a Network Application. Network Application 100 includes an Application Logic 110 and a Network Interface 170 .
[0039] In one embodiment, Network Application 100 also includes an Input/Output Function 150 , such as a speaker and a microphone, or other special purpose sensors or drivers. Application Logic 110 communicates with one or more network devices connected to Consumer Network 190 via Network Interface 170 .
[0040] In one embodiment, Consumer Network 190 is an IP network over Ethernet technology.
[0041] In one embodiment, Consumer Network 190 is an IP network over Wi-Fi technology.
[0042] In one embodiment, Consumer Network 190 is an IP network over a plurality of technologies.
[0043] Application Logic 110 includes a plurality of Network Function Component 130 . A Network Function Component 130 relates to the interaction between Application Logic 110 and Network Interface 170 .
[0044] In one embodiment, a Network Function Component 130 is an IP address, a subnet mask, a remote server address, a default gateway address, an option for static or dynamic IP address allocation, or the SSID of a wireless network access point.
[0045] In one embodiment, a Network Function Component 130 is an indication of the connectivity to a default gateway, an indication of the quality of a communication link such as an Ethernet connection.
[0046] In one embodiment, a Network Function Component 130 is the transmission rate at Network Interface 170 , the number of dropped packets in a communication session, or an indication of the quality of a wireless link.
[0047] In one embodiment, a Network Function Component 130 is a test of a network capability of Application Logic 110 . For example, a Network Function Component 130 is a test of the connectivity of Network Interface 170 and Consumer Network 190 , a test of the connectivity towards the default gateway of Consumer Network 190 , a test of connectivity towards a remote server, the request to renew an IP address from a DHCP server application, or a test of the functionality of a firewall.
[0048] A consumer network device runs a number of applications, including one or more network applications. In one embodiment, a network application is a DHCP server application.
[0049] In one embodiment, a network application is a network access point application, such as a wireless network access point application.
[0050] In one embodiment, a network application is an IP phone application.
[0051] In one embodiment, a network application is a routing application, such as a DSL routing application, or a cable modem routing application.
[0052] In one embodiment, a network application is a firewall application.
[0053] In one embodiment, a network application is a network multi-media application, such as a network music application, a network photo album application, or a network video application.
[0054] In one embodiment, a network application is a network security application, such as a network surveillance application, a baby room monitoring application, or a network alarm application.
[0055] In one embodiment, a network application is a network remote control application, such as a home appliance remote control application, a swimming pool remote control application, or a home landscape remote irrigation application.
[0056] FIG. 2 is a diagram illustrating a Control Console. Control Console 200 is a part of a Consumer Network Device 280 . Control Console 200 connects to Network Application 270 over Operation and Management Interface 205 . Operation and Management Interface 205 is a programming interface. Control Console 200 operates and manages a plurality of Network Function Component 275 over Operation and Management Interface 205 .
[0057] Control Console 200 may include Display Module 210 , Input Module 230 , and Console Controller 250 .
[0058] Input Module 230 allows a user to provide input to Console Controller 250 . In one embodiment, Input Module 230 includes a plurality of keys.
[0059] In one embodiment, Input Module 230 includes a plurality of dials.
[0060] In one embodiment, Input Module 230 includes a voice recognition module.
[0061] Display Module 210 displays information about Network Application 270 . In one embodiment, Display Module 210 includes an alphanumeric display panel.
[0062] In one embodiment, Display Module 210 includes a graphic display.
[0063] In one embodiment, Display Module 210 includes a speaker.
[0064] Console Controller 250 receives user inputs from Input Module 230 , communicates with Network Application 270 , determines the content to display and sends the content to Display Module 210 for display.
[0065] In one embodiment, the user input is to obtain the status information for a Network Function Component 275 of Network Application 270 .
[0066] In one embodiment, Console Controller 250 requests the status information of a Network Function Component 275 from Network Application 270 , and receives the status information from Network Application 270 . Console Controller 250 sends the status information to Display Module 210 .
[0067] In one embodiment, the user input is to set the value of a Network Function Component 275 of Network Application 270 , Console Controller 250 sends the identity and the value of a Network Function Component 275 to Network Application 270 , receives the result from Network Application 270 , and sends the result to Display Module 210 .
[0068] In one embodiment, the user input is to test a Network Function Component 275 of Network Application 270 , Console Controller 250 requests Network Application 270 to test a Network Function Component 275 , receives the test result from Network Application 270 , and sends the information to Display Module 210 .
[0000] Input Module and Display Module
[0069] FIG. 3 illustrates an embodiment of Input Module 330 and Display Module 310 . Input Module 330 includes four input keys, Key-A 331 , Key-B 332 , Key-C 333 , and Key-D 334 . A user presses the input keys at Input Module 330 to provide input to Console Controller 250 .
[0070] Display Module 310 is an alphanumeric display panel with three lines of display. The first line is Line-A 312 . The second line is Line-B 314 . The third line includes four parts. The first part Key-Function-A 351 is located directly above Key-A 331 . The second part Key-Function-B 352 is located directly above Key-B 332 . The third part Key-Function-C 353 is located directly above Key-C 333 . The fourth part Key-Function-D 354 is located directly above Key-D 334 .
[0071] In one embodiment, Line-A 312 displays a name. For example, Line-A 312 displays “MAIN MENU”.
[0072] In one embodiment, Line-B 314 displays a name, for example, “TEST MENU”.
[0073] In another embodiment, Line-B 314 displays “IP ADDRESS”.
[0074] In one embodiment, Line-B 314 displays “172.168.66.62”. In one embodiment, Line-B 314 displays “255.255.240.0”.
[0075] In one embodiment, Line-B 314 displays “rc: 12 kbps tx: 15 kbps dp pkt: 0”.
[0076] In one embodiment, Line-B 314 displays “link quality is good, signal strength at 75%”.
[0077] In one embodiment, Line-B 314 displays “DEFAULT GATEWAY TEST”.
[0078] In one embodiment, Line-B 314 displays “NETWORK CONNECTION TEST”.
[0079] In one embodiment, Line-B 314 displays “normal, round trip latency is 159 ms”.
[0080] In one embodiment, Key-Function-A 351 displays the name of the function for Key-A 331 . Key-Function-B 352 displays the name of the function for Key-B 332 . Key-Function-C 353 displays the name of the function for Key-C 333 . Key-Function-D 354 displays the name of the function for Key-D 334 .
[0081] In one embodiment, Key-Function-A 351 displays “CHANGE”, Key-Function-B 352 displays “LOCATE”, Key-Function-C 353 displays “EXIT”, and Key-Function-D 354 displays “SAVE”.
[0000] Console Controller State Machine
[0082] FIG. 4 illustrates a Console Controller State Machine. Console Controller State Machine 400 is a state machine. The Console Controller 250 includes a plurality of Console Controller State Machine 400 . Console Controller State Machine 400 has zero or more state variables. Console Controller State Machine 400 has one Initial State 410 , a plurality of State 430 , a plurality of State Transition 450 , and a plurality of Trigger Event 470 . Console Controller 250 starts a Console Controller State Machine 400 at the Initial State 410 . Console Controller State Machine 400 enters a State 430 automatically. A user presses one of the four input keys, Key-A 331 , Key-B 332 , Key-C 333 , or Key-D 334 at Input Module 330 to provide input to Console Controller 250 . Console Controller State Machine 400 processes the input from Input Module 330 , determines that a Trigger Event 470 has occurred and triggers a State Transition 450 . A State Transition 450 leaves a State 430 , enters a different State 430 , or enters the same State 430 . During a State Transition 450 , Console Controller State Machine 400 takes zero or more actions. Each action acts on one or more state variables. Upon entering a State 430 , Console Controller State Machine 400 takes zero or more actions.
[0083] In one embodiment, an action acts on zero or more state variables. In another embodiment, an action invokes communications to Network Application 270 .
[0084] In one embodiment, an action invokes a command to Display Module 310 .
[0085] In one embodiment, Console Controller State Machine 400 determines that the input from Input Module 330 does not correspond to a Trigger Event 470 and ignores the input from Input Module 330 .
[0000] Main Menu State Machine
[0086] FIG. 5 illustrates a Main Menu State Machine. Main Menu State Machine 500 is a Console Controller State Machine 400 . Main Menu Machine 500 includes a Main_Menu_Line_Item_Table. Main_Menu_Line_Item_Table includes a plurality of Main_Menu_Line_Item.
[0087] In one embodiment, the Console Controller 250 includes a Main Menu State Machine.
[0088] FIG. 6 illustrates a Main_Menu_Line_Item. Main_Menu_Line_Item 600 includes a Line_Item_Name 602 , and a State_Machine_Identity 605 . Line_Item_Name 602 stores a name. State_Machine_Identity 605 refers to a Console Controller State Machine 400 . Main Menu State Machine 500 includes state variable Main_Menu_Line_Item_Table_Index. Main_Menu_Line_Item_Table_Index refers to a Main_Menu_Line_Item 600 in the Main_Menu_Line_Item_Table.
[0089] Main Menu Initial State 510 is the Initial State 410 of Main Menu State Machine 500 . Main Menu State Machine 500 includes a plurality of State 430 ; Main Menu State-A 530 , and Main Menu State-B 550 . Main Menu State Machine 500 includes a plurality of State Transition 450 ; Main Menu Transition-A 513 and Main Menu Transition-B 515 . Main Menu State Machine 500 includes a plurality of Trigger Event 470 ; Trigger Event-SCROLL 5133 and Trigger Event-SELECT 5153 .
[0000] Main Menu Initial State
[0090] Console Controller 250 starts Main Menu State Machine 500 .
[0091] In one embodiment, Console Controller 250 starts Main Menu State Machine 500 when a user switches on the power at Consumer Network Device 280 . Main Menu State Machine 500 enters Main Menu Initial State 510 . Main Menu State Machine 500 sets Main_Menu_Line_Item_Table_Index to refer to the first Main_Menu Line_Item 600 in the Main_Menu_Line_Item_Table. Main Menu State Machine 500 enters Main Menu State-A 530 .
[0000] Main Menu State-A
[0092] FIG. 7 illustrates an example of Output Module 710 after the display actions.
[0093] In FIG. 7 , Main Menu State Machine 500 displays “MAIN MENU” on Line-A 712 . Main Menu State Machine 500 retrieves the Main_Menu_Line_Item 600 referred to by Main_Menu_Line_Item_Table_Index. Main Menu State Machine 500 displays the name stored in the Line_Item_Name 602 on Line-B 714 , for example, “TEST MENU”. Main Menu State Machine 500 displays “SCROLL” on Key-Function-A 751 and “SELECT” on Key-Function-D 754 .
[0000] Main Menu State-B
[0094] Console Controller 250 stops Main Menu State Machine 500 . Console Controller 250 retrieves the Main_Menu_Line_Item 600 referred to by Main_Menu_Line_Item_Table_Index, and starts the Console Controller State Machine 400 referred to by the State_Machine_Identity 605 .
[0000] Main Menu Transition-A
[0095] In FIG. 7 , when a user presses Key-A 731 . Main Menu State Machine 500 determines that Trigger Event-SCROLL 5133 has occurred and triggers Main Menu Transition-A 513 . Main Menu State Machine 500 changes Main_Menu_Line_Item_Table_Index to refer to the next Main_Menu_Line_Item 600 in the Main_Menu_Line_Item_Table.
[0000] Main Menu Transition-B
[0096] In FIG. 7 , when a user presses Key-D 734 . Main Menu State Machine 500 determines that Trigger Event-SELECT 5153 has occurred and triggers Main Menu Transition-B 515 . Main Menu State Machine 500 takes no action in Main Menu Transition-B 515 .
[0000] Status Menu State Machine
[0097] FIG. 8 illustrates a Status Menu State Machine. Status Menu State Machine 800 is a Console Controller State Machine 400 . Status Menu State Machine 800 includes a Status_Menu_Line_Item_Table. Status_Menu_Line_Item_Table includes a plurality of Status_Menu_Line_Item.
[0098] In one embodiment, the Console Controller 250 includes a Status Menu State Machine.
[0099] FIG. 9 illustrates a Status_Menu_Line_Item. Status_Menu_Line_Item 900 includes a Line_Item_Name 902 , and a Status_Menu_Line_Item_Identity 905 . Line_Item_Name 902 stores a name. Status_Menu_Line_Item_Identity 905 relates to a plurality of Network Function Component 275 . Status Menu State Machine 800 has a state variable Status_Menu_Line_Item_Table_Index. Status_Menu_Line_Item_Table_Index refers to a Status_Menu_Line_Item 900 in the Status_Menu_Line_Item_Table.
[0100] Status Menu Initial State 810 is the Initial State 410 of Status Menu State Machine 800 . Status Menu State Machine 800 includes a plurality of State 430 ; Status Menu State-A 830 , Status Menu State-B 850 , and Status Menu State-C 870 . Status Menu State Machine 800 includes a plurality of State Transition 450 ; Status Menu Transition-A 813 , Status Menu Transition-B 815 , Status Menu Transition-C 817 , and Status Menu Transition-D 819 . Status Menu State Machine 800 includes a plurality of Trigger Event 470 ; Trigger Event-SCROLL 8133 , Trigger Event-SELECT 8153 , Trigger Event-EXIT 8173 , and Trigger Event-EXIT 8193 .
[0000] Status Menu Initial State
[0101] In one embodiment, Console Controller 250 starts Status Menu State Machine 800 as an action in the Main Menu State-B 550 . Status Menu State Machine 800 sets Status_Menu_Line_Item_Table_Index to refer to the first Status_Menu_Line_Item 900 in the Status_Menu_Line_Item_Table. Status Menu State Machine 800 enters Status Menu State-A 830 .
[0000] Status Menu State-A
[0102] In FIG. 10 , Status Menu State Machine 800 displays “STATUS MENU” on Line-A 1012 . Status Menu State Machine 800 retrieves the Status_Menu_Line_Item 900 referred to by Status_Menu_Line_Item_Table_Index. Status Menu State Machine 800 displays the name stored in the Line_Item_Name 902 on Line-B 1014 , for example, “DATA LINK STATUS”. Status Menu State Machine 800 displays “SCROLL” on Key-Function-A 1051 , “EXIT” on Key-Function-C 1053 and “SELECT” on Key-Function-D 1054 .
[0103] FIG. 10 illustrates an example of Display Module 1010 after the display actions.
[0000] Status Menu State-B
[0104] In FIG. 11 , Status Menu State Machine 800 displays “EXIT” on Key-Function-C 1153 .
[0105] Status Menu State Machine 800 retrieves the Status_Menu_Line_Item 900 referred to by Status_Menu_Line_Item_Table_Index. Status Menu State Machine 800 sends a request to the Network Application 270 via the Operation and Management Interface 215 . The request includes the Status_Menu_Line_Item_Identity 905 . Network Application 270 sends the result to the Console Controller 250 . Status Menu State Machine 800 displays the result, for example, “rc: 12 kpbs tx: 15 kpbs dp pkt: 0” on Line-B 1114 .
[0106] FIG. 11 illustrates an example of Display Module 1110 after the display actions.
[0000] Status Menu State-C
[0107] Console Controller 250 stops Status Menu State Machine 800 . Console Controller 250 starts Main Menu State Machine 500 .
[0000] Status Menu Transition-A
[0108] In FIG. 10 , when a user presses Key-A 1031 . Status Menu State Machine 800 determines that Trigger Event-SCROOL 8133 has occurred and triggers Status Menu Transition-A 813 . Status Menu State Machine 800 changes Status_Menu_Line_Item_Table_Index to refer to the next Status_Menu_Line_Item 900 in the Status_Menu_Line_Item_Table.
[0000] Status Menu Transition-B
[0109] In FIG. 10 , when a user presses Key-D 1034 . Status Menu State Machine 800 determines that Trigger Event-SELECT 8153 has occurred and triggers Status Menu Transition-B 815 . Status Menu State Machine 800 takes no action in Status Menu Transition-B 815 .
[0000] Status Menu Transition-C
[0110] In FIG. 11 , when a user presses Key-C 1133 . Status Menu State Machine 800 determines that Trigger Event-EXIT 8173 has occurred and triggers Status Menu Transition-C 817 . Status Menu State Machine 800 takes no action in Status Menu Transition-C 817 .
[0000] Status Menu Transition-D
[0111] In FIG. 10 , when a user presses Key-C 1033 . Status Menu State Machine 800 determines that Trigger Event-8193 has occurred and triggers Status Menu Transition-D 819 . Status Menu State Machine 800 takes no action in Status Menu Transition-D 819 .
[0000] Set Menu State Machine
[0112] In one embodiment, the Console Controller 250 includes a Set Menu State Machine.
[0113] FIG. 12 illustrates a Set Menu State Machine. Set Menu State Machine 1200 is a Console Controller State Machine 400 . Set Menu State Machine 1200 includes a Set_Menu_Line_Item_Table. Set_Menu_Line_Item_Table includes a plurality of Set_Menu_Line_Item.
[0114] FIG. 13 illustrates a Set_Menu_Line_Item. Set_Menu_Line_Item 1300 includes a Line_Item_Name 1302 , and a Set_Menu_Line_Item_Identity 1305 . Line_Item_Name 1302 stores a name. Set_Menu_Line_Item_Identity 1305 relates to a plurality of Network Function Component 275 . Set Menu State Machine 1200 includes state variables Set_Menu_Line_Item_Table_Index, Set_Menu_Line_Item_Value, and Set_Menu_Line_Item_Value_Character_Index. Set_Menu_Line_Item_Table_Index refers to a Set_Menu_Line_Item 1300 in the Set_Menu_Line_Item_Table. Set_Menu_Line_Item_Value includes a plurality of alphanumeric character. Set_Menu_Line_Item_Value_Character_Index refers to an alphanumeric character in Set_Menu_Line_Item_Value.
[0115] Set Menu Initial State 1210 is the Initial State 410 of Set Menu State Machine 1200 . Set Menu State Machine 1200 includes a plurality of State 430 ; Set Menu State-A 1220 , Set Menu State-B 1230 , Set Menu State-C 1240 , Set Menu State-D 1250 , Set Menu State-E 1260 , and Set Menu State-F 1290 . Set Menu State Machine 1200 includes a plurality of State Transition 450 ; Set Menu Transition-A 1271 , Set Menu Transition-B 1272 , Set Menu Transition-C 1273 , Set Menu Transition-D 1274 , Set Menu Transition-E 1275 , Set Menu Transition-F 1276 , Set Menu Transition-G 1277 , Set Menu Transition-H 1278 with, Set Menu Transition-I 1279 , Set Menu Transition-J 1281 , Set Menu Transition-K 1282 , and Set Menu Transition-L 1283 . Set Menu State Machine 1200 includes a plurality of Trigger Event 470 ; Trigger Event-SCROLL 12713 , Trigger Event-SELECT 12723 , Trigger Event-LOCATE 12733 , Trigger Event-LOCATE 12743 , Trigger Event-CHANGE 12753 , Trigger Event-CHANGE 12763 , Trigger Event-EXIT 12773 , Trigger Event-EXIT 12783 , Trigger Event-EXIT 12793 , Trigger Event-SAVE 12813 , Trigger Event-EXIT 12823 , and Trigger Event-EXIT 12833 .
[0000] Set Menu Initial State
[0116] In one embodiment, Console Controller 250 starts Set Menu State Machine 1200 as an action in the Main Menu State-B 550 . Set Menu State Machine 1200 sets Set_Menu_Line_Item_Table_Index to refer to the first Set_Menu_Line_Item 1300 in the Set_Menu_Line_Item_Table. Set Menu State Machine 1200 enters Set Menu State-A 1220 .
[0000] Set Menu State-A
[0117] In FIG. 14 , Set Menu State Machine 1200 displays “SET MENU” on Line-A 1412 .
[0118] Set Menu State Machine 1200 retrieves the Set_Menu_Line_Item 1300 referred to by Set_Menu_Line_Item_Table_Index. Set Menu State Machine displays the name stored in the Line_Item_Name 1302 on Line-B 1414 , for example, “IP ADDRESS”. Set Menu State Machine 1200 displays “SCROLL” on Key-Function-A 1451 , “EXIT” on Key-Function-C 1453 and “SELECT” on Key-Function-D 1454 .
[0119] FIG. 14 illustrates an example of Output Module 1410 after the display actions.
[0000] Set Menu State-B
[0120] In FIG. 15 , Set Menu State Machine 1200 displays “LOCATE” on Key-Function-B 1552 and “EXIT” on Key-Function-C 1553 . Set Menu State Machine 1200 retrieves the Set_Menu_Line_Item 1300 referred to by Set_Menu_Line_Item_Table_Index. Set Menu State Machine sends a request to the Network Application 270 via the Operation and Management Interface 215 . The request includes the Set_Menu_Line_Item_Identity 1305 . Network Application 270 sends the result to the Console Controller 250 . Set Menu State Machine 1200 stores the result in Set_Menu_Line_Item_Value. Set Menu State Machine 1200 displays the result, for example, “172.168.29.43” on Line-B 1514 .
[0121] FIG. 15 illustrates an example of Output Module 1510 after the display actions.
[0000] Set Menu State-C
[0122] In FIG. 16 , Set Menu State Machine 1200 displays “CHANGE” on Key-Function-A 1651 , “LOCATE” on Key-Function-B 1652 , “EXIT” on Key-Function-C 1653 , and “SAVE” on Key-Function-D 1654 . Set Menu State Machine 1200 displays Set_Menu_Line_Item_Value on Line-B 1614 , and highlights the alphanumeric character referred to by Set_Menu_Line_Item_Value_Character_Index. In one embodiment, Set_Menu_Line_Item_Value_Character_Index refers to the second alphanumeric character. Set Menu State Machine 1200 displays “172.168.29.43” with the second alphanumeric character “4” in white color and darkened background. In a different embodiment, Set Menu State Machine 1200 underlines the second alphanumeric character “4” on Line-B 1614 .
[0123] FIG. 16 illustrates an example of Output Module 1610 after the display actions.
[0000] Set Menu State-D
[0124] In FIG. 17 , Set Menu State Machine 1200 displays “CHANGE” on Key-Function-A 1751 and “EXIT” on Key-Function-C 1753 . Set Menu State Machine 1200 changes the alphanumeric character referred to by Set_Menu_Line_Item_Value_Character_Index to the next alphanumeric value. In one embodiment, the alphanumeric character has an alphanumeric value of “4”. Set Menu State Machine 1200 changes the alphanumeric value from “4” to “5”. Set Menu State Machine 1200 displays Set_Menu_Line_Item_Value on Line-B 1714 , and highlights the alphanumeric character referred to by Set_Menu_Line_Item_Character_Index. For example, Set Menu State Machine 1200 displays “172.168.29.53” and highlights the alphanumeric character “5”.
[0125] FIG. 17 illustrates an example of Output Module 1710 after the display actions.
[0000] Set Menu State-E
[0126] In FIG. 18 , Set Menu State Machine 1200 displays “EXIT” on Key-Function-C 1853 .
[0127] Set Menu State Machine 1200 retrieves the Set_Menu_Line_Item 1300 referred to by Set_Menu_Line_Item_Table_Index. Set Menu State Machine sends a request to the Network Application 270 via the Operation and Management Interface 215 . The request includes the Set_Menu_Line_Item_Identity 1305 , and the Set_Menu_Line_Item_Value. Network Application 270 sends the result to the Console Controller 250 . Set Menu State Machine 1200 determines the content and sends the content to Display Module 1810 for display. In one embodiment, Set Menu State Machine 1200 displays “set value stored successfully” on Line-B 1814 .
[0128] FIG. 18 illustrates an example of Output Module 1810 after the display actions.
[0000] Set Menu State-F
[0129] The Console Controller 250 stops Set Menu State Machine 1200 . The Console Controller 250 starts Main Menu State Machine 500 .
[0000] Set Menu Transition-A
[0130] In FIG. 14 , when a user presses Key-A 1431 . Set Menu State Machine 1200 determines that Trigger Event-SCROLL 12713 has occurred and triggers Set Menu Transition-A 1271 . Set Menu State Machine 1200 sets the value of Set_Menu_Line_Item_Table_Index to refer to the next Set_Menu_Line_Item of the Set_Menu_Line_Item_Table.
[0000] Set Menu Transition-B
[0131] In FIG. 14 , when a user presses Key-D 1434 . Set Menu State Machine 1200 determines that Trigger Event-SELECT 12723 has occurred and triggers Set Menu Transition-B 1272 . Set Menu State Machine 1200 takes no action in Set Menu Transition-B 1272 .
[0000] Set Menu Transition-C
[0132] In FIG. 15 , when a user presses Key-C 1532 . Set Menu State Machine 1200 determines that Trigger Event-LOCATE 12733 has occurred and triggers Set Menu Transition-C 1273 . Set Menu State Machine 1200 sets Set_Menu_Line_Item_Value_Character_Index to refer to the first alphanumeric character of the Set_Menu_Line_Item_Value.
[0000] Set Menu Transition-D
[0133] In FIG. 16 , when a user presses Key-B 1632 . Set Menu State Machine 1200 determines that Trigger Event-LOCATE 12743 has occurred and triggers Set Menu Transition-D 1274 . Set Menu State Machine 1200 sets Set_Menu Line_Item_Value_Character_Index to refer to the next alphanumeric character of the Set_Menu_Line_Item_Value.
[0000] Set Menu Transition-E
[0134] In FIG. 16 , when a user presses Key-A 1631 . Set Menu State Machine 1200 determines that Trigger Event-CHANGE 12753 has occurred and triggers Set Menu Transition-E 1275 . Set Menu State Machine 1200 takes no action in Set Menu Transition-E 1275 .
[0000] Set Menu Transition-F
[0135] In FIG. 17 , when a user presses Key-A 1731 . Set Menu State Machine 1200 determines that Trigger Event-CHANGE 12763 has occurred and triggers Set Menu Transition-F 1276 . Set Menu State Machine 1200 takes no action in Set Menu Transition-F 1276 .
[0000] Set Menu Transition-G
[0136] In FIG. 17 , when a user presses Key-C 1733 . Set Menu State Machine 1200 determines that Trigger Event-EXIT 12773 has occurred and triggers Set Menu Transition-G 1277 . Set Menu State Machine 1200 takes no action in Set Menu Transition-G 1277 .
[0000] Set Menu Transition-H
[0137] In FIG. 16 , when a user presses Key-C 1633 . Set Menu State Machine 1200 determines that Trigger Event-EXIT 12783 has occurred and triggers Set Menu Transition-H 1278 . Set Menu State Machine 1200 takes no action in Set Menu Transition-H 1278 .
[0000] Set Menu Transition-I
[0138] In FIG. 15 , when a user presses Key-C 1533 . Set Menu State Machine 1200 determines that Trigger Event-EXIT 12793 has occurred and triggers Set Menu Transition-I 1279 . Set Menu State Machine 1200 takes no action in Set Menu Transition-I 1279 .
[0000] Set Menu Transition-J
[0139] In FIG. 16 , when a user presses Key-D 1634 . Set Menu State Machine 1200 determines that Trigger Event-SAVE 12813 has occurred and triggers Set Menu Transition-J 1281 . Set Menu State Machine 1200 takes no action in Set Menu Transition-J 1281 .
[0000] Set Menu Transition-K
[0140] In FIG. 18 , when a user presses Key-C 1833 . Set Menu State Machine 1200 determines that Trigger Event-EXIT 12823 has occurred and triggers Set Menu Transition-K 1282 . Set Menu State Machine 1200 takes no action in Set Menu Transition-K 1282 .
[0000] Set Menu Transition-L
[0141] In FIG. 14 , when a user presses Key-C 1433 . Set Menu State Machine 1200 determines that Trigger Event-EXIT 12833 has occurred and triggers Set Menu Transition-L 1283 . Set Menu State Machine 1200 takes no action in Set Menu Transition-L 1283 .
[0000] Test Menu State Machine
[0142] In one embodiment, the Console Controller 250 includes a Test Menu State Machine.
[0143] FIG. 19 illustrates a Test Menu State Machine. Test Menu State Machine 1900 is a Console Controller State Machine 400 . Test Menu State Machine 1900 includes a Test_Menu_Line_Item_Table. Test_Menu_Line_Item_Table includes a plurality of Test_Menu_Line_Item.
[0144] FIG. 20 illustrates a Test_Menu_Line_Item. Test_Menu_Line_Item 2000 includes a Line_Item_Name 2002 , and a Test_Menu_Line_Item_Identity 2005 . Line_Item_Name 2002 stores a name. Test_Menu_Line_Item_Identity 2005 relates to a plurality of Network Function Component 275 . Test Menu State Machine 1900 has a state variable Test_Menu_Line_Item_Table_Index. Test_Menu_Line_Item_Table_Index refers to a Test_Menu_Line_Item 2000 in the Test_Menu_Line_Item_Table.
[0145] Test Menu Initial State 1910 is the Initial State 410 of Test Menu State Machine 1900 . Test Menu State Machine 1900 includes a plurality of State 430 ; Test Menu State-A 1930 , Test Menu State-B 1950 , and Test Menu State-C 1970 . Test Menu State Machine 1900 includes a plurality of State Transition 450 ; Test Menu Transition-A 1913 , Test Menu Transition-B 1915 , Test Menu Transition-C 1917 , and Test Menu Transition-D 1919 . Test Menu State Machine 1900 includes a plurality of Trigger Event 470 ; Trigger Event-SCROLL 19133 , Trigger Event-SELECT 19153 , Trigger Event-EXIT 19173 , and Trigger Event-EXIT 19193 .
[0000] Test Menu Initial State
[0146] In one embodiment, Console Controller 250 starts Test Menu State Machine 1900 as an action in the Main Menu State-B 550 . Test Menu State Machine 1900 sets Test_Menu_Line_Item_Table_Index to refer to the first Test_Menu_Line_Item 2000 in the Test_Menu_Line_Item_Table. Test Menu State Machine 1900 enters Test Menu State-A 1930 .
[0000] Test Menu State-A
[0147] FIG. 21 illustrates an example of Display Module 2110 after the display actions.
[0148] In FIG. 21 , Test Menu State Machine 1900 displays “TEST MENU” on Line-A 2112 . Test Menu State Machine 1900 retrieves the Test_Menu_Line_Item 2000 referred to by Test_Menu_Line_Item_Table_Index. Test Menu State Machine displays the name stored in the Line_Item_Name 2002 on Line-B 2114 , for example, “DATA LINK TEST”. Test Menu State Machine 1900 displays “SCROLL” on Key-Function-A 2151 , “EXIT” on Key-Function-C 2153 and “SELECT” on Key-Function-D 2154 .
[0000] Test Menu State-B
[0149] FIG. 22 illustrates an example of Display Module 2210 after the display actions.
[0150] In FIG. 22 , Test Menu State Machine 1900 displays “EXIT” on Key-Function-C 2253 . Test Menu State Machine 1900 retrieves the Test_Menu_Line_Item 2000 referred to by Test_Menu_Line_Item_Table_Index. Test Menu State Machine 1900 sends a request to the Network Application 270 via the Operation and Management Interface 215 . The request includes the Test_Menu_Line_Item_Identity 2005 . Network Application 270 sends the result to the Console Controller 250 . Test Menu State Machine 1900 displays the result, for example, “rc: 12 kpbs tx: 15 kpbs dp pkt: 0” on Line-B 2214 .
[0000] Test Menu State-C
[0151] The Console Controller 250 stops Test Menu State Machine 1900 . Console Controller 250 starts Main Menu State Machine 500 .
[0000] Test Menu Transition-A
[0152] In FIG. 21 , when a user presses Key-A 2131 . Test Menu State Machine 1900 determines that Trigger Event-SCROOL 19133 has occurred and triggers Test Menu Transition-A 1913 . Test Menu State Machine 1900 changes Test_Menu_Line_Item_Table_Index to refer to the next Test_Menu_Line_Item 2000 in the Test_Menu_Line_Item_Table.
[0000] Test Menu Transition-B
[0153] In FIG. 21 , when a user presses Key-D 2134 . Test Menu State Machine 1900 determines that Trigger Event-SELECT 19153 has occurred and triggers Test Menu Transition-B 1915 . Test Menu State Machine 1900 takes no action in Test Menu Transition-B 1915 .
[0000] Test Menu Transition-C
[0154] In FIG. 22 , when a user presses Key-C 2233 . Test Menu State Machine 1900 determines that Trigger Event-EXIT 19173 has occurred and triggers Test Menu Transition-C 1917 . Test Menu State Machine 1900 takes no action in Test Menu Transition-C 1917 .
[0000] Test Menu Transition-D
[0155] In FIG. 21 , when a user presses Key-C 2133 . Test Menu State Machine 1900 determines that Trigger Event-EXIT 19193 has occurred and triggers Test Menu Transition-D 1919 . Test Menu State Machine 1900 takes no action in Test Menu Transition-D 1919 .
[0000] Control Console and Console Controller State Machine
[0156] In one embodiment, the Console Controller 250 obtains the Main_Menu_Line_Item_Table, the Status_Menu_Line_Item_Table, the Set_Menu_Line_Item_Table, and the Test_Menu_Line_Item_Table from the Network Application 270 over the Operation and Management Interface 205 .
[0157] In one embodiment, Main_Menu_Line_Item_Table, Status_Menu_Line_Item_Table, Set_Menu_Line_Item_Table, the Test_Menu_Line_Item_Table are part of the programming functionalities of Console Controller 250 .
[0158] In one embodiment, Control Console 200 includes a data store. In one embodiment, the data store is a flash memory.
[0159] In one embodiment, the data store is a hard disk. In a different embodiment, the data store is a memory. Console Controller 250 retrieves Main_Menu_Line_Item_Table, Status_Menu_Line_Item_Table, Set_Menu_Line_Item_Table, and Test_Menu_Line_Item_Table from the data store.
[0000] One Key Testing
[0160] In one embodiment, the Input Module includes an additional single-test-key. A user presses the single-test-key. The Console Controller sends a request to a Network Application to invoke a set of tests for a plurality of Network Function Component.
[0161] In one embodiment, the set of tests includes all tests invoked by the Test Menu State Machine. In another embodiment, the set of tests is a subset of the tests invoked by Test Menu State Machine. Console Controller communicates with Network Application to invoke the tests.
[0162] In one embodiment, Console Controller determines the set of tests and communicates with Network Application to invoke these tests.
[0163] In one embodiment, Console Controller communicates with Network Application and Network Application determines the set of tests to conduct. Network Application conducts the tests and sends the test result to Console Controller. Console Controller receives the test results and determines the content to display and sends the content to the Display Module for display.
[0164] In one embodiment, the content to display includes one line. In another embodiment, the content to display includes multiple lines. Console Controller allows the user to use an input key in Input Module to scroll through the multiple lines of test result.
[0000] Input and Display Modules Revisited
[0165] The foregoing description illustrates a Display Module with three lines of display.
[0166] In one embodiment, the Display Module includes five lines of display.
[0167] In one embodiment, Display Module includes one line of display.
[0168] In one embodiment, the line of display is shorter than the content to display. The Console Controller allows the user to use an input key in the Input Module to scroll through the content on the line of display.
[0169] In one embodiment, Display Module includes a graphic display.
[0170] In one embodiment, Display Module includes a speaker.
[0171] In one embodiment, Console Controller converts the content to voice signal and sends the voice signal to the speaker.
[0172] In one embodiment, Console Controller sends the content to Display Module. Display Module converts the content to voice signal and sends the voice signal to the speaker.
[0173] In one embodiment, the Input Module includes seven input keys.
[0174] In one embodiment, Input Module includes two input keys.
[0175] In one embodiment, the Consumer Network Device manufacturer prints the functions of the inputs keys next to the input keys at the Input Module.
[0176] In one embodiment, the Consumer Network Device manufacturer prints “EXIT” next to an input key.
[0177] In one embodiment, the Consumer Network Device manufacturer prints “SCROLL/CHANGE” next to an input key.
[0178] In one embodiment, Input Module includes a microphone. A user reads a voice command to the microphone.
[0179] In one embodiment, Input Module includes a voice recognition function. Input Module converts the voice signal to a format for communications with the Console Controller.
[0180] In one embodiment, the format for communications is VoiceXML.
[0181] In one embodiment, the format for communications is based on proprietary definitions.
[0182] In one embodiment, Console Controller includes a voice recognition function. Input Module sends the voice signal to Console Controller. Console Controller processes the voice signal.
[0000] Console Controller Revisited
[0183] In one embodiment, the Console Controller includes software program running on a microprocessor.
[0184] In one embodiment, Console Controller is based on integrated circuit technology.
[0185] In an embodiment, Console Controller is implemented in an ASIC.
[0186] In one embodiment, Console Controller is based on FPGA technology.
[0187] In one embodiment, the Operating and Management Interface is based on FPGA technology.
[0188] In one embodiment, Operation and Management Interface is based on shared memory.
[0189] In one embodiment, Operation and Management Interface is based on ASIC technology.
[0190] In one embodiment, the communications over Operation and Management Interface is based on MIB-II specifications.
[0191] In one embodiment, the communications over Operation and Management Interface is based on SMNP standards.
[0192] In one embodiment, the communications over Operation and Management Interface is based on standard ECMA-335 Common Language Infrastructure (CLI).
[0193] In one embodiment, the communications over Operation and Management Interface is based on EIA/TIA-232 CLI Console Interface.
[0194] In one embodiment, the communications over Operation and Management Interface is based on proprietary specifications.
[0195] A Console Controller with equivalent functionalities includes a State Machine that has different number of States, different number of State Transitions, different number of Trigger Events, and different number of state variables.
[0196] In one embodiment, a Console Controller includes a State Machine with twenty-six States, sixty-four State Transitions, sixty-four Trigger Events, and five state variables.
[0197] In one embodiment, a Console Controller includes a State Machine with thirty States, fifty-two State Transitions, fifty-two Trigger Events, and seven state variables.
[0198] In one embodiment Control Console 200 can provide support and service for First Day of Service (FDS) capabilities, thus reducing time, cost, frustration and number of returns of product to vendor or manufacturer typically associated with the installation or maintenance of consumer network devices. Typically, FDS capabilities can include, but are not limited to, service configuration, service activation and service confirmation.
[0199] In one embodiment, during installation of a consumer network device, network status and configuration information can be displayed on Display Module 210 of Control Console 200 when and if there is a need for a call to the manufacturers technical support.
[0200] In one embodiment, Control Console 200 can input network configuration and functionality settings through Input Module 230 as per technical supports instructions; Console Controller 250 can then program Network Application 270 over Operation and Management Interface 205 .
[0201] In one embodiment, when configuration settings are changed, Control Console 200 can activate any or all settings entered by a user. Console Controller programs network or other functionality settings or configurations to Network Application 270 over Operation and Management Interface 205 .
[0202] In on embodiment, pay, prepaid or subscription services are associated with the use of a consumer network device, such as, but not limited to, cable television or internet service, virtual private networking, or VoIP telephony service, Control Console 200 can display information and prompts on Display Module 210 for user to remotely activate such services with Input Module 230 .
[0203] In one embodiment, pay, prepaid or subscription services are associated with the use of a consumer network device, such as, but not limited to, cable television or internet service, virtual private networking, or VoIP telephony service, Control Console 200 can display information and prompts on Display Module 210 for user to remotely confirm such services with Input Module 230 .
[0204] In one embodiment, remote assistance can be requested, activated and confirmed over a network through a remote assistance network function component executed in a Network Application 270 by Control Console 200 .
[0205] In one embodiment, Control Console 200 can be programmed to offer remotely-assisted, semiautomatic or automatic initial setup procedures through which a user can review, enter and confirm network device settings.
[0206] In one embodiment, Control Console can be programmed to deliver messages, advertisements or offers for services or upgrades.
[0207] Foregoing described embodiments of the invention are provided as illustrations and descriptions. They are not intended to limit the invention to precise form described. In particular, it is contemplated that functional implementation of invention described herein may be implemented equivalently in hardware, software, firmware, and/or other available functional components or building blocks, and that networks may be wired, wireless, or a combination of wired and wireless. Other variations and embodiments are possible in light of above teachings, and it is thus intended that the scope of invention not be limited by this Detailed Description, but rather by Claims following.
|
Embodiments of the present invention include apparatuses for a console controller in a network device. In one embodiment, the present invention includes a console controller, a display module and an input module in a network device so that a user can view, enter, or program network or network device settings at the network device. In another embodiment, the present invention can be programmed to include automated out-of-the-box initial setup procedures to guide a user in the setup, management and operation of a network devices such a DSL/Cable modems or routers, VoIP routers, wireless access points or gateways with or without remote or onsite technical support or update services.
| 7
|
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to an improved mechanism for assembling cutters on supporting bearing spindles in roller cutter earth boring bits. The invention reduces the number of catastrophic drill bit failures due to cutter loss during the drilling operation, thereby providing greater reliability and reduced wellbore drilling costs.
Much of the cost associated with drilling wellbores into the earth for recovery of hydrocarbons is directly related to the performance of the earth boring bit. Although the cost of the bit itself is often trivial in relation to other drilling expenses, the consequences of an unexpected or premature bit failure are significant. For example, a typical 77/8" three rolling cutter drill bit costs about $4,500. If one or more rolling cutters of this drill bit were to come off during drilling, the additional cost to recover the "junk" cutter could exceed $150,000. If the wellbore is deeper than about 10,000 ft. or is deviated from vertical more than about 30 degrees (as in directional drilling), the cost to recover the lost cutter could easily be $300,000. Therefore, one critical component of all modern, sealed rolling cutter earth boring bits is its mechanism for retaining the cutter on the body of the bit.
Cutter retention systems are well known in the art. For example, ball bearings can be inserted through a hole in the body to fill a groove between the rolling cutter and the bit body as shown in U.S. Pat. No. 3,989,314. Alternatively, a snap ring can be positioned in the same general area as the ball bearings as shown in U.S. Pat. No. 4,236,764. Finally, a split threaded thrust bearing member can be installed in the bit as shown in U.S. Pat. No. 3,971,600. Other threaded ring rolling cutter retention mechanisms are shown in U.S. Pat. Nos. 4,911,255; 4,991,671; 5,012,701 and 5,024,539.
Through several years of wide commercial use, the threaded ring retention mechanism has been found to provide superior cutter retention performance as compared to the other retention systems as long as the threaded ring remains securely seated within the rolling cutter. If the threaded ring becomes unseated, i.e. unscrewed from its intended position, the resulting excessive axial cutter displacement is detrimental to the cutter seal, resulting in premature bearing failure and shorter than expected bit life. As described in U.S. Pat. No. 3,971,600, the threaded ring is designed to resist unseating (unscrewing) after the bit is assembled by provision of a right hand thread so that the threaded ring will not loosen as the cutter turns in drilling using the normal clockwise drill bit rotation. In spite of this design, extensive analysis of used bits has indicated that the most common failure mode of the threaded ring was unseating.
Forces present during drilling can cause loosening of the threaded ring, especially when drilling wellbores with angular deviations greater than about 30 degrees from vertical. There are times during the drilling operation when the rolling cutter of a drill bit experiences reverse rotation. Because the threaded ring is designed to tighten during normal cutter rotation, reverse rotation of the cutter can cause the threaded ring to loosen. During normal wellbore drilling operations the rotation of the bit is often stopped so that an additional section of drill pipe can be added to the drill string. During this operation, the drill string and drill bit are first raised then lowered in the wellbore without rotation. If one cutter of the bit is scraping the side of the wellbore as the drill string is raised or lowered, the dragging action can cause reverse rotation of the cutter. The force of gravity urging the bit against the side of a directional wellbore makes this sidewall scraping worse, and consequently increases the chances of reverse cutter rotation, as the wellbore increasingly deviates from vertical.
The trend in today's oil and gas industry is to drill more highly deviated and horizontal wellbores. Due to the higher hourly rates for the specialised equipment required for this drilling, bit performance and reliability are critical. This is also the same type of drilling where reverse cutter rotation is most likely to occur. It is critical to keep the threaded retention ring securely locked in place during any conditions which may be encountered during drilling. It is also critical to provide very high resistance to further turning of the ring if it were to become loose. Therefore, the reliability of the locking means for the threaded retention ring is critical. For these reasons, there is a need for a drill bit with a threaded ring cutter retention system which is capable of withstanding reverse cutter rotation or any other condition encountered during drilling without loosening of the threaded ring.
SUMMARY OF THE INVENTION
The present invention has been contemplated to overcome the foregoing deficiencies and meet the above described needs.
According to one aspect of the invention there is provided a method of manufacturing a rolling cutter drill bit of the kind comprising a bit body, at least one bearing spindle on the bit body, a rolling cutter rotatably mounted on the bearing spindle, and a retention assembly mounted between said cutter and spindle, the retention assembly comprising a threaded retention ring coaxial with the spindle and in screw-threaded engagement with one of said cutter and spindle, the method comprising the steps of providing in one of said retention ring and the component which it screw-threadedly engages an aperture which passes through a portion of one of the screw-threads to expose a portion of the other screw-thread, forming the drill bit with a passage which extends from the exterior of the bit to said aperture in said one screw-thread so as to provide access to said exposed portion of the other screw-thread, and physically altering said exposed portion of the other screw-thread in a manner to prevent subsequent relative rotation between the screw-threads, thereby locking the retention ring to the component which it screw-threadedly engages.
This interlocking has been found, through testing, to provide a high degree of resistance to loosening for the threaded ring. The threaded rings of bits made in accordance with the present invention have been found to withstand reverse cutter rotation without becoming loose, even when drilling highly deviated wellbores.
The portion of the other screw-thread may be physically altered by being mechanically deformed by an implement inserted along said passage and through said aperture. Preferably said mechanically deformed other screw-thread is provided with greater yield strength than said one screw-thread containing said aperture.
Said exposed portion of the other screw-thread may be plastically deformed by impact thereon of said implement.
The retention ring may be in screw-threaded engagement with the cutter, the retention ring having an external screw-thread which engages an internal screw-thread on an interior surface of a cavity formed in the cutter.
In one such embodiment of the invention the aperture is formed in the retaining ring and exposes a portion of the internal screw-thread on the cutter, said passage being formed in the bearing spindle and extending from the exterior of the bit to said aperture in the retaining ring to provide access, through said passage and aperture, to said exposed portion of the screw-thread on the cutter.
The invention also provides a rolling cutter drill bit comprising a bit body, at least one bearing spindle on the bit body, a rolling cutter rotatably mounted on the bearing spindle, and a retention assembly mounted between said cutter and spindle, the retention assembly comprising a threaded retention ring coaxial with the spindle and in screw-threaded engagement with one of said cutter and spindle, there being provided in one of said retention ring and the component which it screw-threadedly engages an aperture which passes through a portion of one of the screw-threads to expose a portion of the other screw-thread, said exposed portion of the other screw-thread being physically altered in a manner to prevent relative rotation between the screw-threads, thereby locking the retention ring to the component which it screw-threadedly engages.
According to a second aspect of the invention there is provided a method of manufacturing a rolling cutter drill bit of the kind comprising a bit body, at least one bearing spindle on the bit body, a rolling cutter rotatably mounted on the bearing spindle, and a retention assembly mounted between said cutter and spindle, the retention assembly comprising a threaded retention ring coaxial with the spindle and in screw-threaded engagement with one of said cutter and spindle, the method comprising the steps of providing in one of said retention ring and the component which it screw-threadedly engages an aperture which passes through a portion of one of the screw-threads to expose a portion of the other screw-thread, forming the drill bit with a passage which extends from the exterior of the bit to said aperture in said one screw-thread so as to provide access to said exposed portion of the other screw-thread, providing a recess in said exposed portion of the other screw-thread, and securing in said aperture a pinning element having a portion which engages within said recess in a manner to prevent subsequent relative rotation between the screw-threads, thereby locking the retention ring to the component which it screw-threadedly engages.
Said recess may be formed in the exposed portion of said other screw-thread by physically deforming said exposed portion of the screw thread after assembly of the cutter, retention ring and spindle.
Said recess may be formed by mechanical deformation of the exposed portion of said other screw-thread by an implement inserted along said passage and through said aperture. For example, said recess may be formed by impact on the exposed portion of said other screw-thread by said implement.
Said recess may be pre-formed in the exposed portion of said other screw-thread prior to assembly of the cutter, retaining ring and spindle, and brought into register with the aperture in said one screw-thread, to receive said portion of the pinning element, during said assembly.
The retention ring may be in screw-threaded engagement with the cutter, the retention ring having an external screw-thread which engages an internal screw-thread on an interior surface of a cavity formed in the cutter. In this case said aperture may be formed in the retaining ring to expose a portion of the internal screw-thread on the cutter, said passage being formed in the bearing spindle and extending from the exterior of the bit to said aperture in the retaining ring to provide access, through said passage and aperture, to said exposed portion of the screw-thread on the cutter.
The invention further provides a rolling cutter drill bit comprising a bit body, at least one bearing spindle on the bit body, a rolling cutter rotatably mounted on the bearing spindle, and a retention assembly mounted between said cutter and spindle, the retention assembly comprising a threaded retention ring coaxial with the spindle and in screw-threaded engagement with one of said cutter and spindle, there being provided in one of said retention ring and the component which it screw-threadedly engages an aperture which passes through a portion of one of the screw-threads to expose a portion of the other screw-thread, a recess in said exposed portion of the other screw-thread, and secured in said aperture a pinning element having a portion which engages within said recess in a manner to prevent relative rotation between the screw-threads, thereby locking the retention ring to the component which it screw-threadedly engages.
In a further aspect the invention provides a method of manufacturing a rolling cutter drill bit of the kind comprising a bit body, at least one bearing spindle on the bit body, a rolling cutter rotatably mounted on the bearing spindle, and a retention assembly mounted between said cutter and spindle, the retention assembly comprising a threaded retention ring coaxial with the spindle and in screw-threaded engagement with one of said cutter and spindle, the method comprising the steps of providing in one of said retention ring and the component which it screw-threadedly engages an aperture which passes through a portion of one of the components to expose a surface portion of the other component, forming the drill bit with a passage which extends from the exterior of the bit to said aperture so as to provide access to said exposed surface portion, providing a recess in said exposed surface portion, and securing in said aperture a pinning element having a portion which engages within said recess in a manner to prevent subsequent relative rotation between the retention ring and the component which it screw-threadedly engages.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a rolling cutter drill bit of the present invention.
FIG. 2 is a cross sectional view of one preferred embodiment of an earth boring bit of the present invention showing the general arrangement of the cutter's lubrication and bearing system.
FIG. 3A is a plan view of one preferred embodiment of a threaded ring for use in a drill bit.
FIG. 3B is a perspective view of the threaded ring of FIG. 3A.
FIG. 3C is a cross sectional view of an earth boring bit of the present invention showing one preferred manner of thread deformation accomplished in accordance with the present invention.
FIG. 4A is a cross sectional view of the threads of the threaded ring of the present invention.
FIG. 4B a cross sectional view of the threads of an alternative preferred embodiment of the threaded ring of the present invention.
FIG. 5A is a perspective view of a prior art split threaded ring.
FIG. 5B is a perspective view of a prior art threaded ring utilising a plastic insert thread locking system.
FIG. 5C is a perspective view of a prior art setscrew type thread locking device.
FIG. 5D is a perspective view of a prior art threaded ring utilising the setscrew type retention system shown in FIG. 5C.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in more detail, and particularly to FIGS. 1 and 2, an earth boring bit 10 is a rolling cutter type of drill bit and includes a body 12 (portions of which are not shown). The body of a typical rolling cutter drill bit comprises three similar leg portions 14 (only two are shown). A cantilevered bearing spindle 16 formed on each leg 14 extends inwardly and downwardly. A rolling cutter 18 is rotatably mounted upon the spindle 16 as hereinafter explained. Attached to the rolling cutter 18 are cutting inserts 20 which engage the earth to effect a drilling action and cause rotation of the rolling cutter 18. Typically, each cutting insert 20 will be formed of hard, wear resistant material. Internal passageways 22, 24 & 26, as well as a reservoir 28 and bearing area 30 of the leg 14, are filled with lubricant (not shown) during bit assembly. The lubricant helps reduce friction during bit operation and is retained within the cutter 18 by a dynamic seal 32. One passageway 26 provides an access used in assembly of the bit. Pressure differentials between the lubricant and the external environment of the bit are equalised by the movement of a pressure balance diaphragm 34.
The cutter 18 is mounted upon the cantilevered bearing spindle 16 formed on the leg 14. A separate sliding bearing member 36 is mounted between the spindle 16 and a mating bearing cavity 38 formed in the cutter 18. An internal thread 40 is formed on the surface of an internal cavity of the cutter adjacent the bearing area 30, and a split externally threaded retaining ring 42 is positioned in a peripheral groove 44 on the spindle 16 and is threadedly engaged with the threads 40 on the cutter. This threaded ring 42 retains the cutter upon the spindle, as explained in U.S. Pat. No. 3,971,600.
The dimensional characteristics of the threaded ring 42, the groove 44 in the spindle 16, and the cavity 38 in the cutter are such as to allow some axial displacement of the cutter 18 with respect to the spindle 16. Manufacturing tolerances usually establish this permitted axial displacement to a maximum of about 0.017". If the threaded ring 42 were to become loosened on the cutter 18, the axial displacement would dramatically increase. For example, in a typical drill bit, a rotation of 120 degrees (1/3 of a full turn) of the threaded ring 42 from its intended position would double the axial displacement of the cutter on the spindle during operation. As noted in U.S. Pat. No. 3,971,600, excessive axial displacement leads to premature seal failure. Also, modern drill bits are designed with very close spacing between the cutting inserts 20 projecting from one cutter and the surface of the adjacent cutter. If the threaded ring 42 were to loosen just one full turn, the cutting inserts of one cutter 18 would engage the adjacent cutter, causing catastrophic fracture of the cutting inserts.
Reference will now be made to FIGS. 3A, 3B, 3C, 4A and 4B. For earth boring bits, the inventors hereof have found that to securely lock the threaded retention ring 42 in place, some form of mechanical interference or interlocking must be created between the retention ring and the rolling cutter. In accordance with the present invention, after the assembly of the cutter 18 upon the bearing spindle 16, a mechanical interlocking means is applied to prevent subsequent loosening of the threaded ring. The interlock can be created by physically altering the threads 46 on the threaded retention ring 42, the internal threads 40 in the rolling cutter 18, or both thread sets. Alternatively, the interlock can be created by providing a separate pin 58 (see FIG. 4B) secured in a hole 48 in the threaded ring 42 and engaging a recess 50 in the cutter. Field testing has shown that when the retention ring 42 and cutter 18 are mechanically interlocked in accordance with the above described invention the threaded ring 42 does not loosen during operation. In fact these bits have been extremely difficult to disassemble due to the effectiveness of this interlock. Test comparisons illustrating this effectiveness are provided herein.
For applications where the cutter threads 40 are altered, the difference in yield strength between the threaded ring 42 and the rolling cutter 18 can be used to advantage. In the preferred embodiment, shown in FIGS. 3A, 3B, 3C and 4A, the hole 48 is preformed in the threaded ring 42 so as to provide access, after assembly, to an exposed portion of the threads 40 on the cutter 18. The thread alteration is performed by a thin cylindrical tool 52 formed from material of higher yield strength than the cutter threads. A rounded end portion 54 of this tool 52 has a diameter slightly less that the diameter of the hole 48 in the threaded ring 42. The remainder of the tool 52 can have a larger diameter to help resist bending during use. During assembly, after the threaded ring 42 and cutter 18 have been assembled and seated upon the bearing spindle 16, as is well known to those skilled in the art, the tool 52 is introduced through the passage 26 in the spindle 16 so that the rounded end 54 of the tool passes through the hole 48 in the ring 42 and bears against the threads 40 of the cutter. The other end of the tool 52 is then struck with enough force to plastically deform the cutter threads 40 without causing thread fracture. The outline of such a deformed area is shown at 56 in FIG. 4A. The yielded cutter material forms a crater like depression which overlaps the path of the threads 46 on the threaded ring 42. This overlap caused by thread yielding causes a mechanical interlock between the threaded ring 42 and the cutter 18. It was found through testing that two moderate blows with a ball peen hammer cause sufficient yielding for an effective interlock. This technique will hereafter be referred to as the "peening" process.
A mechanism which makes the peening process even more successful is the interaction between the relatively hard cutter threads 40 and the relatively softer threaded ring threads 46. As forces present during drilling attempt to loosen the threaded ring 42, the softer ring threads 46 are pushed over the deformed cutter threads 40. During this motion, a small segment of the threads 46 themselves becomes permanently deformed. This additional deformation further increases the effectiveness of the present invention. As will be described in more detail later, laboratory testing has shown breakout torque for peened assemblies ranges from 100 to 120 ft-lbs, increasing to more than 200 ft-lbs during the first revolution. Bits run in the field assembled with the peening technique are very difficult to disassemble, and those that are disassembled are severely damaged in the process.
Any means of effecting a significant change in the shape of the cutter's threads without significant loss of material will result in satisfactory mechanical interlocking. In the sense that there are many ways to cause this change, any deliberate action which causes physical distortion of the threads, even if the means used to distort the threads is non-mechanical, is considered applicable and part of the "peening" process.
The assembly method of the above described bit utilising thread distortion as a way to mechanically interlock the cutter 18 to the threaded retention ring 42 comprises the steps of assembling the threaded retention ring 42 about the bearing spindle 16 of the bit, mounting the rolling cutter 18 upon the threaded ring 42 and bearing spindle 16, and acting upon the threads 40 in the rolling cutter 18 such that they are mechanically altered to prevent rotation of the threaded ring 42 with respect to the cutter 18.
In an alternative preferred embodiment of the present invention shown in FIG. 4B a pin 58 is passed through the hole 48 in the threaded retention ring 42 and introduced into a recess 50 formed in the cutter. The pin 58 can be held in the hole 48 by an interference fit, screw-threading, gluing or any other suitable means. The recess 50 can be formed in the cutter threads 40 or elsewhere in the cutter 18.
Normal dimensional variations of the threaded ring 42 and the rolling cutter 18 occur during manufacture and these variations from piece to piece make the desired location of a particular pin 58 vary with respect to a particular cutter 18 once they have been assembled. For this reason, the recess 50 in the cutter is preferably formed after assembly with the threaded retention ring 42. One method of forming the recess 50 is striking a sharp cornered tool (not shown) inserted through the access hole 48 of the threaded retention ring 42. If this tool is sufficiently harder than the cutter threads 40, a portion of the threads in the cutter will be sheared off leaving a suitable recess 50. After the pieces of thread are removed, the pin 58 is inserted into the recess 50 and held in place as indicated above. Hereinafter, this method of preventing loosening of the threaded ring is called the "pinning" process.
Testing performed with pinned-type mechanical interlocking showed breakout torques of about 140 ft-lbs generally decreasing to about 40 ft-lb torque as the threaded ring was loosened. The primary failure mode of this design was shearing of the mild steel pin 58. The inventors believe that a harder and/or tougher pin material such as hardened AISI 4140 steel could increase this breakout torque to well beyond 200 ft-lbs.
The assembly method of the above described bit utilising a pinned means of interlocking the cutter 18 to the threaded retention ring 42 comprises the steps of assembling the threaded retention ring 42 about the bearing spindle 16 of the bit 10, mounting the rolling cutter 18 upon the threaded ring 42 and bearing spindle 16, and inserting a permanently attached pinning element 58 through the threaded retention ring 42 into the recess 50 formed in the rolling cutter 18 to prevent subsequent rotation of the threaded ring 42 with respect to the cutter 18.
Many modifications and variations may be made in the techniques and structures described and illustrated herein without departing from the scope of the present invention. For instance, the threaded ring could be threadedly attached to the bearing spindle 16, rather than to the cutter 18, in which case the threaded ring will be mechanically interlocked to the spindle by physically deforming the exposed threads on the retaining ring, or by engaging a recess in the threads on the retaining ring by a separate pinning member which is permanently secured within an aperture in the spindle. Also, methods other than peening which accomplish physical thread alteration--such as electrical discharge, thermal warpage, corrosion and melting, to name a few, may be equally effective. Finally, there are many alternative ways to form a suitable pinning recess in the cutter such as by drilling during assembly or by providing preformed grooves in the cutter prior to assembly.
To illustrate the improvement of the present invention, a series of tests were performed in the Research Laboratory of Reed Tool Co. to compare various means of preventing the threaded ring from turning within the cutter. Many conventional, prior art ways to secure the threaded ring within the cutter were tested for both breakout torque and resistive torque after one revolution. Bit assemblies designed in accordance with the present invention were also tested. A summary of the testing is presented in Table 1. The performance of these prior art designs compared to the performance of the design in accordance with the present invention emphasises the significance of the invention. All testing described herein was performed with the 2 5/16" diameter threaded ring described below and with standard production rolling cutters and bit bodies that were modified to acquire torque data. Empirical analysis of bits with threaded rings assembled with thread locking compound, run in the field, and later disassembled indicated that when breakout torques of about 50 ft-lbs or higher were required for disassembly, there was no evidence of the threaded ring having previously become loose. The used bits tended to require either significant breakout torques or near zero breakout torques to effect disassembly. The inventors concluded, therefore, that a breakout torque of about 50 ft-lbs or higher must be maintained during the bit's operation to securely lock the threaded ring within the cutter.
FIG. 5A shows a typical prior art split threaded retention ring 60. A typical threaded ring 60 for a Reed Tool Co. 81/2" HP51 drill bit has a 2 5/16" diameter, and a 16 threads per inch class UN-2A thread 62 formed on its outside diameter. For proper operation the fatigue resistance, yield strength and toughness of the ring must be optimised. Therefore, the threaded ring 60 is made of steel, preferably AISI 4140, hardened within 28 to 34 Rockwell "C" (Rc), with a preferred hardness of about 30 Rc. The thrust surface 64 of the threaded ring 60 may be plated with silver or other suitable material to help reduce rubbing friction. A mating thread, corresponding to the thread 40 in FIGS. 4A and 4B, is formed in a portion of the cutter which is typically hardened to about 40 Rc. Prior to the present invention, the liquid thread locking compound known as "PERMATEX" (Registered Trade Mark) "Secures Gears" (Registered Trade Mark) was the preferred locking means for the threaded ring 60. This compound was identified from an array of thread locking compounds as having the best compromise between thread locking ability and chemical compatibility with other rock bit components.
In the tests, the "Secures Gears" (Registered Trade Mark) thread locking compound used in the prior art provided a maximum breakout torque of about 180 ft-lbs which rapidly dropped to 30 ft-lbs during the first revolution, as shown in Table 1. It was found that jarring of the cutter before torque was applied could reduce the breakout torque to about 40 ft-lbs. These results are misleading, however, because many bits assembled with this thread locking compound and run in the field had less than 5 ft-lbs of breakout torque after being run. Many of these bits also showed clear evidence of the threaded ring having become loose during operation. The reason for the reduced holding power of the thread locking compound is loss of bond integrity. It is believed that the combination of thermal, chemical and mechanical agitation during drilling causes degradation of the thread locking material, allowing the thread to loosen.
Other prior art locking means were also tested with the results shown in Table 1. Test No. 2, for example, showed that tightening the threaded ring to about 200 ft-lbs torque resulted in a breakout torque of less than 5 ft-lbs. Once breakout occurred, the resistive torque was less than 1 ft-lb. It is believed that the high elastic modulus and yield strength of the cutter and threaded ring assembly prevents adequate elastic deformation for thread locking at the assembly torques possible for drill bits. Because of the difficulties in fixturing, an assembly torque of greater than 200 ft-lbs is impractical.
Another prior art thread locking device is the use of a tough plastics or plastics-like material as shown in FIGS. 5B and 5C. This material is inserted in a recess formed in the threads 62 of the threaded ring as shown by 66. Upon assembly, the device provides a frictional engagement between the mating portions of the threads. One such thread locking device is "ND PELL-IT" (Registered Trade Mark). A similar product, "NYLOK" (Registered Trade Mark), is also commercially available. The result of removal torque tests with a 1/8" diameter plastics insert 66 as shown in FIG. 5B is shown as test number 3 of Table 1. Standard No. 8 cup point setscrews and variants thereof were also tested. As shown in FIG. 5C, the standard setscrew configuration 68 can be modified to include a tip 70 made of a relatively soft material. A setscrew 68 with a tip 70 is shown mounted in a threaded ring 60 in FIG. 5D. Standard setscrews and setscrews with tips of brass and the same tough plastics as above were tested. The results are shown respectively as tests 4, 5 and 6 of Table 1. Each setscrew was tightened into the threads 40 of the cutter 18 after the cutter 18 and the threaded ring 60 were assembled onto the bearing spindle 16. In this prior art arrangement, the holding torque of these setscrews is determined primarily by the axial force they exert upon the cutter threads, called the axial holding power. Deformation of the relatively soft tips of the tipped setscrews helps increase the friction coefficient slightly, with a resulting increase in holding torque. There is no significant deformation of the cutter threads themselves.
Based upon Table 23 on pages 8-31 of Marks Standard Handbook for Mechanical Engineers, seventh edition, a No. 8 cup point setscrew has an axial holding power of 385 lb. Based upon Note 1 listed below this table and the dimensions of the rings tested, the setscrew has an expected holding torque of about 37 ft-lbs. Test No. 4 showed breakout torque with this design to be less than 10 ft-lbs, dropping to less than 5 ft-lbs torque within a 90 degree revolution. The plastics tipped setscrew, Test No. 5, had about the same breakout torque, and the brass tipped setscrew, Test No. 6, had only slightly higher breakout torque. The inventors believe that the various setscrews and the plastics thread inserts were ineffective partly due to the superior lubricity of the rock bit grease present and the high hardness (40 Rc) of the threads in the cutter.
TABLE 1______________________________________Test Results of Various Thread Locking Means Breakout Torque @ 1Locking methood torque Rev______________________________________Prior Art:1. Prior art thread locking 0-180 ft-lb 30 ft-lb compound (inconsistent)2. Assembly torque of 5 ft-lb <1 ft-lb 200 ft-lbs3. Prior art plastics thread 5 ft-lb <5 ft-lb insert4. Prior art setscrew 5-10 ft-lb <5 ft-lb5. Prior art setscrew with 5-10 ft-lb <5 ft-lb plastics tip6. Prior art setscrew with 15 ft-lb <5 ft-lb brass tipPresent Invention:7. Thread "peening" in 100-120 ft-lb >200 ft-lb accordance with the present invention8. "Pinning" device in 140 ft-lb 40 ft-lb accordance with the present invention______________________________________
With the exception of thread locking compound, the conventional means of thread locking shown above are not suitable for retention of the threaded ring within a drill bit, exhibiting a maximum breakout torque of only 15 ft-lbs. Also, field results often shown degradation of the thread locking compound's breakout torque, frequently less than 5 ft lbs at disassembly, with many assemblies showing evidence of loosened threaded rings. By comparison, however, the mechanisms of the present invention consistently exhibit breakout torques in excess of 100 ft-lbs. None of the approximately 1000 drill bits tested to date with threaded rings secured by the "peening" method have had failures due to loosened threaded rings. Therefore, it can be seen that the mechanisms of the present invention provide threaded ring retention performance superior to all previous retention mechanisms.
|
A method of manufacturing a rolling cutter drill bit of the kind where each cutter is rotatably mounted on a bearing spindle on the bit body and is retained on the spindle by a threaded retention ring in screw-threaded engagement with the cutter. The retention ring is provided with an aperture to expose a portion of the screw-thread on the cutter and an implement is passed along a registering passage in the spindle and through the aperture in the retaining ring to deform or otherwise alter the exposed screw-thread in a manner to prevent subsequent relative rotation between the screw-threads, thereby locking the retention ring to the cutter. Instead of deforming the screw-thread it may be formed with a recess which is engaged by a pinning element secured in the aperture in the retaining ring.
| 8
|
[0001] This application claims priority from Japanese Patent Application No. 2002-251988 filed Aug. 29, 2002, which is incorporated hereinto by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an ink jet recording apparatus, particularly, to a conveying device for the ink jet recording apparatus.
[0004] 2. Description of the Related Art
[0005] There is a type using a recording head of a full-line type in an ink jet recording apparatus, which is capable of recording a high-quality image at a high speed. In this recording apparatus, a method has generally been known in which an electro-static force is generated in a conveyor belt by applying electric charge thereto from electro-conductive electrodes provided in the conveyor belt to attract a conveyed article.
[0006] The above-mentioned conveyor device will be described with reference to FIGS. 1 to 3 .
[0007] As shown in FIG. 1, the conveyor belt is formed of electrode plates 36 a , 36 b made of electro-conductive metal, a base layer 36 c , a surface layer 36 d and charged members 36 e . The charged members 36 e and the surface layer 36 d are made flat and function as insulation layers for insulating the electro-conductive members from outside.
[0008] [0008]FIG. 2 is an illustration of a conventional apparatus as seen in the lateral direction, and FIG. 3 is a top view thereof.
[0009] In FIG. 2, charging means includes a brush 51 ′, an electrode 52 ′ and a support member 53 ′.
[0010] The charging brush 51 ′ is brought into contact with the charged members 36 e for the purpose of supplying electric charge to the latter. The electric charge is supplied from the charging brush to the electrode plates 36 a to generate an electro-static force.
[0011] The charging means are arranged both on left and right sides to be capable of supplying voltages different from each other; for example, one supplies a plus voltage and the other supplies a minus voltage. Thereby, it is possible to always generate a favorable attracting force.
[0012] Also, ink jet recording heads 7 K, 7 C, 7 M and 7 Y are arranged above the conveyor belt closer thereto so that an image is formed when a copy is conveyed.
[0013] According to such a structure, it is necessary to approach the ink jet recording heads as close as possible to the conveyor belt so that the hitting accuracy of ink dots ejected from the recording heads is improved to obtain a favorable image free from the printing unevenness.
[0014] On the other hand, the ink head recording head is not always constituted by materials resistant to a high voltage but may generally be often weak to the static electricity or a high voltage. Thus, since the high voltage is always applied to the conveyor belt, there may be a leakage current between the electro-conductive section of the conveyor belt and the ink jet recording head if the insulation layer of the conveyer belt is damaged during the use due to a wear or a fatigue, resulting in the malfunction of the recording head.
[0015] Further, when the conveyor belt having a defect such as a pin hole is continuously used as it is, the damage of the recording head becomes larger to cause the trouble in the printed image.
SUMMARY OF THE INVENTION
[0016] To solve the above-mentioned problem, an object of the present invention is to provide a recording apparatus capable of detecting the deterioration of the insulation by knowing whether there is the leakage current from the surface of a conveyer belt to avoid the damage of the recording head beforehand.
[0017] According to a first aspect of the present invention, a recording apparatus comprises conveyor means for conveying a recording medium comprising a plurality of inner electro-conductive members, charging means for charging the inner electro-conductive members by a predetermined voltage to attract the recording medium onto the conveyor means by an electro-static force generated due to the charging, a recording head for carrying out the recording on the recording medium attracted onto the conveyor means, an insulation deterioration detecting means for detecting the deterioration of the insulation of the conveyor means, and control means for treating the abnormality in accordance with the results detected by the insulation deterioration detecting means.
[0018] The insulation deterioration detecting means may detect the leakage current between the conveyor means and the insulation deterioration detecting means.
[0019] The charging means may have a first charging means for charging at least one of the inner electro-conductive members by a first voltage and a second charging means for charging at least one of the others of the inner electro-conductive members by a second voltage, and the insulation deterioration detecting means may determine whether the leakage current is caused by the first voltage or the second voltage.
[0020] When the insulation deterioration detecting means detects the current leakage, the control means may stop the driving of the conveyor means.
[0021] When the insulation deterioration detecting means determines which of the first and second voltages causes the leakage current, the control means may stop the charging by the charging means corresponding to the leakage current.
[0022] When the insulation deterioration detecting means determines which of the first and second voltages causes the leakage current, the control means may lower the charging voltage of the charging means corresponding to the leakage current to a level at which the leakage current is not detected.
[0023] The insulation deterioration detecting means may be disposed upstream from the recording head in the conveying direction of the recording medium.
[0024] The conveyor means may include a surface insulation layer, and the insulation deterioration detecting means is constituted by an electro-conductive material, wherein a distance between the insulation deterioration detecting means and the surface insulation layer is shorter than a distance between the recording head and the surface insulation layer.
[0025] According to a second aspect of the present invention, a sheet conveying device comprises a conveyor belt for conveying a sheet including a first electrode group having a plurality of electrodes arranged in the conveying direction and a second electrode group having a plurality of electrodes, respectively, arranged between every adjacent two electrodes in the first electrode group, charging means for charging the first and second electrode groups at predetermined potentials, respectively, to attract the sheet onto the conveyor belt by an electro-static force generated due to a potential difference between the first and second electrode groups, and detection means for detecting a leakage current from either of the first and second electrode groups.
[0026] Control means may be further provided for stopping the drive of the conveyor belt when the detection means detects the leakage current.
[0027] Also, control means may be further provided for stopping the charging operation of the charging means when the detection means detects the leakage current.
[0028] According to the present invention, it is possible to know a degree of the deterioration of the conveyor belt by providing the means for detecting the leakage current, and even if the leakage current occurs, to stop the conveyor belt before the faulty portion thereof reaches the recording head.
[0029] Thus, when the leakage current is detected, it is possible to stop the drive of the conveyor belt to prevent the charged faulty portion thereof from approaching the recording head, whereby the damage of the recording head is avoidable.
[0030] Further, by detecting the leakage current caused by the different voltages, respectively, it is possible to determine which electrode leaks. Thereby, even if the faulty portion of the conveyor belt is found, the charging to the electrode corresponding to the faulty portion can be made to stop. As a result, the printing operation can be normally completed without damaging the recording head as well as stopping the apparatus during the printing operation.
[0031] Furthermore, even if the leakage current occurs, it is possible to prevent the current from flowing between the recording head and the conveyor belt and, thus, to prolong the life of the conveyor belt.
[0032] The above and other objects, effects, features and advantages of the present invention will become more apparent from the following description of embodiments thereof taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] [0033]FIG. 1 is a sectional view of a conventional conveyor belt;
[0034] [0034]FIG. 2 is a side view of a conventional recording apparatus;
[0035] [0035]FIG. 3 is a plan view of the conventional recording apparatus;
[0036] [0036]FIG. 4 is an illustration of the entirety of an ink jet recording apparatus according to the present invention;
[0037] [0037]FIG. 5 is an illustration of a charging section according to the present invention;
[0038] [0038]FIG. 6 is a top view of an illustrative conveyor belt for explaining the present invention;
[0039] [0039]FIG. 7 is an illustration for explaining means for generating an attractive force according to the present invention;
[0040] [0040]FIG. 8 is an illustration for explaining a charging method according to the present invention;
[0041] [0041]FIG. 9 is an illustration of leakage detection means according to the present invention;
[0042] [0042]FIG. 10 is a control block diagram according to the present invention;
[0043] [0043]FIG. 11 is a flow chart for explaining a first embodiment of the present invention; and
[0044] [0044]FIG. 12 is a flow chart for explaining a second embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0045] The present invention will be described below based on the preferred embodiments with reference to the attached drawings.
[0046] (First Embodiment)
[0047] [0047]FIG. 4 illustrates a cross-section of the entirety of a recording apparatus according to the present invention, including a sheet feeding section, a conveyor section, a recording head section and a sheet delivery section described hereinafter.
[0048] In the sheet feeding section, a presser plate 21 on which recording sheets P are laid and a feed roller 22 for feeding sheets P are provided. The recording sheet P is biased by a presser plate spring 24 to the feed roller 22 rotatable about a rotary shaft coupled to a base 20 . In this state, the recording is carried out on the recording sheet P while the feed roller 22 is rotating. A separation pad not shown having a high frictional coefficient for avoiding the double feed of the recording sheets P and a separation nib not shown for separating the recording sheet are provided in the presser plate 21 . Also, a release cam not shown is provided for releasing the contact of the presser plate 21 with the feed roller 22 .
[0049] According to the above-mentioned structure, the release cam pushed the presser plate 21 downward in a waiting state to release the contact of the presser plate 21 with the feed roller 22 . When the driving force of a conveyor roller 32 is transmitted to the feed roller 22 and the release cam via gears or the like in this state, the release cam is apart from the presser plate 21 which then moves upward, whereby the recording sheet P is brought into contact with the feed roller 22 and picked up in accordance with the rotation of the rotating feed roller 22 . Thus, the sheet delivery is started. The feed roller 22 continues the rotation until the recording sheet P has been put into the conveyor section.
[0050] The conveyor section which is conveying means includes a conveyor belt 31 attracting and conveying the recording sheet P and a PE sensor not shown.
[0051] The conveyor belt 31 is driven by a drive roller 34 and wrapped around a conveyor roller 32 and a tension roller 35 which are driven rollers. A drive source of the drive roller 34 is a belt motor 50 .
[0052] A speed of the belt motor 50 is controllable by control means described later.
[0053] The conveyor belt 31 is made of synthetic resin such as polyethylene to have an endless form. Reference numeral F denotes charging means. The charging means applies a voltage, for example, of 3 kV to the conveyor belt to bring the recording sheet P into tight contact with the conveyor belt. This voltage is controlled by high-voltage generating means and high-voltage control means not shown.
[0054] The conveyor belt runs at a speed, for example, of 170 mm/sec.
[0055] A pinch roller 33 is disposed at a position confronting the conveyor roller 32 and driven by the conveyor belt 31 in contact therewith. Recording heads 7 K, 7 C, 7 M and 7 Y are arranged downstream from the conveyor roller 32 in the conveying direction.
[0056] The recording head is an ink jet recording head of a line type having the resolution of 600 dpi in which a plurality of nozzles are arranged transverse to the conveying direction. In the recording head, the nozzles are made of Si wafer and an indication member is made of metal such as SUS.
[0057] These recording heads are capable of imparting heat to ink by a heater or the like. The ink is film-boiled by this heat, which causes the pressure variation by the expansion or contraction of bubbles due to the film boiling, whereby ink is ejected from the nozzle to form an image on the recording sheet P.
[0058] A leakage detection roller 26 is provided as insulation deterioration detecting means between the arrangement position of the conveyor roller 32 and the arrangement position of the recording heads 7 K, 7 C, 7 M and 7 Y (upstream from the recording heads). The leakage detection roller 26 is an electro-conductive member made, for example, of metal such as SUS or electro-conductive rubber. If there is a fault such as a pin hole in the conveyor belt 31 , a leakage current occurs between the conveyor belt 31 and the leakage detection roller 26 . In this regard, a method for detecting the leakage (leakage current) will be described in more detail with reference to FIG. 9.
[0059] The sheet delivery section is constituted by a delivery roller 41 and a nip roller 42 , in which the recording sheet P on which the image is formed is nipped between the delivery roller 41 and the nip roller 42 , conveyed thereby and discharged into a tray 43 .
[0060] A cleaning roller 38 is used when it is necessary to clean the belt 31 .
[0061] An antistatic brush 27 is used for grounding the residual charge on the belt 31 to facilitate the delivery of sheet.
[0062] [0062]FIG. 5 is an illustration for explaining charging means according to the present invention.
[0063] A plurality of charging means groups arranged in the conveying direction are constituted by a charging brush 51 and a charging electrode 52 a ; a charging brush 51 and a charging electrode 52 b ; and an antistatic brush 27 and a charging electrode 52 c . The charging electrodes 52 a to 52 c are fixed to a support member 53 .
[0064] The recording sheet is conveyed from a feeding side (right side) to a delivery side (left side).
[0065] The charging brush 51 is brought into contact with a charged portion of the belt so that the voltage is applied to the charged portion of the belt. In this drawing, a group of charging electrodes are constituted by charging electrodes 52 a and 52 c having the same length in the conveying direction and that 52b having a length different from the former.
[0066] Concretely, the lengths of the respective electrodes in the conveying direction are 3 cm in 52 a and 52 c and 20 cm in 52 b.
[0067] A gap between the respective electrodes is 3 cm. It is necessary that the gap is defined so that two charging brushes are not simultaneously brought into contact with one charged portion. In this regard, a length of the charged portion in the conveying direction is 2 cm.
[0068] The electrodes 52 a and 52 b are charged by applying a first voltage of +3.0 kV. The voltage applied to the electrode 52 c is 0 V (grounded).
[0069] An area of the central electrode is a place in which the recording is carried out by the recording heads and therefore a powerful attracting force is required. In correspondence thereto, the charging electrode 52 b is disposed in this area.
[0070] The charging electrode 52 a is a section for supplying a voltage for carrying out the leakage detection, and disposed generally on the same line as the leakage detection roller 26 . The charging brush 51 positioned at a tip end of the charging electrode 52 a is brought into contact with the surface of the belt so that the voltage is supplied via the electrodes 36 c on the belt. It is enough that the charging electrode 52 and the charging brush 51 are disposed at positions on which a leakage current circuit is formed. To smoothly guide the recording sheet to the sheet delivery section, the destaticization of the conveyor belt 31 is carried out in the charging electrode 52 c.
[0071] While a half of the charging section (the first charging means) provided on one side is solely illustrated in this drawing, there is another half of the charging section (the second charging means) of the same structure not shown. In the latter half of the charging section, a voltage applied to the charging electrodes 52 a and 52 b as a second voltage is −3.0 kV and that applied to the charging electrode 52 c is 0 V (grounded).
[0072] [0072]FIG. 6 is an illustration for explaining the conveyor belt 31 and attracting means 36 , when the belt is seen from above the recording apparatus. The attracting means is constituted by a plurality of minus electrode plates 36 a and plus electrode plates 36 b which are inner electro-conductive members arranged alternately on the conveyor belt 31 like the teeth of a comb to confront each other in the direction vertical to the conveying direction of the belt.
[0073] Charged members 36 e 1 and 36 e 2 are arranged on opposite sides of the conveyor belt 31 in the conveying direction of the conveyor belt 31 . Each of the charged members 36 e 1 and 36 e 2 projects outside from one end of the electrode 36 a or 36 b and is brought into contact with the electro-conductive brush 51 at a predetermined pressure.
[0074] By this charging brush 51 , the first voltage +3 kV is applied to the charged member 36 e 2 from a high-voltage electric source not shown. Also, the second voltage −3 kV is applied to the charged member 36 e 1 . In this regard, the charging brush 51 is preferably made of an electro-conductive material having a volume resistivity of 10 −4 , to 10 −5 Ωcm.
[0075] [0075]FIG. 7 is an illustration for explaining the generation of attracting force by the attracting means 36 .
[0076] An electric force is generated as shown by an arrow when the voltage is applied to the minus electrode plates 36 a (the first electrode group) arranged in the conveying direction in an inner portion of the conveyor belt, and a line of electric force is formed. Due to the potential difference between the minus electrodes 36 a and the plus electrode plates 36 b (the second electrode group) arranged between the minus electrodes 36 a , the attracting force is generated above the conveyor belt 31 to attract the recording sheet P on the conveyor belt.
[0077] Since the volume resistivity Ωcm of the base layer is larger than that of the surface layer in the present invention, the line of electric force generated is more powerful on the upper surface of the belt, whereby the attracting force becomes larger.
[0078] [0078]FIG. 8 is an illustration for explaining the charging from the charging means to the conveyor belt.
[0079] The attracting force generating means 36 is constituted by the minus electrode plates 36 a , the plus electrode plates 36 b , the base layer 36 c , the insulated surface layer 36 d , the charged members 36 e , the charging brush 51 , an electrodes 52 and a support member 53 . The charged members 36 e are flush with the surface layer 36 d.
[0080] The charging brush 51 is brought into contact with the charged members 36 e at a constant pressure and charges the latter. The minus electrode plates 36 a and the plus electrode plates 36 b are protected by the base layer 36 c and the surface layer 36 d in a sandwiched manner. The base layer 36 c and the surface layer 36 d are made of synthetic resin such as polyethylene, polycarbonate or PVDF having the volume resistivity of 10 15 to 10 17 Ωcm and that of 10 10 to 10 14 Ωcm, respectively.
[0081] The minus electrode plates 36 a and the plus electrode plates 36 b are also protected by the charged members 36 e and the base layer 36 c in a sandwiched manner. The charged members 36 e are made of electro-conductive synthetic resin containing carbon having the volume resistivity of 10 −4 to 10 −5 Ωcm.
[0082] Upper surfaces of the surface layer 36 d and the charged members 36 e are subjected to the fluorine resin treatment to have a favorable water-repellency.
[0083] [0083]FIG. 9 illustrates a leakage detection circuit.
[0084] The charging brush 52 a disposed above the conveyor belt 31 is connected to a high-voltage electric source 101 . The charging brush 52 a disposed at one end is connected to an output terminal 102 of +3.0 kV via a resistor 104 , and the charging brush 52 a ′ disposed at the other end is connected to an output terminal 103 of −3.0 kV via a resistor 105 , respectively. In such a manner, when the high voltage is applied to the electrodes of the conveyor belt 31 and the apparatus is in a recording state as well as the belt is being driven, the electrode plates protected by the insulating layers are sequentially passes by the leakage detection roller 26 . While no accident occurs if the insulation layers are in a normal state, the leakage current occurs between the electrode plates 36 a , 36 b and the detection roller 26 when the abnormality occurs in the insulation layers, such as a pin hole due to the fatigue or wear of the belt. To improve the sensitivity for detecting the leakage current for the purpose of preventing the recording head from being damaged, a distance between the leakage detection roller 26 and the conveyor belt 31 is preferably smaller than a distance between the recording head and the conveyer belt 31 .
[0085] The leakage current flows through a cable 106 .
[0086] If the leakage current occurs in the electrode plate of +3.0 kV, the leakage current flows through a diode 107 and a resistor 108 . While a potential between the diode 107 and the resistor 108 is approximately 2V when no leakage occurs, it exceeds this value if the leakage current flows. Accordingly, it is possible to detect whether or not the leakage occurs by detecting this potential difference. Then, this potential is input to a comparator 112 after a noise is removed by a low-pass filter formed of a resistor 109 and a capacitor 110 . A Zener diode 111 is used for the protection. The comparator 112 transmits the information whether or not the leakage occurs obtained in comparison with a threshold value determined by resistors 113 and 114 to a control circuit 130 .
[0087] Similarly, if the leakage occurs in the electrode plate of −3.0 kV, the leakage current flows through a diode resistor 115 and a diode 116 . While the potential difference between the resistor 115 and the diode 116 is approximately 4 V when no leakage occurs, it becomes lower than this value if the leakage current flows. Accordingly, it is possible to detect whether or not the leakage occurs by detecting this potential difference. This potential is input to a comparator 120 after a noise is removed by a low-pass filter formed of a resistor 117 and a capacitor 118 . A Zener diode 119 is used for the protection. The comparator 120 transmits the information whether or not the leakage occurs obtained in comparison with a threshold value determined by resistors 121 and 122 to a control circuit 130 .
[0088] As a result, the control circuit detects the leakage in the electrode plate of +3.0 kV when the input 131 is at a “H” level, while it detects the leakage in the electrode plate of −3.0 kV when the input 132 is at the “H” level.
[0089] [0089]FIG. 10 illustrates a block diagram for controlling the apparatus according to the present invention.
[0090] A control section 80 is constituted by CPU 80 a operated in accordance with a control program, ROM 80 b storing the control program and RAM 80 c which is a memory for saving various memories or data of the operation. A gate array 80 d is an LSI for controlling signals output to the recording heads or the charging electrodes in association with CPU.
[0091] The control section is connected to various devices described below.
[0092] A belt motor 50 is a drive source for rotating the conveyor belt. 7 K, 7 C, 7 M AND 7 Y are recording heads of black, cyan, magenta and yellow, respectively.
[0093] A charging electrode section is constituted by a first charging electrode 52 a , a second electrode 52 b , a third electrode 52 c and a fourth charging electrode 52 d.
[0094] [0094]FIG. 11 illustrates an operational flow chart of the control section in a first embodiment.
[0095] When the apparatus initiates the recording operation (step 1 ), the conveyor belt motor is first driven (step 2 ).
[0096] Then, the high voltage is applied to the conveyor belt when the speed of the conveyor belt becomes constant (step 3 ), and when the attracting force necessary for conveying the recording sheet has been obtained, the recording sheet is conveyed to start the printing operation (step 4 ).
[0097] The control section always carries out the detection of the leakage if any until the printing operation is finished (step 5 ), and if the printing operation has finished without detecting the leakage (step 6 ), a usual finishing treatment is carried out (step 7 ).
[0098] If the leakage is detected during the printing operation, the application of the high voltage is immediately made to stop as one of the abnormality treatments and the conveyor belt is also made to stop (step 8 ). According to these treatments, the leakage portion does not approach the recording head, whereby no leakage occurs between the recording head and the conveyor belt. Thereafter, an abnormality treatment such as displaying information about the occurrence of the leakage (e.g. a service man call) is carried out (step 9 ). Thus, a series of the treatments are finished (step 10 ).
[0099] (Second Embodiment)
[0100] In the first embodiment, a method is disclosed, for stopping the operation of the apparatus at a time when the leakage is detected. Contrarily, in the second embodiment, another method is disclosed, in which even if the leakage is detected in either one group of the electrode plates, the printing is continued as it is.
[0101] [0101]FIG. 12 illustrates an operational flow chart of the control section in the second embodiment.
[0102] Upon starting the printing operation (step 1 ), the conveyor belt motor is first driven.
[0103] The high voltage is applied to the conveyor belt when the speed of the conveyor belt becomes constant, and when the attracting force necessary for conveying the recording sheet has been obtained, the recording sheet is conveyed to start the printing operation (step 2 ).
[0104] The control section always carries out the detection of the leakage if any until the printing operation is finished. If the leakage is detected in the voltage charging section of +3.0 kV (step 3 ), the application of the high voltage of +3.0 kV is made to stop (step 4 ).
[0105] On the other hand, if the leakage is detected in the voltage charging section of −3.0 kV (step 5 ), the application of the high voltage of −3.0 kV is made to stop (step 6 ). The printing operation and the leakage detection are alternately repeated in such a manner. When the printing operation has finished (step 7 ), a usual finishing treatment is carried out (step 8 ). If the leakage has been detected in either of the voltage charging sections, the situation thereof is output as messages in this finishing treatment.
[0106] If the leakage is detected, the charging voltage applied to the voltage charging section corresponding to the leakage may be lowered to a level at which no leakage is detected.
[0107] When the leakage is detected in both of the electrode plates, the abnormality treatment identical to that in the first embodiment is carried out. According to these treatments, no leakage occurs in the faulty portion even if the leaked portion approaches the recording heads since the faulty portion is not charged.
[0108] The present invention has been described in detail with respect to preferred embodiments, and it will now be apparent from the foregoing to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and it is the intention, therefore, in the appended claims to cover all such changes and modifications as fall within the true spirit of the invention.
|
To provide a recording apparatus capable of detecting the deterioration of insulation to prevent the damage of a recording head by detecting whether or not there is the current leakage from a surface of a conveyor belt. The inventive recording apparatus includes a conveyor belt for conveying a recording medium comprising a plurality of inner electro-conductive members, a charging section for charging the inner electro-conductive members by a high voltage to attract the recording medium onto the conveyor belt by an electro-static force, a recording head for carrying out the recording on the recording medium attracted onto the conveyor belt, a leakage detection roller for detecting the deterioration of the insulation of the conveyor belt, and a control section for treating the abnormality in accordance with the results detected by the leakage detection roller.
| 6
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.